DAEWOO DWF-5020, DWF-4220 Service Manual

DAEWOO ELECTRONICS CO., LTD.

DWF-4220 (Series)
DWF-5020 (Series)

Full-Auto Electric Washing Machine

Service Manual

612-1, AHYEON-DONG, MAPO-GU,
SEOUL, KOREA.
C.P.O. BOX 8003 SEOUL KOREA
TELEX: DWELEC K28177-8
CABLE:"DAEWOOELEC"
FAX: [phone]
TEL: [phone]~7

DAEWOO ELECTRONICS CO., LTD.

S/M NO.: WF42200100 PRINTED DATE: APR. 1996

1

TABLE OF CONTENTS

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

2. FEATURE AND TECHNICAL EXPLANATION

FEATURE OF THE WASHING MACHINE...............................................................................................................................3

WATER CURRENTS TO ADJUST THE UNBALANCED LOAD ..............................................................................................3

PULSATOR SYSTEM................................................................................................................................................................4

AUTOMATIC DRAINING TIME ADJUSTMENT........................................................................................................................4

SOFTENER DISPENSER...........................................................................................................................................................5

AUTOMATIC UNBALANCE ADJUSTMENT ............................................................................................................................6

CIRCULATING-WATER COURSE AND LINT FILTER.............................................................................................................6

SYNCRONOUS MOTOR...........................................................................................................................................................7

YNCRONOUS GEAR MECHANISM ASS'Y.............................................................................................................................8

PRINCIPLE OF BUBBLE GENERATOR...................................................................................................................................8

FUNCTIONAL PRINCIPLE OF BUBBLE WASHING MACHINE .............................................................................................9

3. STRUCTURE OF THE WASHING MACHINE..................................................................................................................... 10

4. FUNCTIONS OF THE CONTROL PANEL........................................................................................................................... 11

5. DIRECTIONS FOR INSTALLATION AND USE

HOW TO INSTALL THE WASHING MACHINE......................................................................................................................12

HOW TO CONNECT THE INLET HOSE.................................................................................................................................14

HOW TO GROUND THE WIRE...............................................................................................................................................15

6. PROCEDURE OF FULL-AUTOMATIC WASHING............................................................................................................. 16

7. DIRECTIONS FOR DISASSEMBLY AND ADJUSTMENT

GEAR MECHANISM ASS'Y REPLACEMENT........................................................................................................................18

SYNCRONOUS MOTOR AND VALVE REPLACEMENT.......................................................................................................19

BRAKE ADJUSTMENT............................................................................................................................................................19

8. TROUBLE SHOOTING GUIDE

CONCERNING WATER SUPPLY...........................................................................................................................................20

CONCERNING WASHING......................................................................................................................................................21

CONCERNING DRAINING......................................................................................................................................................22

CONCERNING SPINNING......................................................................................................................................................23

CONCERNING OPERATION..................................................................................................................................................24

9. PRESENTATION OF THE P.C.B. ASS'Y

CONCERNING ERROR MESSAGE........................................................................................................................................25

CONFIGURATION OF FULL CIRCUITS.................................................................................................................................27

MINUTE EXPLANATION DIAGRAM FOR EACH PARTS......................................................................................................28

APPENDIX

WIRING DIAGRAM..................................................................................................................................................................40

PARTS LIST (THE WHOLE).....................................................................................................................................................42

PARTS DIAGRAM....................................................................................................................................................................46

P.C.B. PARTS LIST ................................................................................................................................................................. 49

CIRCUIT DIAGRAM.................................................................................................................................................................54

BARE PCB ..............................................................................................................................................................................56

2

1. SPECIFICATIONS

NO ITEM SPECIFICATIONS

1 POWER SOURCE

AC 220V/60Hz AC 127V/50,60Hz AC 110V/60Hz AC 220V/50Hz AC 240V/50Hz

2 POWER DWF-4220 370W 370W 370W 330W 330W

CONSUMPTION DWF-5020 430W 430W 430W 370W 370W

3

MACHINE

DWF-4220

NON PUMP: NET; 30.5kg, GROSS: 35 kg PUMP: NET; 31.5kg, GROSS; 36kg

WEIGHT DWF-5020

NON PUMP: NET; 31.5kg, GROSS: 36 kg PUMP: NET; 32.5kg, GROSS; 37kg

4 DIMENSION (WXHXD) 502X820X500
5 WASHING COURSE FULL AUTOMATIC 4 COURSES

(FUZZY, SPEED, HEAVY, WOOL)
6 WATER CONSUMPTION NORMAL 128| (131|: DWF-5020)

7 WATER LEVEL DWF-4220 HIGH (47|), MEDIUM (38|), LOW (30|), SMALL(22|)

SELECTOR DWF-5020 HIGH (48|), MEDIUM (39|), LOW (31|), SMALL(23|)

8

OPERATING WATER PRESSURE

0.3~8kgf/cm2(2.9~78.4N/cm2)

SPIN:690 (50Hz)

9 REVOLUTION PER MINUTE SPIN: 750 WASH:130 SPIN: 750 SPIN: 690

WASH: 140 SPIN: 750 (60Hz) WASH: 140 WASH: 130

WASH: 140

10 PULSATOR 5 WINGS (Ø 321mm)
11 WATER LEVEL CONTROL ELECTRONICAL SENSOR
12 OUTER CABINET SGCC
13 GEAR MECHANISM ASS'Y PLANETARY GEAR ASSEMBLY OF ENGINEERING PLASTIC
14 LINT FILTER O
15 SOFTENER INLET O
16 ALARM SIGNAL O
17 AUTO WATER SUPPLY O
18 NEW WATER FLOW WATER FLOW FOR ADJUST THE UNBALANCED LOAD

19 FUNCTION FOR BUBBLE OPTION
20 DWF-4220 4.2 kg

DWF-5020 5.0 kg

MAXIMUM
MASS OF
TEXTILE

3

FEA TURE OF THE W ASHING MACHINE

1) The first air bubble washing system in the world.

2) Quiet washing through the innovational low-noise design.

3) The wash effectiveness is much more enhanced because of the air bubble washing system.

4) The laundry detergent dissolves well in water because of the air bubble washing system.

5) The adoption of the water currents to adjust the unbalanced load.

6) One-touch operation system.

WATER CURRENTS TO ADJUST THE UNBALANCED LOAD

It is a function to prevent eccentricity of the clothes after washing by rotating pulsator C.W and C.C.W for 20 seconds.

WATER FLOW

NOTE: "I" mark indicates the operation of the water currents to adjust the unbalance load.

EFFECT

It reduces vibration and noise effectively during spinning.

2. FEATURE AND TECHNICAL EXPLANATION

WASH I DRAIN SPIN FILL RINSE 1 I DRAIN SPIN FILL RINSE 2 I DRAIN

...

MOTOR

C.W

SIGNAL

C.C.W

TIME (SEC.) 0.3 0.5 0.3 0.5 0.3 0.5

20 SEC. (About 13 Times)

4

PULSA TOR SYSTEM

When the new shaped pulsator is rotated C.W or C.C.W at a high speed, it makes the 'heart-shaped' water currents as
shown below.

AUTOMA TIC DRAINING TIME ADJUSTMENT

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

FUNCTIONAL PRINCIPLE

1. The micom can remember the time from the beginning 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 + 60

(T sec.)

WATER CURRENTS

A Water is pushed up near the tub

wall by rotation of the pulsator.

B Water is pulled down in the middle

of the tub by rotation of the
pulsator

C Water currents is generated by

rotation of the pulsator.

C

Rotate

A A

B

Good draining The washer begins spin process after drainage.

Draining

Bad draining Draining time is prolonged.

condition

No draining Program stops and gives the alarm.

Drain Time Movement of the Program

Less than 5 minutes Continue draining.

More than 5 minutes Program stops and gives the alarm with all lamps of the "COURSE" light up.

Residual drain time.
The time remembered by micom.

DRAINING

TIME

WATER

LEVEL

T4

T3

T2

T1

TRIP POINTS

RESET POINTS

*

*

*

*

*

*

*

*

LOW MED HIGH

0

60

160

220

280

(mm)

340

60

D1

D2

D3

D4

T1=D1+60 (Sec.) T2=D2+60 (Sec.) T3=D3+60 (Sec.) T4=D4+60 (Sec.)

SMALL

5

SOFTENER DISPENSER

This is the device to dispense the softener automatically by centrifugal force.
This is installed inside the Balancer Ass'y.

FUNCTIONAL PRINCIPLE

1. Softener stays in room (A) when poured into softener inlet.

2. Softener in moved from (A) to (B) by centrifugal force during intermittent spin process.

3. Softener flows from (B) to (C) during rinse process next to intermittent spin.

4. Softener in moved from (C) to (D) by centrifugal force during second intermittent spin.

After spin process is finished, the softener is added into the tub through softener outlet.

FLOW OF THE SOFTENER

FLOW OF THE SOFTENER INSIDE OF THE BALANCER

NOTE: Softener moves into the next room when r.p.m. of the tub is more than 100 r.p.m.
HOW TO CHECK MOVEMENT

Pour a reasonable amount of "MILK" into softener
dispenser and operate the washer with no load. In final
rinse cycle, make sure that the milk is added into the
tub through softener outlet.

Wash Intermittent Hold Intermittent Rinse Spin

Spin Spin

Normal Centrifugal Flow in Centrifugal Flow in

force force

Course (A) (B) (C) (D)

Room inside

ABCD

the balancer
Centrifugal force

Flowing by
weight

Balancer

Softener

B

A

D

C

outlet

Softener inlet

6

AUTOMA TIC UNBALANCE ADJUSTMENT

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

FUNCTIONAL PRINCIPLE

1. When the door is closed, the safety 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 are stopped and
rinse process is started automatically by P.C.B.
ASS'Y.

4. If the safety switch is operated due to the

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

CIRCULA TING-W ATER COURSE AND LINT FILTER

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 vane
creates a water currents as shown in figure.

Contact of safety switch door closing

Contact lever A

Normal(ON)

Position of
unbalanced
load(OFF)

door opening

NOTE:

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

Filter

Water
channel

Pulsator

Tub

Outer tub

7

LINT FILTER

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 CLEAN THE 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.

SYNCRONOUS MOTOR

STRUCTURE

FUNCTIONAL PRINCIPLE

1. When the SYNCRONOUS MOTOR connected to the power source the SYNCRONOUS MOTOR rotates 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 is 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.

PulsatorFilterBleach inlet

Pull

Loosen

Pulley

Lever

Inductive ring
Magent

Coil of motor
Magnet of motor

8

GEAR MECHANISM ASS'Y

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

PRINCIPLE OF BUBBLE GENERA TOR

STRUCTURE

Pulsator shaft

One clutch bearing

Brake lever

Spinner shaft

Planetary gear

Clutch spring

Clutch boss

Spinner pulley

Sun gear

Planetary gear

Pulsator

Motor

Internal gear

Planetary

Motor

V.belt

1 revolution

5 revolutions

Spinner
pulley

Bobbin & coil

Magnet

Trans core

Armature

V.BELT

Spinner Pulley

Bellows

Planetary

gear

1/5.0

Directly

Air out hole

Pulsator

Tub

Air

Air

Air in hole

Protector A

Protector B

9

PRINCIPLE OF INTAKE & OUTLET OF THE AIR

INTAKE : ARMATURE moves up, and BELLOWS inhales the air. At the same time, protector B is open and A is close.
OUTLET: ARMATURE moves down, and BELLOWS exhausts the air. At the same time, protector B is close and A is

open.

FUNCTIONAL PRINCIPLE OF TRANS & MAGNET

• The phase of A.C electric power changes to 60 cycle/second.

• The magnetic pole of trans core is changed by the change of the phase of A.C electric power.

• The core repeats push and pull (3600 times/min.) of the armature magnet.

FUNCTIONAL PRINCIPLE OF BUBBLE WASHING MACHINE

ACROSS SECTION

FUNCTIONAL PRINCIPLE

Bubble generator 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.

A.C A.C

N

S

NS

Magnet

Leaf spring

Trans core

S

N

NS

Air bubble

Tub

Outer tub

Pulsator

Nozzle

10

3. STRUCTURE OF THE WASHING MACHINE

Inlet Hose (COLD)

Inlet Hose

(HOT) [Option]

Water Tap Adapter
(COLD)
Water Tap Adapter
(HOT) [Option]

In case of screw-shaped inlet
hoses water tap adapters will
not be provided.

Drain Hose
Clamp

Under Base
Cover [Option]

Drain Hose

Pump Model

Non-Pump Model

• SOFTENER INLET

Pour softener into the
softener inlet just before
wash and it will be added
into the tub automatically
just before the final rinse.

• BLEACH
INLET

• TUB

• CONTROL

PANEL

• ADJUSTABLE

LEG

• POWER SWITCH

• HOOK HOLE

• LINT FILTER

• HANDLE

• GROUND WIRE

• POWER CORD

ACCESSORIES

UP

11

4. FUNCTIONS OF THE CONTROL PANEL

Control Panel

It has micom sensor .
As the buttons are pressed, the lamps indicating the
selection of your desired washing program will light up.

Power Switch

• Press this switch to turn
the power ON or OFF.

• After turning off the power,
wait for more than 3
seconds and then turn it
on again.

Temperature Selection
Button

• This button is used to
select the water
temperature according to
the clothes being washed.

• Press this button until your

desired temperature
indicator light comes on,
and it will repeat following
signs:
COLD ¤AWARM ¤AHOT

Water Level Selector

• This selector is used to select the
washing water level according to
the size of the wash load.

Start/Hold Button

• Press this button to begin
operation or to stop
operation temporarily.

• Operation and temporary
stop are repeated as it is
pressed.

Process Selection Button

• This button is used to select the
desired process of washing.

• If a full cycle of wash, rinse, and
spin is not desired, the desired
process can be selected by
pressing this button until your
desired process indicator light
comes on.

Course Selection Button

• This button is used to select the
washing course according to
the type of the clothes being
washed.

• You can choose one of the four
courses by pressing this button
until your desired course
indicator light comes on.

ON

POWER

OFF

[Option]

HIGH

MEDIUM

HOT

WARM

COLD

WATER TEMP.

WATER LEVEL

LOW

SMALL

FUZZY

SPEEDY

COURSE

HEAVY

WOOL

WASH

RINSE

PROCESS

SPIN

START/HOLD

12

HOW TO INST ALL THE W ASHING MACHINE
Selection of the Installing Place

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

How to install on an Inclined Place

5. DIRECTIONS FOR INSTALLA TION AND USE

Never install in these places.

• The place where it would be exposed to direct
sunlight.

• The place nearby a heater or heat appliances.

• The place where it would be supposed to be frozen in
winter.

• The kitchen with coal gas and a damp place like a
bathroom.

1. Height Setting

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

2.

Check the Horizontal Status

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

NOTES:

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

• The proper installation of the washing machine can
increase the wash effectiveness and the life of it.

If the washer is installed on an inclined floor, it could make considerable noise
and vibration and could cause a malfunction.
Use the height adjust rubber to adjust the washing machine so that it sits
properly.

In case that it goes over a
doorsill.
Don't let the height of the
drain hose exceed 20cm
from the gound.

Installing the Drain Hose [Non-pump Model]

¡

™

In case of extending the drain
hose.
Don't let the total length
exceed 3m.

Be careful that the end of the
drain hose is not immersed
in water.

20Cm

3m

£

13

Installing the Drain Hose [Pump Model]

Never forget to install drain hose before operating this
washing machine. The packing box opened, there are a
drain hose, a clamp, and a hose fixture.

Attach the hose guide, included
in the accessory kit, to guide
the drain hose over the tub or
standpipe.

PULL HOSE
THROUGH

55mm

FLEX HOSE
GUIDE
APART

Hook the drain hose to the
edge of the tub, paying
attention that there are no
bends or constractions along
the drain hose.

Or, connect the drain hose to a
standpipe of a diameter greater than
that of the drain hose and at a height
of min. 70cm.

70Cm min

Position the washing machine
next to the wall.

MUST be
ventilated

NOTES:

1. Let the highest point of the drain hose be more than 1m above the floor.
If not so, the water in the washer could be drained during operation

2. Be sure that the height of the drain hose must be less than 1.5m above the floor.
If not so, the water in the washer could not drain.

3. The hose guide MUST be fitted to the drain hose. The drain hose sould not extend more than 55mm from the end of
the hose guide. This is to prevent ‘SYPHONING’.
If necessary the drain hose can be trimmed to length.

Connect the drain hose to the
drain outlet at the rear side of
the washing machine, and
fasten it tightly with the clamp
supplied.

¡

™

¢

£

14

HOW TO CONNECT THE INLET HOSE
In Installing the Inlet Hose

¶

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

Connector D

Connector C

Rubber
Packing

Hose

™

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

• Please check the
rubber packing
inside the connector
C of the inlet hose.

™

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

Connector A

Tape

Connector B

Tap

Adapter

@

!

Connector B

∞

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

§

Connect the con­nector C of the inlet
hose to the water inlet
of the washer by
turning it clock-wise
to be fixed tightly.

• Please check the rubber
packing inside the
connector C of the inlet
hose.

For Screw-Shaped Tap

¡

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

£

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

¢

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

Collar

Water Tap
Adapter

Rubber
packing

Connector C

15

HOW TO GROUND THE WIRE
Grounding Method

• If your water tap or water pipe is
not made of metal, connect the
ground wire to a copper plate or a
metal rod and bury it in the earth.

* It is of no use connecting the
ground wire to the water pipe
made of plastic.

• If both your water tap and water
pipe are made of metal, connect
the ground wire to the base of
the water tap.

• In case of using 3-core cord,
there is no need for grounding.

20Cm

• Never connect it to a gas pipe because of danger of a
explosion.

• Never connect it to a telephone wire or a
lightning rod because it is very dangerous at a
thunderbolt.

Never Connect the Ground Wire to Such a Thing

Gas Pipe

Telephone Wire

16

6. PROCEDURE OF FULL-AUTOMATIC WASHING

Full Automatic Course

Fuzzy General clothes
Course

Speed Lightly stained
Course clothes: under-

wear, T-shirts,
Y-shirts, etc..

Heavy Heavily stained
Course clothes: blue-jean,

climbing clothes,
ruck-sack, sports
wear, etc..

Wool Delicate clothes:
Course Sweater, silk,

lingerie, etc.

After Operation is finished

• Close the water tap, and disconnect the inlet hose if
necessary.

• Turn off the power, and disconnect the power cord from
the electric outlet, being sure to take hold of the plug.

• Clean the lint filter.

Pressing

the Power

Switch

Selecting

Water level

• The Water
level is
selected
automatically

• The Water

level is fixed
to "HIGH"

Selecting Course

Kinds of the

Course

Clothes

POWER

HIGH

MEDIUM

LOW

SMALL

HIGH

MEDIUM

LOW

SMALL

START/HOLD

End of Washing

It is informed
by buzzer.

FUZZY

SPEEDY

HEAVY

WOOL

Procedure to

Press the Button

COURSE

START/HOLD

WATER LEVEL

FUZZY

SPEEDY

HEAVY

WOOL

FUZZY

SPEEDY

HEAVY

WOOL

FUZZY

SPEEDY

HEAVY

WOOL

COLD

HIGH

WATER LEVEL

HOT

WARM

WATER TEMP.

MEDIUM

LOW

SMALL

FUZZY

SPEEDY

COURSE

HEAVY

WOOL

WASH

RINSE

PROCESS

SPIN

START/HOLD

17

START/HOLD

COURSE

WATER LEVEL

WATER TEMP.

PROCESS

WASH

RINSE

SPIN

HOT

WARM

COLD

HIGH

MEDIUM

LOW

SMALL

FUZZY

SPEEDY

HEAVY

WOOL

Partial Selections Among Wash, Rinse or Spin

Stage 1 Only Wash

Stage 2 Only Rinse

Stage 3 Only Spin

Stage 4 Wash and

Rinse

Stage 5 Rinse and

Spin

Pressing

the Power

Switch

Selecting

Water level

Selecting Process

WATER LEVEL

HIGH

MEDIUM

LOW

SMALL

PROCESS

WASH

RINSE

SPIN

START/HOLD

End of
Process

It is informed
by buzzer.

POWER

WASH

RINSE

SPIN

WASH

RINSE

SPIN

WASH

RINSE

SPIN

WASH

RINSE

SPIN

WASH

RINSE

SPIN