GE EWA4600G0, WCSR4170G0, GJRR4170H0, GJSR4160H0, WHDRR418G0 Technical Service Manual

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Page 1

GE Consumer & Industrial

Technical Service Guide

November 2006

GE Washers With

Electromechanical Controls

and Mode Shifter Assembly

SIZE

O O

A RG

ARG

EWA4600G0

OPT

ARM

O T

BURL

L D

COT

YCARE

I C

31-9146

GJRR4170H0

GJSR4160H0

WCSR4170G0

WHDRR418G0

WJRR4170G0

WJSR4160G0

WLRR4500G0

GE Appliances General Electric Company Louisville, Kentucky 40225

Page 2

IMPORTANT SAFETY NOTICE

The information in this service guide is intended for use by individuals possessing adequate backgrounds of electrical, electronic, and mechanical experience. Any attempt to repair a major ap pli ance may result in personal injury and property damage. The man u fac tur er or seller cannot be responsible for the in ter pre ta tion of this in for ma tion, nor can it assume any liability in connection with its use.

WARNING

To avoid personal injury, disconnect power before servicing this prod uct. If electrical power is required for diagnosis or test purposes, disconnect the power immediately after performing the necessary checks.

RECONNECT ALL GROUNDING DEVICES

If grounding wires, screws, straps, clips, nuts, or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened.

GE Consumer & Industrial

Technical Service Guide

– 2 –

Page 3

Table of Contents

AC Line Filter ........................................................................................................................................................................ 17

Agitator .................................................................................................................................................................................. 13

Belt ........................................................................................................................................................................................... 20

Brake Test .............................................................................................................................................................................36

Component Locator Views ........................................................................................................................................... 12

Control Panel ......................................................................................................................................................................14

Control Timer ......................................................................................................................................................................14

Control Features ...............................................................................................................................................................10

Cover/Lid Assembly .........................................................................................................................................................19

Diagnostics and Service Information ...................................................................................................................... 30

Drain Pump ..........................................................................................................................................................................20

Front Panel ........................................................................................................................................................................... 19

Harness Fuse ......................................................................................................................................................................23

Inverter/Motor .................................................................................................................................................................... 22

Inverter/Motor Error Codes .......................................................................................................................................... 33

Inverter/Motor Test .......................................................................................................................................................... 35

Leveling Legs ...................................................................................................................................................................... 13

Lid Switch .............................................................................................................................................................................18

Mode Shifter Coil Test .....................................................................................................................................................35

Motor and Drive System ................................................................................................................................................ 5

Nomenclature .................................................................................................................................................................... 4

Schematic ............................................................................................................................................................................ 37

Shaft and Mode Shifter Assembly ............................................................................................................................26

Shaft and Mode Shifter Overview ............................................................................................................................. 6

Shipping Rod ....................................................................................................................................................................... 13

Suspension .......................................................................................................................................................................... 23

Temperature Selector and Options Switches ......................................................................................................16

Tub Assembly .....................................................................................................................................................................24

Tub Cover .............................................................................................................................................................................. 24

Warranty .............................................................................................................................................................................. 38

Washer Components ...................................................................................................................................................... 13

Water Level Switch .......................................................................................................................................................... 15

Water Valve ......................................................................................................................................................................... 17

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Page 4

Nomenclature

The nomenclature tag is lo cat ed under the lid in the right rear corner.

The mini-manual is located inside the control panel.

Nomenclature

Serial Number

The ﬁ rst two characters of the serial number identify the month and year of manufacture. Example: AL123456S = January, 2006

A - JAN 2006 - L D - FEB 2005 - H F - MAR 2004 - G G - APR 2003 - F H - MAY 2002 - D L - JUN 2001 - A M - JUL 2000 - Z R - AUG 1999 - V S - SEP 1998 - T T - OCT 1997 - S V - NOV 1996 - R Z - DEC 1995 - M

The letter des ig nat ing the year re peats every 12 years.

Example:

T - 1974 T - 1986 T - 1998

– 4 –

Page 5

Motor and Drive System

The new GE washers incorporate a new motor and drive system. The 120 VAC input powers a three phase induction inverter/motor assembly. The inverter produces approximately 340 VDC, which is pulse width modulated (PWM) to control motor speed. There is no location to check inverter output voltage to the motor. Voltage given is for information only. The motor is bidirectional, constantly reversing it’s direction to provide agitation. The motor is connected by a belt to the shaft and mode shifter assembly. By energizing or deenergizing a coil, the mode shifter assembly engages or disengages the shaft and tube. This allows for agitation and spin cycle modes.

Motor status is displayed through a series of ﬂ ash codes from a green LED located on the front side of the inverter just above the motor. These codes are stored in memory until cleared.

Green LED

Inverter/Motor

– 5 –

Page 6

Shaft and Mode Shifter Overview

The shaft and mode shifter assembly consists of the shaft and tube, mode shifter cam, and mode shifter coil. It operates in 2 distinct modes, spin and agitation.

The shaft and tube transfers power to the wash system. Motor power is transmitted to the shaft and tube from the drive belt to the drive pulley. The drive pulley is attached to one end of the agitator shaft and the agitator is attached to the other. The tube is ﬁ xed to the washer basket at all times.

The mode shifter changes the shaft and tube from spin to agitation. In agitation mode, the tube is ﬁ xed to the platform and the agitator shaft rotates freely. In spin mode, the agitator shaft is ﬁ xed to the tube and both rotate together.

Basket

Agitator

Tub

Inverter

Motor Pulley

Motor

Drive Belt

Tube

Agitator Shaft

Platform

Mode Shifter

Drive Pulley

View from Right Side

(Continued next page)

– 6 –

Page 7

Shaft and Mode Shifter Assembly

Mode Shifter Coil

Mode Shifter Cam

Drive Shaft

Agitate Position

Mode Shifter Coil

Mode

Shifter

Cam

Drive Pulley

Note: Mode shifter coil energized for agitate mode; cam teeth disengaged from drive pulley.

Spin/Idle Position

Mode Shifter Coil

Note: Mode shifter coil de-energized for spin/idle mode; cam teeth engaged in drive pulley.

Mode

Shifter

Cam

Drive Pulley

(Continued next page)

– 7 –

Page 8

Mode Shifter Operation - Agitation

The mode shifter is controlled by the motor inverter circuit. When the washer starts the agitation cycle, the inverter energizes the mode shifter coil. The magnetic field of the coil lifts the mode shifter cam, disengaging it from the drive pulley. Without the cam engaged, the drive pulley rotates only the agitator shaft.

MODE SHIFTER

AGITATE

PROGRAM

RUNS

(18 SEC)

At the beginning of the agitation cycle, the inverter energizes the mode shifter coil with 135 VDC (PWM) for approximately 18 seconds. This high voltage pulls the mode shifter cam up from the drive pulley. During this time, the motor also rotates clockwise and counterclockwise in short strokes to ensure the mode shifter cam has been released from the drive pulley. This operation is called the Mode Shifter Agitate Program. It is normal to hear metal-to-metal "clunking" sounds during this time as the cam and drive pulley disengage. The washer runs this program when the agitation cycle first starts, when power is restored if lost during agitation or when the user restarts the washer if paused.

Once the Mode Shifter Agitate Program has completed (18 seconds), agitation begins. During agitation, the inverter continues to supply 30 VDC (PWM) to the mode shifter coil. This voltage is sufficient to hold the mode shifter cam away from the drive pulley throughout the remainder of the agitation cycle.

The inverter motor controls the speed of agitation. The agitator stroke rate is approximately 30 strokes per minute. This rate is the same for all cycles. The speed of the motor controls the arc. At fast speed, the arc is approximately 360 degrees. At slower speeds, the arc is substantially less. It is the distance of the arc that determines normal or gentle wash cycles.

Mode Shifter Operation - Spin

At the beginning of the spin cycle, the inverter runs a short sequence (approximately 30

MODE SHIFTER

SPIN

PROGRAM RUNS

(30 SEC

seconds) to make certain the mode shifter cam is engaged with the drive pulley. The inverter does not supply voltage to the mode shifter coil during this sequence. Since the coil is not energized, the spring loaded cam drops down into the teeth of the drive pulley. During this time, the motor also rotates clockwise and counterclockwise in short strokes to ensure the cam has engaged with the drive pulley. This 30 second operation is called the Mode Shifter Spin Program. It is normal to hear metal-to-metal "clunking" sounds during this time as the cam and drive pulley engage.

Notes:

If the washer is paused while in agitation, it is NORMAL to hear sounds for an additional 30 seconds as the inverter control runs the Mode Shifter Spin Program to de-energize the coil and enter a pause state.

If the washer is in agitation and power is lost, the inverter control will run the Mode Shifter Agitate Program when power is restored.

If the washer is in spin and power is lost, the inverter control will run the Mode Shifter Spin Program when power is restored.

To help prevent out-of-balance conditions, the last 10 seconds of agitation on certain cycles will be short, fast strokes to help redistribute the clothes load prior to entering the spin cycle.

(Continued next page)

– 8 –

Page 9

END

CYCLE

COMPLETED

SPIN BASKET

BEGINS

SPIN CYCLE

STOP

COASTS TO A

USER PRESSES

LID SWITCH

TIMER KNOB IN

OPENS

STOP

SPIN BASKET

COASTS TO A

STOPS

(7 SEC)

SPIN BASKET

USER

PULLS

KNOB

TIMER

CLOSED

LID SWITCH

OUT

SPIN

CYCLE

CONTINUES

SPIN

MODE SHIFTER

PROGRAM RUNS

CYCLE

AGITATION

CYCLE

AGITATION

(30 SEC

ENDS

BEGINS

POWER IS

LOST

USER

PRESSES

LID SWITCH

(7 SEC

STOPS

SPIN BASKET

TIMER

KNOB IN

OPENS

POWER IS

RESTORED

SPIN

MODE SHIFTER

PROGRAM RUNS

STOPS

MOTOR

MOTOR STOPS

(30 SEC

SPIN

MODE SHIFTER

PROGRAM RUNS

USER

PULLS

TIMER

CLOSED

LID SWITCH

(30 SEC)

KNOB OUT

AGITATE

PROGRAM

MODE SHIFTER

CYCLE

AGITATION

RUNS

(18 SEC)

CONTINUES

RUNS

(18 SEC)

AGITATE

PROGRAM

MODE SHIFTER

CYCLE

START

TUB FILLS

SELECTED

PRESSURE

SWITCH

Control Logic Flowchart

OPENS

POWER IS

LOST

– 9 –

POWER IS

RESTORED

AGITATE

PROGRAM

MODE SHIFTER

RUNS

(18 SEC)

Page 10

Control Features

• Add detergent

• Add diluted fabric softener (on models with a fabric softener dispenser)

• Add clothes

• Select load size and other wash options

• Select wash cycle

• Close lid

• Pull knob

Quick Start Guide

Load Size

Loosely load clothes no higher than the top row of holes in the washer basket. The water level should just cover the clothes. Adjust the load size accordingly.

Temperature (on some models)

Select the water temperature for the wash and rinse cycles. Always follow fabric manufacturer’s care label or instructions when laundering.

Options (on some models)

2nd Rinse Option

When you use extra detergent or bleach to clean heavily soiled clothes, you may want to use the 2nd Rinse option. It provides a second deep cold rinse.

Step 1

Step 2

Step 3

Step 4

Controls

Features and appearance may vary between models.

GE Models

(Continued next page)

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Page 11

Wash Cycle—Cycle Selector Knob

The chart below will help you match the wash cycle setting with your clothing. The chart is ranked from longest to shortest cycle time and wash intensity.

Your washer may not have all these cycles. (Cycles vary by model.)

PREWASH For removing surface dirt from heavily soiled clothes. Make sure to follow with a

regular wash cycle.

COTTONS For heavy to lightly soiled cottons, household linens, work and play clothes.

or WHITES

EASY CARE For wrinkle-free and permanent press items, and knits.

DELICATES For lingerie and special-care fabrics with light to normal soil.

SPIN For draining the tub and spinning water out of the clothes.

RINSE SPIN For quickly rinsing chlorine, perspiration, stains, etc., out of clothes.

15 MIN/30 MIN For very soiled clothes. Begins with agitation, soaks for a specified period of time, then moves

AUTO SOAK through the rest of the cycle automatically.

2nd RINSE Provides an automatic, second deep rinse to thoroughly remove detergent or bleach from

your clothes.

– 11 –

Page 12

Front View

Component Locator Views

Pressure Hose

Suspension Rod

Inverter

Platform

Motor

Drive Pulley

Control Panel (in service position)

Water Level Switch

Drain Pump

Belt

Motor Pulley

Water Valve

AC Line Filter

Temperature

Selection

Switch

Options Switch

Timer

– 12 –

Page 13

Washer Components

WARNING: Sharp edges may be exposed when

servicing. Use caution to avoid injury. Wear Kevlar gloves or equivalent protection.

Shipping Rod

There is a new location for the shipping rod. The rod is inserted and removed through a hole located on the lower right side of the cabinet and now passes in front of the drain pump.

Shipping Rod

Rod Inlet Hole

Leveling Legs

The front legs are screw type and are adjusted by turning the legs counterclockwise to increase height. The rear leveling legs are contained in an assembly and will level the rear of the washer left to right.

To level the washer, tilt the washer forward to lift the rear legs off the ﬂ oor, then gently set it back down. Adjust the front leveling legs to level the washer front to back and left to right across the front.

Agitator

The agitator is a dual-action ratcheting type, which sets on an air bell coupling. Remove the agitator by grasping the bottom and sharply pulling up. To protect from back injury, use agitator strap, part number WX5X1326 or equivalent.

To align the agitator for reassembly, match the grooves in the air bell to the grooves inside the agitator. The ﬁ ns on the outside of the agitator are aligned with the grooves on the inside of the agitator. To remove the air bell coupling, remove the

-in. bolt and lift coupling off the shaft.

The shipping rod passes through the chassis rod brackets and the platform brackets.

Chassis Rod

Bracket

Platform Brackets

Chassis Rod

Bracket

– 13 –

Page 14

Control Panel

Control Timer

It is necessary to remove the control panel from the backguard and place it in the service position to access:

Control timer

•

Water level switch

•

Water valve

•

AC line ﬁ lter

•

Caution: To prevent damage to the control panel, place a protective pad on the cover/lid assembly.

To place the control panel in the service position:

Disconnect power.

Remove the three ¼-in. hex-head screws from

2. the rear of the control panel.

The control timer is mounted on the inside of the control panel. It is held in place with a single ¼-in. hex-head screw and 2 tab-locks.

To remove the control timer:

Disconnect power.

Using a ﬂ at blade screwdriver, remove the spring

2. clip that attaches the timer knob to the timer shaft.

Pull the knob and dial straight out from the

3. timer.

Screwdriver

Clip

Rotate the top of the control panel forward

3. approximately 1 inch and slide to the right to unlock the 3 bottom locking tabs.

Lift the panel up and off the cover panel and rotate

4. down.

Tab

Service Position

Dial

Knob

Place the control panel in the service position.

4. (See Control Panel.)

(Continued next page)

– 14 –

Page 15

Remove the wire harness from the control timer.

Remove the single ¼-in. hex-head screw.

Wire Harness

Lift up slightly on the tab where the screw

7. was located and rotate the timer clockwise (as viewed from back) to release it from the 2 tablocks.

Water Level Switch

The minimum ﬁ ll volume is 9 gallons. The water

• level measures approximately 7½ inches (6 holes) above the bottom of the basket.

The maximum ﬁ ll volume is 22 gallons. The

• water level measures approximately 15 inches above the bottom of the basket (between holes 2 and 3 from the top).

Minimum Fill Level

Control Timer Removed From Control Panel

Tab-lock

To remove the water level switch:

Disconnect power.

Remove the water level switch knob by gently

2. pulling it outward.

Place the control panel in the service position.

3. (See

Control Panel.)

– 15 –

Page 16

Note: The water level switch red and black wire has a locking tab that must be depressed to be disconnected. To remove this wire from the water level switch, depress the clip using a small blade screwdriver and pull the wire off the terminal as shown.

ELECTRICAL TERMINAL

RELEASE/LOCKING TAB

Disconnect the 3 wires and the pressure hose

4. attached to the water level switch.

Temperature Selector and Options Switches

To remove the temperature selector and options switches:

Disconnect power.

Remove the knob by gently pulling it outward.

Place the control panel in the service position.

3. (See Control Panel.)

Mark and disconnect the wires attached to the

4. switch.

Press the plastic locking tab, rotate the switch

5. counterclockwise, and pull the switch out of the control panel.

Pressure Hose

Disconnect

Press the plastic locking tab, rotate the switch

5. counterclockwise, and pull the switch out of the control panel.

Temperature Selector Switch

Plastic Locking Tab

Options Switch

Plastic Locking Tab

– 16 –

Page 17

Water Valve

The washer utilizes a 3-coil water valve. This “triple water valve” meters water ﬂ ow through ﬁ xed oriﬁ ces. The chart below identiﬁ es the valves energized at each temperature setting and approximate water temperatures obtained (+/- 5°F). These temperatures are based on the DOE nominal temperatures of 135°F for hot and 60°F for cold.

Setting Valve(s) Energized Temperature

Hot Hot Valve 135°F

Warm Hot Valve

Slow Cold Valve

Cool Hot Valve

Fast Cold Valve

Slow Cold Valve

Cold Fast Cold Valve 60°F

HOT SOLENOID

90°F

75°F

Remove the ﬁ ll hoses from the water valve.

Note: The ﬁ ll funnel hose is difﬁ cult to remove.

Remove the ﬁ ll funnel hose. Squeeze the clamp

5. and slide it back. Carefully break the hose loose by inserting a small ﬂ at-blade screwdriver under the hose to break the seal.

Remove the two ¼-in. hex-head screws that

6. hold the valve to the cabinet.

Fill Funnel

Hose

SLOW COLD SOLENOID

FAST COLD SOLENOID

•

The water valve has a ﬂ ow rate of approximately 2.1 gallons (8 liters) per minute.

•

Each solenoid coil has an approximate resistance value of 1.1K Ω.

•

When energized, there should be approximately 120 VAC at the appropriate coil.

The water valve is accessed by placing the control panel in the service position. It is inserted and retained in a cutout in the rear of the backguard and held in place by 2 hex-head screws. It is only available as a complete assembly.

AC Line Filter

The potential exists for the washer to cause electronic devices in the vicinity to experience disruption. In addition, electrical devices in the area could cause erratic behavior in the washer electronic control. To eliminate the likelihood of disruption, the washer is equipped with a conductive noise ﬁ lter. Should interference with electronic devices or erratic control behavior be reported, suspect a problem with the ﬁ lter. The ground wire attached to the ﬁ lter must have a good connection for the ﬁ lter to operate properly. Check to make certain that the ground wire is connected properly before replacing the ﬁ lter.

The ﬁ lter is accessed by placing the control panel in the service position. (See Control Panel.)

Note: When untaping and disconnecting the wires from the AC line ﬁ lter, note wire locations.

To remove the water valve:

Disconnect power.

Disconnect the wiring from the solenoids.

Place the control panel in the service position.

Control Panel.)

(See

AC Line Filter

– 17 –

Page 18

Lid Switch

The lid switch is installed in the cover assembly at the right front corner of the lid recess. The switch is held to the underside of the cover by a latch.

The lid switch is a safety feature that prevents the washer from agitating or spinning when the lid is open. The switch is closed by a magnet that is attached to the lid. When the lid is shut, the magnet will cause the switch to close the circuit, allowing normal functions to occur. When the lid is opened, the switch will open the circuit, which will prevent agitating or spinning.

If the lid switch:

Is closed, it will provide 120 VAC to the inverter/

• motor assembly at pin 6 of the C2 connector.

Is open, agitation and spin will not occur, but the

• timer will continue to advance and the washer will ﬁ ll with water and drain at the appropriate times in the cycle.

Was opened during a cycle, left open and the

• timer ﬁ nished the cycle, when the lid is closed again, the inverter completes a spin algorithm to ensure the mode shifter is de-energized.

Note:

The motor inverter control monitors lid switch

• operation by monitoring voltage through pin 6 on connector C2.

As a safety measure, the inverter control

• monitors lid openings by recording motor run sequences. If the control runs 4 continuous agitation/spin cycles (usually 2 complete wash cycles) WITHOUT seeing the lid switch open, it will shut down the motor and initiate a lid switch error code. This error will prevent the motor from operating until the problem is repaired.

To access the lid switch it is necessary to open the lid and reach under the cover assembly. To release it from the cover requires pressing the lid switch latch in ﬁ rmly and gently pushing the switch up. The switch can then be lifted through the opening.

Bottom View

Latch

Opens during agitation, the control will keep

• the mode shifter energized. When the lid switch closes while still in agitation, the washer will resume agitation.

Opens during the execution of the mode shifter

• agitate program, the control will stop the agitate program and drop the mode shifter voltage to 0 VDC. When the lid switch is closed again, the control will run the mode shifter spin program and then re-run the agitate program from the beginning.

Opens during the mode shifter spin program,

• the control will stop the spin program. When the lid is closed again, the control will run the spin program from the beginning.

Lid Switch

– 18 –

Page 19

Front Panel

Cover/Lid Assembly

The front panel is a removable, galvanized sheet metal section. The front panel is fastened at the top by 2 metal spring clips, and at the bottom by 2 metal tabs, which protrude from the base of the unit into slots in the panel bottom.

Most major mechanical components can be accessed by removing the front panel.

To remove the front panel:

Locate 2 spring clips between the top cover and

1. front panel by aligning a putty knife with left or right edge of lid.

Insert the putty knife and push forward to

2. release clips.

The cover/lid assembly is fastened at the front by 2 screws, on the sides by 2 metal catches, and at the back by 3 locking tabs that protrude from the bottom of the control panel.

Note: Do not allow lid to swing open when cover/lid assembly is removed. Damage may result.

To remove the cover/lid assembly:

Remove the front panel. (See Front Panel.)

Remove the lid switch. (See Lid Switch.)

Remove the two ¼-in. hex screws securing the

3. front of the cover/lid assembly to the cabinet.

Rotate the front panel forward and lift off the

3. bottom tabs.

Pull the top cover toward you while lifting up the

4. front edge to release the side catches. Slide the top cover to the left to release from the 3 tabs.

– 19 –

Page 20

Drain Pump

Belt

The drain pump is coupled to a 120 VAC, 60 Hz, 85 watt motor. The pump motor has an approximate resistance value of 12 Ω.

Note: If a wash cycle has started and the customer stops the washer by pushing in on the timer knob, the pump will not drain any water in the tub. The washer will go through a spin algorithm to deenergize the mode shifter and shut down. The water stays in the tub.

To remove the pump:

Note: Water will remain in hoses even when the tub

appears empty. Use care to avoid water spills.

Disconnect power to the machine.

Lower the drain hose into a small bucket to

2. remove any water remaining in hose.

Remove the front panel. (See

Disconnect the pump wires.

Front Panel.)

Since the belt provides constant tension, there is

• no need for adjustments (an adjustment method is not provided).

A worn or damaged belt can result in excessive

• brake time and will initiate a motor inverter slipping belt error code. This code will prevent the inverter/motor from operating.

To replace the drive belt it may be helpful to use

• the belt install tool (part number WX05X10102).

Belt Install Tool Kit

Pinch off the black sump hose to prevent water spills.

Remove hose clamps and hoses from the pump.

Remove two

-in. hex-head screws.

Sump Hose

Drain Pump

Pump Wires

To replace the drive belt using the tool kit:

Note: If not using the belt install tool, follow steps 1

through 3, and 6 through 7. Remove wire tie after step 7.

Disconnect power.

Remove the front panel. (See Front Panel.)

Center belt on drive pulley and secure tightly

3. with wire tie as shown on following page. Align wire tie as shown.

Stretch the belt install tool to ﬁ t over the end of

4. the motor shaft. (See Figure A.)

Slide belt install tool upward until it snaps into

5. the ﬁ rst groove of the motor shaft. (See Figure B.)

Center belt on motor shaft grooves and slowly

6. turn drive pulley clockwise.

Continue rotating drive pulley until belt is fully

7. engaged.

– 20 –

Remove wire tie and belt install tool.

(Continued next page)

Page 21

Note:

A new belt will be slightly smaller than the drive pulley.

•

A belt that has been installed on the drive pulley will stretch

• to the diameter of the pulley over time. This is normal and does not indicate a bad belt.

New Belt on Pulley

– 21 –

Page 22

Inverter/Motor

The inverter/motor assembly receives 120 VAC, which the inverter converts to approximately 340 VDC. The inverter then uses pulse width modulation (PWM) to supply the motor with an AC varying frequency to control speed.

Note: There is no location to check inverter output voltage to the motor. Voltage given is for information only.

The inverter/motor assembly consists of a motor and inverter board. A brake resistor is molded into the underside of the inverter cover and absorbs energy from the reversing of the motor during the braking cycle. A Hall effect sensor mounted on the inverter board measures motor speed (RPM).

The motor and inverter are available only as an assembly.

WARNING: Do not attempt to remove the inverter cover to service the board or brake resistor.

To remove the inverter/motor:

Disconnect power.

WARNING: Exposed terminals, inverter board, and rotating parts may cause injury and/or electrical shock. To reduce the risk of electrical shock, disconnect power and allow at least 5 minutes for capacitors to discharge before servicing motor. An audible clicking sound will be heard when the inverter capacitor discharges (inrush relay closing).

Remove the front panel. (See

Disconnect 3 wire harnesses from the motor.

Release the compression tabs that attach the

Front Panel.)

wire retainer to the front of the platform.

Remove the belt by rolling it off the bottom of

5. the motor pulley.

Remove the front two

-in. motor nuts and

loosen the rear 2 nuts.

Note:

•

There is a nonresettable fuse, located in the motor harness along the right side of the cabinet. If the fuse is open, agitate, spin, and mode shifting will not occur.

•

If the motor speed sensor fails, the motor will not run.

•

If the motor is not operating, the washer will still ﬁ ll with water, advance the timer, and drain.

•

If during an agitation cycle, water leaks from the tub and resets the pressure switch,

the inverter

control stops agitation and goes through the mode shifter spin program to de-energize the cam and the washer starts to reﬁ ll with water. The motor will not run again until the pressure switch is satisﬁ ed, at which time the inverter control will run the mode shifter agitate program.

If the mode shifter circuit fails or the coil opens,

• the tub will move back and forth with the agitator during the wash cycle.

Cover

Inverter

Motor

Drive

Pully

Disconnect

Wire Retainer

Belt

(Continued next page)

– 22 –

Page 23

Note: Minimal clearance exits between the 2 rear

-in. motor nuts, isolators, and the drive pulley.

Raise the front of the motor high enough to

7. disengage the motor alignment pin from the pin locator hole then slide the motor forward so that the 2 rear spacers clear the drive pulley.

Harness Fuse

A nonresettable 10-amp fuse is wired in the neutral side of the line. The fuse is wrapped in the motor harness located along the right side of the cabinet.

Remove the rear two

Tilt the top of the motor towards the shaft

-in. motor nuts.

and tube. Lift and remove the motor from the platform.

WARNING: The motor casing is NOT at chassis ground potential. Voltage may be present on the motor casing. To prevent electrical shock, do not touch the motor when connected to power.

Caution: To prevent motor or inverter board damage, make certain all isolators are in place when reinstalling motor to platform.

Note: When replacing the motor, ensure the motor

alignment pin is fully inserted in the pin locator hole in the platform before tightening motor nuts.

INVERTER

If the fuse is open, agitate, spin, and mode shifting do not occur. Check the fuse connections and wiring harness.

Caution: Bending the harness can damage the fuse.

If the harness is OK, check the inverter/motor; a shorted brake resistor or internal motor problem can cause fuse failure.

Alignment Pin

Pin Locator Hole

Note: When replacing a motor, check its brake operation. Place washer in a spin cycle and lift the lid after it has reached full speed. The basket should stop within 7 seconds. If time exceeds 7 seconds check the lid switch operation, and check the belt for worn ribs or slippage due to residue on the belt or pulleys.

Note: If the fuse is open, use harness fuse kit (part number WH49X10041). Instructions are included with the kit.

Suspension

The tub and motor assembly (spin basket, outer tub, inverter motor, shaft and mode shifter assembly and platform) is suspended by four rod and spring assemblies. The rod and spring assemblies are attached to each corner of the cabinet. They extend down and connect to the platform. This arrangement provides limited movement to the tub and motor assembly, independent of the cabinet when agitating and spinning, thus reducing cabinet travel and vibration. Front and rear suspension rod compressions vary to compensate for different model characteristics. The rods are color-coded to ensure that they are replaced in the correct position.

The outer tub has 4 dampening straps attached to the four corners of the cabinet. These straps prevent excessive outer tub rotation and movement during the wash cycle.

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Page 24

Tub Cover

Tub Assembly

Note: The tub cover can be replaced without

removing the tub.

To remove the tub cover:

Remove the front panel. (See Front Panel.)

Remove the cover/lid assembly. (See

Assembly.

Disconnect 4 dampening straps from the tub

3. cover by removing four

)

-in. hex-head screws.

Tub Cover

Cover/Lid

Note: The motor can be replaced without removing the tub. (See Inverter/Motor.) The tub assembly must be removed when replacing the spin basket, outer tub, or certain speed drive components.

To remove the tub assembly:

Disconnect power.

Lower the drain hose into a small bucket to

2. remove any water remaining in the tub.

Remove the front panel. (See Front Panel.)

Remove the cover/lid assembly. (See Cover/Lid

Assembly.)

Remove the tub cover. (See Tub Cover.)

Remove the agitator. (See Agitator.)

Remove the

-in. hex-head bolt and air bell

coupling from the agitator shaft.

Remove the air bell.

Release the cover from the outer tub by lifting

4. the 8 tabs.

Raise the front of the cover to clear the front

5. cabinet brace and tilt the tub forward.

Carefully lift and remove the cover from the tub.

Tab (1 of 8)

Note: When replacing air bell, tighten the head bolt to 90 in. lbs. of torque.

-in. hex-

(Continued next page)

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Page 25

Caution: Use only a rubber mallet, dead blow hammer, or impact wrench to remove the hub nut. Use of a steel head hammer may result in damage to the spin basket.

Note: The word “LOOSEN” and an arrow appear on the hub nut. Turn clockwise to remove.

Remove the left-hand thread, 1

-in. nut using an impact wrench or a hub nut wrench (WX5X1325) and rubber mallet or dead blow hammer.

WARNING: Exposed terminals, inverter board and rotating parts may cause injury and/or electrical shock. To reduce the risk of electrical shock, disconnect power and allow at least 30 seconds for capacitors to discharge before servicing motor. A distinct click can be heard from the relay on the inverter when the capacitor is discharged.

Disconnect the 2 outer motor harness

10. connectors, and the ¼-in. hex-head screw that attaches the platform ground wire.

Release the compression tabs that attach the 3

11. motor wire harness retainers to the front of the platform.

Disconnect

The hub nut must be torqued to 75 ft. lbs. To ensure the hub nut is tightened sufﬁ ciently when using a hub nut wrench, align the wrench with the holes in the basket and use them as a guide to determine when the nut will not move any further. Impact wrenches are set to more than 75 ft. lbs. and should tighten the nut sufﬁ ciently.

Platform Ground Wire

Wire Retainer (1 of 3)

Remove the water pressure switch hose from

12. the outer tub.

Pinch off the black sump hose to prevent water

13. spills.

Loosen the

14.

-in. screw-type hose clamp and

remove the sump hose at the tub.

(Continued next page)

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Page 26

Note: The front and rear rod and spring assemblies have different spring compressions and should not be interchanged. The rods are color-coded to ensure they are replaced in the correct position. Note the color location before removing.

Disengage the front rod and spring assemblies

15. by raising the tub and removing the spring assemblies from the platform.

Rod and Spring

Assembly

Shaft and Mode Shifter Assembly

The shaft and mode shifter assembly consists of the shaft and tube, mode shifter cam, and mode shifter coil. These parts come only as an assembly.

WARNING: Do not attempt to disassemble the shaft and mode shifter assembly.

To remove the shaft and mode shifter assembly:

Remove the tub assembly from the cabinet. (See

Tub Assembly.)

Remove the split ring and ﬂ at washer from the

2. drive assembly.

Note: The tub assembly will now lean forward. This allows clearance to reach behind the tub and access the rear rod and spring assemblies.

Disengage the rear rod and spring assemblies

16. by raising the rear of the tub and removing the spring assemblies from the platform.

Pull the top of the tub assembly toward the front

17. of the cabinet, then remove the basket from the tub.

Split Ring

Flat Washer

Note: A new seal (part number WH02X10032) is included with a replacement tub or shaft and mode shifter assembly. Replace the seal when the tub has been separated from the shaft and mode shifter assembly.

Remove the tub assembly from the cabinet and

18. place it on a protected surface.

(Continued next page)

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Page 27

Invert the tub assembly on a protected surface

3. and remove the plastic tie that holds the ﬂ ood hose to the platform.

Plastic Tie

Disconnect the mode shifter coil wire harness

4. from the motor.

Release the compression tab that attaches the

5. mode shifter coil wire harness retainer to the front of the platform.

Run the belt off the drive pulley and remove the

6. ¾-in. pulley nut.

Pulley Nut

Note: When replacing pulley, tighten pulley nut to 275 in. lbs. of torque.

Note: In the following step, after removing the pulley nut, it may be helpful to grab the center core of the drive pulley with one hand and gently tap one of the drive pulley arms with a hammer. The drive pulley will “pop” off the tapered shaft.

Retainer

Coil Wire Harness

Remove the drive pulley from the shaft and

7. mode shifter assembly.

Center Core

of Pulley

(Continued next page)

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Page 28

Remove the three

-in. hex-head bolts from the

bottom of the platform.

Remove the four ½-in. hex-head bolts that

9. attach the platform to the tub.

Lift the platform from the tub.10.

Place the platform upright on a protected

11. surface and remove the tub bearing washer from the tube.

Tub Bearing Washer

(Continued next page)

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Page 29

Remove the inverted single

12. from the top of the platform.

-in. hex-head bolt

Note: Torque the four lbs. when reinstalling.

-in. hex-head bolts to 90 in.

Inverted Bolt

Lift the shaft and mode shifter assembly from

13. the platform.

Shaft and Mode

Shifter Assembly

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Page 30

Diagnostics and Service Information

Timer Chart

(Continued next page)

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Page 31

Motor Circuit - High Speed Agitate

Motor Circuit - High Speed Spin

(Continued next page)

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Page 32

Motor Circuit - Low Speed Agitate

Motor Circuit - Low Speed Spin

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Page 33

Inverter/Motor Error Codes

Inverter/Motor Signal LED

LED On

An LED beneath the inverter cover can be viewed for diagnostic testing.

• When motor is operating normally, and running, the LED blinks at a constant rate of ½ second on and ½

• second off.

When motor is operating normally, and idle, the LED blinks at a constant rate of 1 second on and 1

• second off.

Motor/Control error condition – LED is on for .25 seconds and off for .25 seconds for a speciﬁ ed number

• of times, during a 6-second period. The 6-second cycle repeats continuously.

(Continued next page)

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Page 34

Inverter/Motor Signal LED Errors

When excessive stop time is encountered, more than 25 seconds, the LED blinks once for ¼ second and

• then off for the remainder of a 6-second period.

When a broken coupling or slipping belt is detected, the LED blinks twice at a rate of ¼ second on and ¼

• second off for the remainder of a 6-second period.

When an inverter ROM checksum error is detected, the LED blinks 3 times at a rate of ¼ second on and

• ¼ second off for the remainder of a 6-second period.

When a mode shifter error occurs, the LED blinks 4 times at a rate of ¼ second on and ¼ second off for

• the remainder of a 6-second period. The motor continues to operate with this error.

When a locked rotor is detected, the washer will sit idle for 15 seconds and retry. If the motor does not

• operate after 3 tries, the LED blinks 6 times at a rate of ¼ second on and ¼ second off for the remainder of a 6-second period.

When a lid error is detected by the lid switch counter, 4 agitate/spin pairs with no change in state of lid

• switch, the LED blinks 7 times at a rate of ¼ second on and ¼ second off for the remainder of a 6-second period.

When an over temperature condition is detected in motor, the LED blinks 8 times at a rate of ¼ second

• on and ¼ second off for the remainder of a 6-second period. The motor continues to operate at reduced performance levels.

When a brake resistor circuit error is detected in motor, the LED blinks 9 times at a rate of ¼ second on

• and ¼ second off for the remainder of a 6-second period. Maximum spin speed is limited to 50 RPM.

Critical Errors, #1, #2, & #7, will prevent inverter/motor from operating.

•

To clear errors, disconnect power until an audible clicking sound is heard when the inverter capacitor discharges (approximately 15 seconds). Open and close the lid 5 or more times in any 12-second period within the ﬁ rst 30 seconds of power-up. Errors will not clear if washer is in either agitate or spin mode.

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Page 35

Inverter/Motor Test

Voltage readings:

C2 Pin 1 = Ground C2 Pin 3 = Neutral C2 Pin 5 to Pin 3 = 120 VAC C2 Pin 6 to Pin 3 = 120 VAC with lid switch

closed

C7 Pin 1 to Pin 2 = 135 VDC* C7 Pin 1 to Pin 2 = 30 VDC*

Low Speed Agitate

C2 Pin 3 to C4 Pin 2 = 120 VAC C2 Pin 3 to C4 Pin 4 = 120 VAC

High Speed Agitate

C2 Pin 3 to C4 Pin 3 = 120 VAC C2 Pin 3 to C4 Pin 4 = 120 VAC

Low Speed Spin

C2 Pin 3 to C4 Pin 2 = 120 VAC C2 Pin 3 to C4 Pin 5 = 120 VAC

High Speed Spin

C2 Pin 3 to C4 Pin 3 = 120 VAC C2 Pin 3 to C4 Pin 5 = 120 VAC

* 135 VDC is present for approximately 15 seconds at the beginning of the agitate program. 30 VDC is present during the remainder of the agitate cycle.

Note: All electrical testing is done at harness plugs.

Mode Shifter Coil Test

LID SWITCH

Note: The mode shift coil connects to C7 connector on inverter/motor assembly. Unplug C7 connector and check continuity. Mode shift coil resistance value is approximately 98Ω @ room temperature (77ºF).

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Page 36

Brake Test

The brake resistor is permanently molded into the underside of the inverter cover.

Tub should stop spinning 7 seconds after lid is lifted.

• If the tub takes approximately 10 seconds to stop, check drive belt for wear.

• If tub coasts to stop, brake resistor has failed and inverter/motor assembly must be replaced.

• If the tub takes longer than 25 seconds to stop, the inverter will initiate a brake resistor error code. (See

•

Inverter/Motor Error Codes.)

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Page 37

Schematic

WARNING: Disconnect electrical power before servicing.

Caution: Label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation.

Verify operation after servicing.

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Page 38

Warranty

ı ı

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