Whirlpool Direct Drive Washer Service Manual L55
Contents
1. WW WC CC T lt PORAINH _____ FILL AND WASH DRAIN Hi SPIN DRIVE MOTOR HW WC CONTACTS CLOSED PER CHART WASH RINSE TEMP HC WC CC WASH TEMP SWITCH HOT VALVE COLD VALVE z o 2 5 LL 2 lt FILL AGITATE TUB DRAIN AGITATE AGITATE LO __________ FILL AGITATE CENTRIFUGAL ms e f pi romsa e ele mE Ms wxsswes ano 1 1 11 Sg EC HE 1 zm Hz o TE a blll vem mL ahaa 24 pen f sop H am 120 60 Hz GROUND TIMER MOTOR Fig 23 o o a gt N v ON PUSH OFF TIMER KNOB SW PULL l A del X RINSE SW CLOSE FOR EXTRA RINSE AGITATE 1 Once the tub fills with water the water level switch changes from the EMPTY position to the FULL position V to T closes Current is removed from the fill valves and applied to the drive motor and the timer motor 120 60 Hz CABINET GROUND TIMER KNOB we X RINSE SW TIMER MOTOR CENTRIFUGAL DRIVE MOTOR SWITCH a CLOSE FOR SW EXTRA RINSE CAPACITOR Fig 22. a E pen 5 E ___ avo ooon Es ees TTC Ee Pe Pe ELT Esp cer OS sess e fel jet i 19 l Js ts et ei s le 5 5 INDICATES MOTOR OFF 4 SECONDS 38
3. wx Fig 13 12 Screw the legs into the holes at the front corners until the lock nuts touch the washer base 13 Move the washer to its permanent location 14 Tilt the washer forward off the floor and set back down to adjust the rear self leveling legs 15 Check the washer for level both side to side and front to back Adjust the front legs as necessary Tighten the locking nuts to the base of the washer with a wrench If the nuts are not tightened the washer may vibrate excessively 16 Run water through both faucets to get rid of particles in the water lines 17 Attach the hoses to the water faucets The bottom hose should be connected to the hot water supply and the top hose should be connected to the cold water supply 18 Cut the shipping strap at the words CUT HERE and slide it off the power supply plug Fig 14 19 The hook end of the drain hose can be installed into a stand pipe Fig 15 A amp B or laundry tub Fig 15 C and secured with the shipping strap as shown Laundry Drain Requirements Laundry Tub or Utility Sink 1 Laundry tub or utility sink should have a minimum capacity of 20 gallons 2 Top of tub or sink must be a minimum of 34 and not more than 72 from the bottom of the washer Floor Drain 1 Floor drain systems require a Siphon Break Part No 285320 Siphon Break must be above the high water level in the washer tub a minimum of 28 from the bottom of the wash
4. 16 CONFIRMATION OF LEARNING EXERCISES 1 Contact sets 7 and 14 perform what function 2 Will the timer motor advance during a fill cycle 3 What is the purpose of the Neutral Drain mechanism 4 Why doesn t the water drain out during agitation 5 In Figure 22 page 8 what contacts are closed for increment 8 Agitate Lo What function did that change from increment 7 When you are able to complete the above exercise you may advance to the next section 17 NOTES Section Three COMPONENT ACCESS COMPONENT LOCATION ELECTRIC SHOCK HAZARD Disconnect the washer from the electrical power outlet before performing any service or repairs Replace all panels before operating Failure to follow these instructions could result in death or electrical shock ACCESSING COMPONENTS IN THE CONSOLE A number of critical components can be accessed from inside the control console These components are 1 Timer 2 Push button Switch Assembly 3 Water Level Switch Servicing Components in the Console 1 Remove the two Phillips head screws securing the front corners of the console to the washer top 2 Tip the console back on the hinges that secure the top of the console to the washer back Fig 44 19 Removing the Timer There are two types of timers One can be identified by a plastic body The other has a metal body Plastic Body NOTE DO NOT ATTEMPT TO REMOVE THE TIM
5. Drive Assembly Remove the outer cabinet Remove the agitator Remove the tub ring and basket Remove the pump and motor assemblies Carefully lay the washer on its back Remove the three 3 bolts securing the gearcase assembly to the tub support 7 Pull the gearcase straight out from the tube DA support assembly oe 8 Rotate the brake cam driver counterclockwise gt to release the brake Pull the brake and drive y tube straight out Fig 68 Rotate the brake cam driver counterclockwise to release the brake Pull the Fig 68 brake and drive tube straight out 27 CONFIRMATION OF LEARNING EXERCISES If a washer is available perform the following service access procedures 1 2 Remove the outer cabinet Remove the basket and tub assemblies Remove the pump and drive motor assemblies Remove the gearcase from the tub support Remove the brake and drive tube assembly Remove the suspension plate Reassemble and test unit 28 View Section Four of the Video Tape Section Four DIAGNOSIS AND TROUBLESHOOTING POSSIBLE CAUSE ACTION No low voltage to machine Check supply voltage 100 130 volts Thermal overioad tripped Check Overload PROBLEM 1 MOTOR WILL NOT RUN NOTE in diagnosing this Timer Switches Check continuit problem start the washer If Poor connection on timer Secure terminal the motor runs in either agi tate or d
6. TEMP SWITCH SWITCH WASH RINSE TYPE TEMP 3POS HC WC CC Pos we CC HW WC WW WC CC CONTACTS CLOSED PER CHART 32 5 7 1 2 16 Z e oc alls O15 E PE gt e 2 58 gt 6 2 halg gt a T o lt 7 JR IY 7 x Monne i B L WASH HI Tr ag DRAIN HI a BM Lefi EE J _ __ z I NI A M I lt LM i NM LI BH Ld nim a lt 5 14 m LJ 5 Fig 22 6 select the REGULAR cycle push in the push pull knob and turn the cycle selector to the REGULAR cycle Fig 23 7 According to the cycle sequence chart the following contacts on the timer will be closed Contact 10 Contact 5 both Contacts 7 and Contact 11 When the push pull knob is pulled out the electrical current is supplied to the circuit Since the tub is empty V to P is closed on the water level switch With a warm wash selected the current is supplied to both the hot and cold valves to allow warm water to enter the tub Fig 24
7. is designed to assist in training and familiarization of the Whirlpool Direct Drive Washer System and replaces any previous version For specific information on the model being serviced refer to the Use and Care Guide or Tech Sheet provided with the washer The wiring diagrams and strip circuits used in this Job Aid are typical and should be used for training purposes only Always use the wiring diagram on the product when servicing the unit This Job Aid can be used in conjunction with the video tape part no 787929 Rev A GOALS AND OBJECTIVES The goal of this Job Aid is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair Direct Drive Washers The objectives of this Job Aid are to Understand and follow proper safety precautions Successfully troubleshoot and diagnose malfunctions Successfully perform necessary repairs e Successfully return the washer to proper operational status TOTHE INSTRUCTOR INDEPENDENT STUDENT At the end of certain sections of this Job Aid you will find a Confirmation of Learning Exercise A pencil will be necessary to complete these exercises Certain exercises may require that service procedures be performed if an appropriate appliance is available This Job Aid is designed to be used with the video tape DIRECT DRIVE WASHERS Part No 787929 Rev As you use this Job Aid you will see a symbol that looks like this It in
8. the main drive gear and neutral drain mechanism rotate clockwise and the spin gear is idle 3 The trip lever holds the cam at the cam teeth 4 Eachrevolution of the main drive gear causes the trip lever to lift off a cam tooth as it contacts the button on the spin gear boss The first ten revolutions of the main drive gear will cause the mechanism to reset for neutral drain DRAIN AND SPIN 1 Now the machine drains out the dirty water The timer energizes the drive motor to run in the opposite direction through contacts 2 5 and both contacts 14 The motor now turns clockwise 120 VAC 60 Hz PULL ON PUSH OFF TIMER KNOB SW RINSE SW CLOSE FOR TIMER MOTOR CENTRIFUGAL ORIVE MOTOR 2 SWITC EXTRA RINSE r 13 5 2A E 5 She 2 lt 2 2 EIE gt gt ap alc alo gg BH MACHINE FUNCTION zB T 1H 5 82 2 DRANH HF LER ppm LL LE Amm FILL 1 7 11 18 121 1 511 7 D Kim mimm Fig 37 2 When the motor turns clockwise the main drive gear i
9. the water up and through the lint filter at the bottom of the basket The timer cuts power to the drive motor after the timer motor runs for the length of wash time set on the cycle selector The agitator shaft and the agitator stop mov ing back and forth and the wash function is completed Lint Filter Fig 34 SETTING THE NEUTRAL DRAIN The neutral drain mechanism provides a pump out prior to going into spin The gearcase uses the following components A spin Rack Retainer provides two locator pins and two 2 tabs for mounting neutral drain compo nents B Spin Pawl functions to drive the spin gear C D Spin Gear has a molded button added to one of three bosses The button is required during the Reset mode of the drain operation Spin Gear Cam a counting device to reset the neutral drain mechanism The cam is mounted to the hub of the spin gear Trip Lever engages cam teeth The molded button of the spin gear boss contacts the trip lever to lift it off the cam and advance it to the next cam tooth during the Reset mode of the neutral drain operation Latch holds the neutral mechanism stationary to allow for neutral drain pump out prior to Rack Retainer 12 Reset During Agitation 1 The gearcase will always provide direct into spin without draining first except when reset dur ing a brief three to five second agitation period 2 During agitation
10. 5 2 Once there is power to the timer motor the timer will start to advance You can hear the sound of the drive motor run ning The motor is coupled directly to the gearcase Fig 26 and will turn in the agitate direction The direction of current through the start winding determines the direction of motor rotation When con tacts 7 are closed the motor turns counterclockwise 3 When the motor turns counterclockwise the main drive gear in the gearcase will turn clockwise putting the washer into an agitation mode Fig 27 10 4 The main drive gear moves the shift actuator forward so that it engages the agitate cam Fig 28 and pushes it into the agitate position Fig 29 The action of the agitate cam and cam follower allow the agitate gear to be forced down by spring action so that it engages the splines on the agitator shaft Figures 30 and 31 Now everything is set up for agitation Cam Agitate Gear Splines Fig 30 5 Power for the agitate gear is supplied by the connecting rack which moves back and forth as it rotates around the cam on the main drive gear 6 The pump is driven directly by the motor and runs whenever the drive motor runs When the motor turns in the counterclockwise agitate direction it drives the pump in the reverse direction so water does not leave the tub Motor 11 7 The water is recirculated by the pumping vanes on the bottom of the agitator which force
11. CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS DIRECT DRIVE WASHERS JOB AID Part No 787930 Rev A MODEL SERIAL NUMBER DESIGNATIONS The model number for the Whirlpool brand Direct Drive Washer contains the following designations Model Number L S C 9 3 6 5 E Q 0 Marketing Channel if present Product Group L Laundry Domestic Laundry Gold L Large Capacity A W 27 P 24 Compact A W S Super Capacity 27 A W C Clean Touch Console P Push Button R Rotary Cycles Domestic 9 9 and 10 Speeds Domestic Temperatures Domestic A W Water levels Year of Introduction Color White 2 Almond Engineering Changes Numeric The serial number for the Whirlpool brand Direct Drive Washer contains the following designations Serial Number G 03 1 00003 Manufacture Location C Clyde Ohio Year of Manufacture Week of Manufacture Product Serial Number FOR TECHNICAL ASSISTANCE ON WHIRLPOOL DIRECT DRIVE WASHERS WHILE AT THE CUSTOMER S HOME CALL THE TECHNICAL ASSISTANCE LINE 800 253 2870 Have your store number ready to identify you as an Authorized Servicer INTRODUCTION This Job Aid DIRECT DRIVE WASHERS Part No 787930 Rev A provides the technician with information on the installation service and repair of Whirlpool built Direct Drive Washers This Job Aid
12. ER KNOB BY PULLING FROM THE FRONT Doing so will damage the split shaft and require replacing the entire timer assembly 1 To remove the timer knob push the knob in from the front 2 At the back of the timer pull the black tab out approximately 3 16 then pull the timer knob off the shaft BLACK TAB Fig 45 3 Slide the timer dial from the timer hub Unplug the wiring harness connector from the timer assembly terminals Remove the one 1 Hex head screw securing the left side of the timer assembly to the console mounting plate Then lift the left side and slide the tabs at the right side of the timer assembly from the console mounting plate MOUNTING SCREW 20 Metal 1 To remove the timer knob push the knob in from the front and unscrew it from the timer shaft Fig 47 Slide the timer dial from the timer hub Remove the two 2 Hex head screws securing the timer assembly to the console mounting plate Unplug the wiring harness connector from the timer assembly terminals Removing the Push Button Assembly 1 2 Fig 48 Removing the Water Level Switch 1 Pull the knob off of the switch shaft Fig 49 A 2 Unplug the wiring harness connector from the switch assembly terminals and remove DEPRESS pressure switch tubing 3 Remove the Hex head screw securing the Unplug the wiring harness connectors from the switch assembly terminals using a pair of needienose pliers P
13. abinet make sure the following steps are taken 1 When reinstalling the rear panel support press in on the rear panel and rotate the support to lock the panel in position Fig 54 2 The cabinet front flange must be under the washer base Fig 55 A 3 Holes in the cabinet side flange must be placed over the tabs in the washer base Fig 55 B Fig 54 REAR PANEL SUPPORT SERVICING THE TUB AND BASKET 1 To service the tub and basket the cabinet must be removed 2 Ifitis necessary to remove the inner basket begin by removing the tub ring by unsnapping the slots from the tabs on the tub There are a total of eight tabs one of which is a locator tab and which has a narrower slot than the others Fig 56 4 LOCATOR TAB 23 3 The Surgilator Agitator is removed by first pulling off the agitator cap and inner cap Then unscrew the 7 16 found un der the cap and pull straight up on the two piece agitator assembly The clutch and clutch dogs that provide the Surgilator ac tion are found in the upper portion of the agitator assembly Fig 57 Complete the removal of the basket by loosening the spanner nut on the spintube and expand the drive block with a wide bladed screw driver Fig 58 The basket can now be lifted straight up and out of lt Agitator Cap Inner Cap lt Clutch Clutch Dogs gt vi The tub assembly is secured to the tub support at three locations There
14. aphragm inside the water level switch 2 The water level switch goes from the EMPTY position to the FULL position de pending on how much tension there is on the diaphragm 3 As the water level increases in the tub it also causes an increase in air pressure in the air dome assembly Fig 18 A hose between the air dome and the water level switch transfers this pressure against the diaphragm in the water level switch causing electrical contacts V toT to close This happens when the tub is FULL Fig 19 4 When the tub is drained to approximately half its original setting the water level will return back to the empty position V to P Water Level Switch Trapped Air In Hose And Air Dome Assembly Air Pressure Fig 18 Air Dome Assembly Typical Water Level Switch WATER LEVEL SWITCH AT FULL POSITION P Contact d Closed T Contact Diaphragm Air Pressure Applied To Diaphragm Fig 19 HOT VALVE WASH TEMP SWITCH TYPE TEMP 420 CONTACTS CLOSED PER CHART 1 1 t 1 1 1 i 1 i R lt COLD VALVE 5 The water temperature is selected by several switches that are set for mixing hot and cold water during the fill Selecting a WARM wash with a COLD rinse closes these switches Fig 21 The cycle sequence chart shows us that timer contact 11 is closed during the wash cycle Fig 22 HOT VALVE WASH
15. are two screws a suspension spring and a locat ing tab at each of these locations Fig 59 the tub if Spanner Nut Drive Block SUSPENSION PLATE BASE p SUSPENSION Fig 58 SPRING SPRING BRACKET Fig 59 SERVICING THE DRIVE MOTOR AND PUMP The drive motor and pump can be accessed by removing the cabinet The pump is a sealed unit and cannot be serviced It should be replaced if it does not operate properly The pump engages the drive motor directly and is held in place by two retainer clips Fig 60 Fig 60 24 The motor of the Whirlpool Direct Drive Washer is a reversing type running in one direction for agitation and in the other direction for drain and spin The motor is held in place by two retaining clips and is coupled to the gearcase with two three prong couplers and an isolation coupler Fig 61 4 In older models the motor start capacitor is located in the console In newer models it is attached to the motor Figure 62 is a typical capacitor Fig 62 SERVICING THE FRICTION PADS ON THE SUSPENSION PLATE AND BASE ASSEMBLY The tub support and brake assembly are attached to the suspension plate which rests on the base plate This allows the tub and basket assembly to move in a gimbaling action The suspension plate and base assembly have friction resistance pads that provide protection between the metal assemblies 1 Remove the outer cabinet fro
16. art capacitor gt Motor windings 35 NOTE 36 View Section Five the Video Tape Section Five TECH TIPS WIRING DIAGRAM 120 VAC 60 Hz BK CABINET PULL ON PUSH OFF TIMER KNOB SW LID SWITCH TM W w RINSE SW TIMER MOTOR CENTRIFUGAL DRIVE MOTOR CLOSE FOR EXTRA RINSE HOT VALVE CONTACTS CLOSED PER CHART 1 WASH TEMP SWITCH t TEMP apos 1 5Pos HW Wc We CC I R O COLD VALVE 37 CYCLE CHART 440 YULX3 em IN3NVWH3d lt 5 D FILL AND WASH FILL AND WASH COOL DOWN SUDS RETURN RINSE Hi DRAIN Hi SPIN HI SPRAY FILL AGITATE eee OFF AGITATE AGITATE LO DRAIN Hi PAUSE FILL AGITATE LO SPRAY FILL AGITATE es AGITATE LO SOAK AGITATE LO RAIN PIN Hi DRAIN HI PIN Hi D E DRAIN Hi OFF OFF MACHINE FUNCTION TUB DRAIN FILL AGITATE AGITATE Hi AGITATE LO PRAY AGITATE LO 20 wale esee Fe ose LEE LE LEE TT ET ia 5 TTT es any III nimimm
17. commended It wei N grounding is recommended that a separate circuit serving only prong this appliance be provided BUpply cord 20 Plug in the washer 21 Run a small load and check for leaks and proper operation 4 COMMON INSTALLATION PROBLEMS Water does not pump out Causes a Drain hose too high over six feet b Blockage or crimp in the drain hose c Drain pipe not vented Water on the floor Causes A leaking hose on the water inlet valve or faucet b A leaking drain hose connection c The drain hose is coming out of the stand pipe when draining d Restricted drain pipe running beyond capacity The machine vibrates or walks Causes a Improperly installed front feet b The washer is not level c The shipping strap is not removed or a retaining pin is still attached to a shipping pin on the base of the washer d Floor not solid e Rear leveling legs not set The machine doesn t fill Causes a The water faucets are not turned on b There is a blockage in the hose or the fill valves c Drain hose siphoning too low or siphon break not installed CONFIRMATION OF LEARNING EXERCISES Unpack and install a Direct Drive Washer Have an instructor or colleague who is knowledgeable on the Direct Drive Washer check your installation Section Two THEORY OF OPERATION FILL 1 The water level is selected by setting the switch at the desired level This sets the ten sion on the di
18. eeth worn or broken 6 INTERMITTENT AGITATE 5 5 29 POSSIBLE CAUSE ACTION Replace agitator Replace gearcase PROBLEM 7 KNOCK DURING AGITATE 8 TRIES TO AGITATE DURING SPIN 9 WATER DOES NOT DRAIN FROM MACHINE Shift actuator or cam damaged Replace gearcase Clogged drain Remove obstruction Replace pump Drain hose kinked Relocate hose to prevent kink 10 SLOW OR NO SPIN Close lid Check continuit Lid switch defective E v m c 3 5 3 Ho vje 5 8 ole 5 o lt 5 5 5 5 NOTE In diagnosing this Lid switch disconnect plug open problem start the washer in Wiring harness spin and see if the clutch Timer switches gearcase itine clutch crum driver broken gearcase clutch drum does not spin all or some of Weak clutch spring the problem is inside the gearcase 11 MACHINE WILL NOT SPRAY Water temp switch if used RINSE 12 EXCESSIVE MACHINE WAL MACHINE WALKS tight leveling Shipping pins not removed Rear leveling legs stuck Rear Cabinet sides loose Remove pins Loosen Remove top clips push cabinet sides inward when reinstalling top clips Replace plate Replace plate Suspension plate sticky Suspension plate damaged or worn Suspension pads damaged or worn Tub support friction area sticky Tub support damaged or worn Suspens
19. er 2 Additional drain hose will be required for a Floor Drain installation Standpipe Drain 1 A minimum 2 diameter drain pipe with a minimum carry away capacity of 17 gallons per minute is required 2 Top of standpipe must be a minimum of 39 and not more than 72 from the bottom of the washer Electrical Requirements AWARNING ELECTRICAL SHOCK HAZARD GROUNDING INSTRUCTIONS For your personal safety this appliance must be grounded This appliance is equipped with a power supply cord having a 3 prong grounding plug Fig 16 To minimize possible shock haz ard the cord must be plugged into a mating 3 prong grounding type wall receptacle grounded in accordance with the National Electrical Code ANSI NFPA 70 1987 or the latest code and local ordinances If a mating wall receptacle is not avail able it is the personal responsibility and obliga tion of the customer to have a properly grounded 3 prong wall receptacle installed by a qualified electrician Plug into a grounded 3 prong outlet Do not remove ground prong Do not use an adapter 3 prong Do not use an extension cord Fig 16 grounding wall Failure to follow these instructions can result receptacle in death fire or electrical shock 3 prong grounding Observe all governing codes and ordinances A plug 120 VAC 15 or 20 amp fused electrical supply is E required A time delay fuse is re
20. he wa ter temperature switch to warm wash cold rinse Remove the brown red wire and the yellow red wire from the switch Test between the brown red terminal and brown terminal for continuity Test between the green black and yellow red ter minals for continuity Set the water temperature switch to hot wash warm rinse Test between green black and brown red conti nuity 33 WATER LEVEL SWITCH To test the water level switch remove the wires from the water level switch With the tub empty there should be continuity from violet to pink and no continuity between violet and tan With the tub full there should be continuity from violet to tan and no continuity from violet to pink TIMER To test the timer contacts select the contacts to be tested in this case contact 10 Using the cycle sequence chart as a reference turn the timer to the position where the contacts will be closed ZR LINE SWITCH MACHINE FUNCTION FILL AGITATE TUB DRAIN There should be continuity between the contacts Turn the timer to a position where the contacts are open There should be no continuity between the contacts CONFIRMATION OF LEARNING EXERCISE Test the following components to determine if they are good or bad Verify with your instructor the results of your testing b Timer bypass contacts 2 Motor centrifugal switch St
21. inkling A half tub drain in the super wash cycle allows the washer to drain heavily soiled water and refill before going into the main wash cycle Two minutes is more than long enough to drain the tub After two minutes the timer turns off the drive motor You can hear it stop momentarily before the timer advances to the SPIN function 6 Stopping the motor causes the latch to release the spin gear cam allowing it to engage the spin pawl 7 The spin pawl will engage one of the three bosses on the spin gear causing it to turn the spin tube and basket drive assembly in the spin direction Because the clutch is attached to the spin pinion gear the spin pinion gear turns and the clutch hub also turns 8 The clutch lining is forced against the clutch hub by the clutch spring As the clutch hub turns friction between it and the clutch lining causes the clutch lining to turn 9 Asthe clutch turns the tab that holds the clutch spring on the lining contacts the brake cam driver releasing the brake The tab on the clutch lining stays in contact with the brake cam driver The basket is attached to the spin tube with a drive block 15 aog O00 0 d o 6 0 00 C00 0 000 Ro oo a Brake Shoe Clutch Lining lt lt lt gt gt gt Clutch Housing Clutch Tab BRAKE CAM DRIVER Spin Pinion Spin Pinion Gear CLUTCH SPRING Fig 43
22. ion springs missing Broken or not connected Basket ballast missing Base bent out of square Replace pads Replace tub support Replace tub support Replace or reconnect springs Replace basket balance ring Replace base an PROBLEM POSSIBLE CAUSE ACTION 13 CLOTHING DAMAGE Leak at agitator shaft Leak at cover seal Use only 13 15 ounces in gearcase 15 WATER LEAKS Use of low water level with high Advise customer to use higher water agitation level 14 GEARCASE LEAKS OIL Leaking components Repair or replace 16 BRAKE SQUEAL Contaminated linings Replace brake shoe assembly COMPONENT TESTING WATER INLET VALVE To test the water inlet valve remove the wiring harness connectors from each solenoid Set the meter on the R X 100 scale and attach the meter probes to the terminals on each solenoid The meter should show between 200 and 900 ohms resistance 31 CENTRIFUGAL SWITCH To test the centrifugal switch remove the pump and disconnect the motor harness block from the centrifugal switch Remove the switch from the motor and remove the internal motor wires from the centrifugal switch Set the meter on the R X 1 scale and test the switch in the start position by pushing up on the switch actuator Continuity should be present between the red and black terminals and between the orange and blue terminals No continuity should be present between orange and vio
23. let Test the switch in the run position by releasing the actuator Between the orange and violet terminal continuity should be present Between the red and black terminals no continuity should be present DRIVE MOTOR DRIVE MOTOR AT MOMENT OF START MOTOR RUNNING DRIVE MOTOR To check out the motor first remove the motor harness from the centrifugal switch Then set the meter on the R X 1 scale and check the start winding for continuity by testing between the black and yellow wires A resistance reading between four and seven ohms should be present CENTRIFUGAL SWITCH 32 Check the high speed windings by testing between the blue and white wires A resistance reading between 3 4 ohm and 2 ohms should be present Check the low speed winding by testing between the violet and the white wire A resistance reading between 1 1 2 and 3 ohms should be present Check between the white and white black wires There should be 0 ohms resistance START CAPACITOR To test the start capacitor remove the wires from the capacitor leads Discharge the capacitor using an insulated screwdriver With the meter on the R X 100 scale place the meter leads on the capacitor leads The meter needle should deflect toward 0 and then reverse toward infinite resistance if the capacitor is good Is there is no needle deflection the capacitor is open WATER TEMPERATURE SWITCH To test the water temperature switch set t
24. m 37 Switch Cycle 38 Model and Serial Number Designations Inside Back Cover SAFETY YOUR SAFETY AND THE SAFETY OF OTHERS 1 IMPORTANT Safety messages have been provided in this manual where performing certain procedures may cause exposure to hazards that can kill or hurt you This is the safety alert symbol All safety messages will be preceded by the safety alert symbol and the word DANGER or WARNING These words mean DANGER YOU WILL BE KILLED OR SERIOUSLY INJURED IF YOU DON T FOLLOW INSTRUCTIONS YOU CAN BE KILLED OR SERIOUSLY INJURED IF YOU DON T FOLLOW INSTRUCTIONS All safety messages will identify the hazard tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed 5 unpack the washer remove the carton top View Section One of the Video Tape Section One INSTALLATION CONSIDERATIONS UNPACKINGTHEWASHER by carefully cutting around the top along the dotted line with a carton knife Fig 1 After removing the top cut down the four corners and remove the washer Fig 1 Refer to the installation instructions taped to the washer s lid Remove the shipping strap as follows a Carefully read then remove the yellow label securing the power supply cord to the back of the washer Fig 2 b Pullthe yellow shipping strap completely out of the back of the washer Be sure both cotter pins come ou
25. m the washer 2 Disconnect the wiring harness plug from the drive motor terminals 3 Disconnect the tub outlet hose from the tub 4 Remove the pump and motor 5 Lift the entire tub basket and tub support out as one unit The pads on the suspension plate are now ac cessible for replacement 6 Lift the suspension plate from the base assembly The pads on the base assembly are now acces sible for replacement SUSPENSION PLATE PADS SUSPENSION BASE gt A ASSEMBLY 7 2 2 PADS 7 PA BASE ASSEMBLY 25 SERVICING THE GEARCASE Remove the outer cabinet Remove the agitator Remove the pump and motor assemblies Carefully tay the washer on its back Remove the three 3 bolts securing the gearcase assembly to the tub support Pull the gearcase straight out from the tube support assembly Fig 64 d onm 9 Servicing the Clutch 1 Remove the gearcase 2 Toservice just the clutch lining compress the clutch spring with a pair of pliers and lift the lining from the clutch hub Fig 65 Clutch Band and Lining Fig 65 3 To remove the entire clutch assembly begin by removing the spin tube thrust washer up and off the agitator shaft and then remove the tube support ring Fig 66 Thrust Washer Support Fig 66 Ring 4 Remove the retainer ring and lift the clutch hub up and off the spin pinion Fig 67 Reriner Ring 26 Removing the Brake and
26. n the gearcase will turn counterclock wise putting the washer into the drain spin mode This time the shift actuator moves for ward on the other side and pushes the agitate cam in the opposite direction This causes the cam follower to push the agitate gear up and lift it off the splines on the agitator shaft The main drive gear and neutra drain mechanism will rotate and the spin gear is idle 3 The latch stops the washer from going into spin The latch is a weighted lever The long end of it swings out when turn ing in the spin direction as a result of centrifugal force This forces the short end inward where it can engage the spin gear cam and hold it in place Now the Spin gear cam slips the hub and turns with the latch the trip lever and the pawl The spin gear is stationary at this time 14 4 When the motor turns in the drain spin direction it turns the pump so that it pumps water out of the tub through the drain hose This also brings the water down over the filter flushing the lint off it and out the drain hose 0o 00009 0900000092 00000000 5 Because the bypass timer contact 2 is closed the drive motor will continue to run even after the water level switch returns to the empty position This is necessary because the water level switch will trip when the tub is still approximately half full A half tub drain is used in the permanent press cycle to cool down the wash water to reduce wr
27. rain the motor is OK Motor Check windings i Check continuity Check harness connections Check continuit Replace pump Replace gearcase Close lid ncorrect harness wiring Gearcase jammed Lid open in spin cycle SESS 5 315 215 olal 315 2 o S ms Replace coupler Replace gearcase Broken motor coupler Internal gearcase problem 2 NO AGITATE OR SPIN BUT MOTOR RUNS Check faucet turn on Check supply voltage 100 130 volts Check continuit Check continuit Check continuity of wiring Secure terminal 3 WATER WILL NOT ENTER MACHINE No low voltage to machine Water temperature switch Timer switches Wiring harness Poor connection at water infet valve solenoid Water level switch ncorrect harness wiring Water level switch out of calibration Check continuit Check harness connections Replace switch m 2 o Zh gt o c Customer misunderstanding of Check water level per specification correct water level sheet 4 WATER LEVEL TOO LOW Wiring harness Check continui See problem 1 Replace agitator Replace gearcase Replace gearcase Replace gearcase 5 MACHINE WILL NOT AGITATE Stripped agitator spline Damaged agitate cam Damaged agitate gear Broken agitator shaft Normal condition Replace gearcase Replace gearcase Pause in timer Damaged agitate cam Agitate gear clutch t
28. ress in the the two 2 tabs at the bottom of the switch assembly Then lift the bottom of the switch assembly up and lift it away from the console mounting plate Fig 48 HOLES water level switch mounting bracket to the console mounting plate Fig 49 A OR depress tab and rotate the switch 90 and pull it from the console mounting plate ROTATE 90 Fig 49 B Fig 49 B TO REMOVE ACCESSING COMPONENTS INSIDE THE WASHER CABINET Components inside the washer cabinet can be accessed by completely removing the outer cabinet as one unit Refer to Figure 50 for the following instructions 1 Remove the console mounting screws and tilt the console into the service position 2 Unplug the lid switch harness connector from the receptacle in the washer top 3 Remove the cabinet mounting clips by placing the flat blade of a screwdriver in the clip as shown in Figure 50 Inset 1 NOTE If necessary the washer can be operated VIOLET in all cycles with the cabinet removed JUMPER Install a jumper wire in the lid switch VN harness connector as shown Fig 52 f 2 ew IMPORTANT Use extreme caution when HARNESS P operating the washer with CONNECTOR the cabinet removed 22 5 The rear panel can be tilted back for additional access to components at rear of machine by twisting the rear panel support 90 and then tilting the rear panel back Fig 53 REAR PANEL SUPPORT REASSEMBLY NOTES When reassembling the c
29. structs you to view certain section of the video tape The section numbers will appear in the lower left corner of the television screen lt gt Whirlpool CORPORATION WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE OTHER THAN AUTHORIZED SERVICE TECHNICIANS 1998 Whirlpool Corporation Benton Harbor 1 49022 TABLE OF CONTENTS INTRODUCTION ice te Fea univ eris Eau Yeu Inside Front Cover TABLE OF CONTENTS ext d REX Tae tK Ere Y Ra UNI IRE EE eh ase ul vc D US IV SECTION ONE INSTALLATION CONSIDERATIONS 9009000000000 0900000000009090000000 1 SECTION TWO THEORY OF OPERATION 7 55 00000000000 19 Components Console 17 Components Inside the Washer Cabinet 22 SECTION FOUR DIAGNOSIS AND TROUBLESHOOTING 29 Diagnostic Chart 29 Component Testing 1 eue coe rr ec recen eese ener ra 31 SECTION FIVE TECH TIPS 909090009099000900909009000900 LAA A A 900000000000 37 Wiring Diagra
30. t of the washer Note that the power supply cord plug will still be attached to the yellow shipping strap Fig 3 c Firmly pull on the end of the yellow shipping strap that is attached to the bottom of the back of the washer Fig 4 This will release the self leveling leg mechanism Fig 3 X Fig 4 NOTE To prevent the two 2 shipping pins from falling the floor two 2 plastic holders are attached to the base Fig 5 When the cotter pins are removed the shipping pins fall into these holders These pins may be left in the holder cups Fig 5 INSET They will not interfere with the operation of the washer 6 Remove the items inside the washer basket 4 FLAT WATER Qe as ae INLET HOSES HOSE 7 Fig 7 8 Attach hoses to the water inlet valves Attach the bottom inlet first Be careful not to cross thread the inlet valves Hand tighten and then tighten to turn with pliers 9 Secure the hook end with the yellow hose 10 Push the other end of the drain hose down clamp Fig 9 over the drain hose connector on the back of the washer all the way down to the ribbed stop Fig 10 Secure with the clamp at the posi tion shown in Figure 11 D DRAIN HOSE NS CLAMP RIBBED STOP Fig 10 Fig 11 Fig 9 AL 10 Tilt the washer back and brace it with a piece of packing material Fig 12 11 Screw the lock nut down to within 1 2 inch of the base of the leg
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