Automatic Washing Machine

Maintenance Manual

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 Table of Contents

1. Check and Repair Methods of Washing Machine ............................... Error! Bookmark not defined.

2. Introduction of Non-failure Phenomena of Washing Machine ........ Error! Bookmark not defined.

3. Common Failure Diagnosis of Washing Machine .............................. Error! Bookmark not defined.

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1. Check and repair methods of washing machine
1) General check and repair procedures
(1) Understanding the washing machine to be repaired
Before starting the repair work, the service staff must have a basic understanding
of the repair object, carefully read its use instructions and analyze its electric circuit
diagram (as shown in Fig.
1);

Meanwhile he should understand its basic structure: the composition of such

assemblies as top frame assembly, the body assembly (including bottom bracket
section), tub assembly, etc. The electric components of the washing machine are briefly
described as follows:

① Washing motor
The washing motor is a capacitor-run single-phase asynchronous motor. Its main
components are the stator and the rotor. Between the stator and the rotor there is a gap,
called the air gap for the purpose of heat removal and discharge of moisture. The air
gap is usually made open type.
The washing motor is the main power section for the operation of the washing
machine and the power source for completing washing and spin of the washing
machine. If it is damaged, then the washing machine will be unable to carry out the
washing and spin process.
② Capacitor
The capacitor is composed of the casing, polar plate, dielectric medium, lead
terminal, etc. Its main performance indices are the electric capacitance, the voltage
resistance, dielectric loss and stability, etc. If the capacitance is too big, it can easily
cause too high temperature rise of the electric motor, which will expedite the aging of

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 the dielectric medium; If the capacitance is too small, it will reduce the starting torque
and overload capacity of the electric motor.
③ Torque motor
It is composed of a miniature single-phase permanent magnet synchronous motor,
retaining coils and reducing gears. Its main function is to open the drain valve through
the action of a steel wire or a plastic belt so as to drain water out of the washing
machine tub.
④ Inlet valve
It is composed of the magnetic coil, valve spool, valve body, etc. Its function is to
control water feed of the washing machine or cut off water source.
⑤ Water level sensor
It is composed of the air cavity, coil, iron core, casing, etc. Its function is to detect
the variation of water level in the washing machine tub.
⑥ Interlock switch
The interlock switch is also called safety protection switch, used to prevent from
injuring the user when washing machine is running at a high speed. Its function is to
make the washing machine automatically cut off the power supply when the top cover
for washing is opened (when reaching certain height) during high-speed running, and to
make the clutch automatically brake down. The bias switch is used to prevent from
cabinet bumping due to the clothes leaning to one side when the washing machine
spins.
⑦ Controller board
It is the control section of the washing machine. Its function is to provide the user
with different washing cycles so as to fulfill different workload.

(2) Failure location

In order to find out the cause to failure, the service staff can verify the failure
status by switching on the power supply for trial running. Meanwhile he needs to make
manual checks to further confirm the failure.
(3) Repair and testing of the machine
After the failure is located, the service staff needs to repair the washing machine.
He needs to replace the part with a new one. At the same time, what is noteworthy is
that the failure of the computer board is usually caused by the mechanical failure of the
peripheral electric components. Therefore, he should check the corresponding electric
parts while replacing the controller board. Otherwise, the failure will cause a vicious
cycle.
2) Common instruments and tools for repair of washing machine
(1) Universal meter
(2) Megameter
(3) Universal and special tools such as cross-head screwdriver, slotted head screwdriver,
sharp nose pliers, screwdriver with voltage tester, etc.

2. Introduction of non-failure phenomena of the washing machine

For the abnormal working phenomena of the washing machine, the service staff should first
eliminate the possibility of non-failure causes.

Failure symptom 1: Total operation failure.

Items to be analyzed and checked:
① Check if the power supply is cut off.
② Check if the power supply plug is securely inserted.

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 ③ Check if the power switch is turned on.
④ Check if “Start/ Pause” button has been pushed.
⑤ Check if the safety fuse is blown out.
⑥ Check if the washing machine is in the cycle of delay wash.
Failure symptom 2: Water feed failure.
Items to be analyzed and checked:
① Check if the water tap is opened.
② Check if the inlet hose or filter screen of the inlet valve is blocked.
③ Check if water feed is cut off.
④ Check if the interior of the washing machine is frozen in the case of winter.
⑤ Check if power supply is available.
Failure symptom 3: Water drainage failure.
Items to be analyzed and checked:
① Check if the drain pipe is laid down.
② Check if the drain outlet is blocked or collapsed.
③ Check if the drain pipe is laid too high.
④ Check if the power supply is available.
Failure symptom 4: Spin failure.
Items to be analyzed and checked:
① Check if the clothes are biased to one side.
② Observe if the washing machine is placed levelly.
③ Check if the top cover for washing is opened.
④ Check if the power supply is available.
Failure symptom 5: After the cycle finished and the power supply switch has been turned off,
the operating panel, however, is still hot.
Cause:
① The computer parts are still alive due to the need of memory function of the computer
even if the power supply is switched off.
② Because some parts need to eliminate the heat on them during or at the end of the cycle,
some heat will still be remained on the operating panel.

Failure symptom 6: Automatic spin cycle stops suddenly during operation

Cause:
① Check if the top cover is opened.
② Check if the clothes are biased to one side.
③ Check if the custom cycle program is wrong.
Failure symptom 7: Water comes in during the washing process
Cause:
① Check if additional clothes are put in during the washing process.
② Because the water level sensor detects the fall of level, water makeup is triggered
automatically so as to achieve the best washing effect.
③ Re-adjust water level (up).
Failure symptom 8: The speed is slow at the beginning of spin and spin is intermittent
Cause:
This is a specially designed intermittent spin program in order to achieve better spin effect.
Failure symptom 9: Rinse action is triggered suddenly during spin
Cause:
① The unbalance of the clothes is serious, but is corrected by rinsing after water is fed.

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 ② The cover of the washing machine is opened many times during spin process.
Failure symptom 10: Machine stops during the running process
Cause:
① Check if there is any error indication.
② If the power supply is stopped during the running, the already input program will be
erased, the washing machine won’t continue to run after the power supply is switched
on, please input parameters again and then switch on the power supply in order to run
the machine.
Failure symptom 11: No water is fed when starting from rinse cycle
Cause:
In order to squeeze out water and detergent out of the clothes, the program will start from
spin, following it the water can be fed. (When there is a certain amount of water in the tub,
the program will start from water drainage).
Failure symptom 12: Button press is ineffective
Cause:
After the program starts, only the water level push button is operative during the washing
process. In order to modify other settings, please push “Start/Suspend” button or turn off the
power supply and set the parameters again.

3. Common Failure Diagnosis of the Washing Machine

The service staff should learn the failures of the washing machine and find out the failure
causes through analysis and judgment, as shown in the following examples.

Example 1
Failure symptom: Switch on the power supply and push the power supply switch, the computer
indication lamp is not turned on.
Analysis and repair:
① Check if the power supply is stopped or the plug receptacle is in loose contact in the power
supply section.
② Check if the fuse in the power supply circuit is blown out. If the fuse is blown out, then the
service staff should check for the blowout condition of the fuse. If the fuse is totally broken
or the fuse end is broken, it means there is a short-circuit phenomenon in the electric circuit,
When replacing the fuse, he should check if there is a short-circuit in the computer board,
electric motor, electromagnet, etc. and eliminate it. If the middle part of fuse breaks on sharp
point type, then it is caused by circuit overloading. In this case the machine can be started
for use just by replacing the fuse.
③ If the fuse is normal, then the failure lies in the program controller. Check if the plug wire is
inserted in position. If the plug wire is normal, then replace the controller with a new one to
see if the failure can be eliminated.

Example 2
Failure symptom: Switch on the power supply and push the start button, the controller indication
light is normal, but the water inlet valve fails to feed water.
Analysis and repair:
① If the inlet valve has a “humming” sound, this indicates that the inlet valve is powered on.
The service staff should first check if the water tap is switched on, or the water pressure is
too low, or the filter screen of the inlet valve is blocked due to long-time service. If it is
blocked, then clean it with a brush. If this failure is eliminated, he should check if the
pressure relief hole of the inlet valve is blocked. If the hole is blocked, the control chamber
of the inlet valve always keeps a high water pressure, making the rubber valve gasket hard to

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 open. In this case, the failure can be eliminated by only getting through the hole with a fine
needle.
② If the inlet valve does not have a “humming” sound, then the repair steps should be taken as
below:
a. Check if the inlet valve cord is inserted in position.
b. Check if the winding circuit of the inlet valve is open. Replace the valve with a new one
to see if the failure can be eliminated.
c. Check if the output voltage of the inlet valve on the controller board is AC220V. If the
output voltage is abnormal, replace the controller board.

Example 3
Failure symptom: Switch on the power supply of the washing machine. Open the water tap and
push the power supply switch without pushing the start button. The inlet valve begins to feed
water, but the controller Start/Pause switch cannot control the water feeding of the inlet valve.
Analysis and repair:
Perhaps the bidirectional thyristor valve on the controller board which controls the inlet
valve is short-circuited, which makes the Start/Pause switch fail to control the water feeding of
the inlet valve. In this case, he should open the controller board and measure the output voltage
of the inlet valve on the controller board with a universal meter. After the failure is located, he
should replace the controller board.

Example 4
Failure symptom: Power supply is not switched on. Open the water tap, and the water inlet valve
begins to feed water.
Analysis and repair:
① The pressurizing hole in the inlet valve rubber cushion is blocked which makes the control
chamber fail to generate a high static pressure within it and thus cause the rubber cushion
fail to close the valve. As a result, water often comes into the inlet valve. In this case, open
the inlet valve and get through the pressurizing hole with a fine needle.
② Heat generation in the coil is caused due to the short-circuit of inlet valve, which cause the
plastic frame deformed. The iron core is seized in the frame and cannot be ejected to close
the pressure relief hole. As a result, water often comes into the inlet valve. In this case, he
can only replace the inlet valve.
③ The small spring in the coil is seriously eroded with an insufficient spring force, resulting in
failure of the iron core to effectively close the pressure relief hole. As a result, water
continuously comes into the inlet valve. In this case, he should replace the small spring or
the inlet valve.

Example 5
Failure symptom: Switch on the power supply of the washing machine. Open the water tap and
push the start button. The inlet valve begins to feed water. However when the set water level
height is exceeded, the washing machine will not run and the inlet valve cannot stop feeding
water.
Analysis and repair:
① Because the air cavity of water level sensor leaks so that the contacts cannot be connected.
As a result, the inlet valve cannot stop feeding water. In this case, the sensor should be
repaired.
② Because air leaks due to loose connector of the pneumatic pipe, making the water level
switch fail to close, As a result, the inlet valve cannot stop feeding water. In this case, the
pneumatic pipe should be re-installed. Upon installation, the end of the pneumatic pipe

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 should be cut by 10mm and coated with glue. If the pneumatic pipe becomes aged due to
long-term service, it should be replaced with a new one.

Example 6
Failure symptom: After the washing machine finishes washing and enters spin condition, the
spin tub does not rotate while the washing impeller is always rotating clockwise.
Analysis and repair:
① Spin tub does not rotate because the clutch ratchet is not disengaged from the ratchet wheel.
In this case, the distance between the clutch ratchet and the ratchet wheel should be adjusted
to the correct position. And when the brake bar is reset, the ratchet should be inserted into
the ratchet wheel.
② Because the spacer sleeve screw of water drainage torque motor becomes loose or the spacer
sleeve is too far away from the brake bar of the clutch. When the torque motor picks up, the
ratchet cannot disengage itself from the ratchet. As a result, the spin tub cannot spin. In this
case, the distance position of the torque motor spacer sleeve should be adjusted with the gap
kept at 2.5mm~3.5mm.
③ The square-wire spring cannot drive the spin shaft to rotate due to serious wear and rusting
of the square-wire spring of the clutch. In this case, the square-wire spring or the clutch
should be replaced.

Example 7
Failure symptom: After the washing machine finishes washing and enters spin condition, the
spin tub does not rotate and there is a buzzer alarm.
Analysis and repair:
In this case, the service staff should check if it is due to the unclosed machine cover which
causes spin failure. Otherwise, the contact of the interlock switch is defective. He should open
the back control board to adjust the contact or replace the interlock switch with a new one.

Example 8
Failure symptom: After the washing machine is powered on, open the water tap and push the
power supply button and start button, the inlet valve fails to feed water. But the washing
impeller can rotate normally in both directions.
Analysis and repair:
Water level sensor has a trouble. In this case, the service staff should first open the back
control board and replace the water level sensor.

Example 9
Failure symptom: After the washing machine is powered on, open the water tap and push the
power supply button and start button, the inlet water does not feed water or feed water for about
2 minutes. Then all the program indication lights are flashing, and the power supply switch does
not work when pressed.
Analysis and repair:
The controller can not connect the water level signal of water level sensor due to dropoff or
loosening of the insert of the electronic water level sensor or open circuit of the coil within the
water level sensor which causes all the indication lights to flash, and the machine cannot be shut
down by pressing the power supply switch. In this case, the service staff can only pull off the
power supply plug, and open the back control board to check if the insert of the water level
sensor is placed in position. If the trouble still cannot be eliminated, the water level sensor
should be replaced with a new one.

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Example 10
Failure symptom: The washing machine takes a long time to drain water, causing an alarm.
Analysis and repair:
① Remove the drain valve cover and take out the spool. Check if there are foreign matters
within the drain valve body. If yes, they should be cleaned thoroughly.
② Drain pipe distortion causes unsmooth drainage. In this case, the drain pipe should be
re-installed.
The drain pipe is laid incorrectly with the height of the drain pipe exceeding 10cm or the
length of drain pipe exceeding 3m that causes too long drainage time.

Example 11
Failure symptom: It is found that the washing machine body carries electricity during operation.
Analysis and repair:
In this case, the service staff should check if it is electric leakage or faradic electricity. If it
is electric leakage which causes the machine body to carry electricity, this is very dangerous.
Usually this is caused by the occurrence of short circuit of the electric section, or damage of the
insulation due to moistening or water leakage, or insulation part contacting with the metal due
to frictional rupture and other various causes. In this case, when the service staff contacts the
machine body with an electroprobe, he can find the electroprobe turns on. In this case, he should
check the cause for electric carriage and eliminate it.
If the washing machine has no ground wire, faradic electricity may occur. The current of
faradic electricity is very small and won’t injure human body. The static electricity can be
eliminated by attaching a ground wire to the machine body. The service staff can also check the
electric receptacle in the user’s house and attempt to exchange the position of the wire under
voltage and the zero line of the receptacle in the user’s house and insert the plug of the washing
machine for test. If the poles of the power supply are reversely connected, the load coil in the
washing machine is under a high electric potential, which causes the machine body to carry
faradic electricity. Such faradic electricity won’t occur if the machine is provided with a ground
wire. If the machine is not provided with a ground wire, he can exchange the position of the
wire under voltage and the zero line of the power supply plug. Generally, the faradic electricity
can be eliminated by doing so.

Example 12
Failure symptom: The washing machine spins weakly.
Analysis and repair:
When the washing machine is loaded to the rated capacity and the spin tub rotates feebly,
the possible causes are as follows:
① The belt becomes longer due to loosening and wear. The belt slips during operation and
cannot drive the spin tub to rotate, causing feeble spin. In this case, the motor position
can be moved backward so as to tighten the belt or replace the belt.
② The square-wire spring of the clutch is worn, so its diameter becomes bigger and it
becomes rusty, too which makes the square-wire spring cannot hold the spin shaft tightly
to drive the spin tub to rotate normally. Weak spin is thus caused. In this case, the service
staff should remove the belt pulley of the clutch, replace the square-wire spring or
replace the clutch.
③ The capacitor fails, i.e. aging failure. In this case the capacitor should be replaced.

Example 13
Failure symptom: When the washing machine washes, the impeller rotates on one direction.
Analysis and repair: There are several causes for the impeller to rotate only on one direction

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when the washing machine washes:
①. If the impeller only rotates counter-clockwise, this indicates the clutch ratchet has been
disengaged from the ratchet. The square-wire spring is kept under working condition
and holds the spin shaft tightly to drive the impeller to rotate on one direction. In this
case, the trouble can be eliminated by resetting the ratchet to normal position.
②. The root of square-wire spring is broken, so the square-wire spring is kept under
working condition and holds the spin shaft tightly to drive the impeller to rotate
unidirectionally. In this case, the service staff should remove the clutch belt pulley and
take out the square-wire spring. Change it with a new one or replace the clutch.
③. The washing thrystor valve on the PC board is damaged or a leading-out wire on the PC
board connected with the leading wire of the motor is open circuited. In this case, the
PC board or the leading wire should be replaced.

Example 14
Failure symptom: The washing machine spins with a big vibration under idle condition.
Analysis and repair:
The causes for big spin vibration of the washing machine under idle condition are as
follows:
① The salt water in the balancing ring leaks, so the salt water becomes inadequate during
high-speed rotation, making the tub body eccentric. The balancing ring fails to function
as a balancing role and a damping role either. In this case, the service staff should
remove the washing tub and replace the balancing ring.
② The damping hanger spring fails. If the spring is too hard or too soft, then it cannot
function as a cushioning role during a high-speed rotation. In this case, the service staff
should remove the hanger assembly and replace the damping spring.
③ The retaining nut of the spin tub becomes loose. The loosed internal tub generates
vibratory noise and tub-knocking sound. In this case, the service staff should remove the
impeller and fasten the retaining nut of the spin shaft.
④ The fixing seat of the washing tub is distorted. The internal tub generates vibratory noise
and tub-knocking sound during high-speed rotation. The service staff should remove the
washing tub and replace the fixing seat of the washing tub.

Example 15
Failure symptom: When the washing machine washes, the washing tub rotates along the rotating
direction of the impeller, i.e. tub followup.
Analysis and repair:
After the clothes of the rated capacity are put into the washing machine, the washing tub
rotates clockwise, sometimes it gives a “cheeping” sound, the reason lies in that the torque of
the clutch brake spring is too small, causing tub follow-up to happen easily. (As a standard, 12
mins are a cycle. The rotation of the tub does not exceed 12 turns). The repair method is as
below:
① Remove the clutch and increase the angle of the brake spring. Note that the angle should
not be adjusted too big in order to avoid that too big torque causes insufficient drawing
force of the drainage electromagnet and causes burning of the drainage electromagnet.
② The distance between the spacer sleeve of the drain valve and the brake arm should be
adjusted between 2.5mm and 3.5mm.
③ The distance between the adjusting screw and brake arm should be adjusted between
5mm and 10mm.
④ Replace the clutch.

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Example 16
Failure symptom: The washing machine washes feebly.
Analysis and repair:
The washing machine washes feebly when it runs at the rated washing capacity of clothes.
The causes for failure in tumbling the clothes are as follows:
① Loose or worn belt, which makes the friction area of the belt pulley reduced and the belt
slip, thus causing the machine wash feebly. In this case, he can move the motor position
backward so as to tighten the belt or replace it.
② Worn gear of the clutch input shaft and gear of the reducer output shaft, causing gear to
slip, thus causing feeble washing. In this case, he should check for the clutch output shaft.
Before making checks, he should first fix the output shaft, then turn the belt pulley. If the
input shaft does not rotate, this indicates that the gear of the clutch input shaft and the
gear of reducer output shaft slips, he should replace the clutch.
③ Worn impeller inserts, causing slip during load operation, thus making the clothes fail to
turn or the impeller fail to rotate. Therefore, the machine washes feebly. In this case, he
should replace the impeller.
④ The interior of the lead wire of the motor’s secondary winding or the interior of the lead
wire of the capacitor is short-circuited, causing feeble washing. When repairing, he
should first charge the two end wires of the capacitor for 3s, then short-circuit the two
wires. If there are no strong sparking sounds, he should replace the capacitor. When he
checks the motor, he can test it with a new capacitor. If the motor can run normally, this
indicates the capacitor is defective and the capacitor should be replaced. If the problem
still exists after such replacement, this indicates the motor is defective and he should
replace the motor.

Example 17
Failure symptom: Drain valve leaks when the washing machine is in non-drainage condition.
Analysis and repair:
① There are foreign matters within the valve body, for example, thread pieces, coins, etc.,
which make the valve spool fail to close and causes valve leak. In this case, he should
open the back cover, remove the split pin, loosen the valve cover, take out the valve
spool and remove the foreign matters.
② Valve leaks due to longer service time, aging, shortening, hardening of the valve spool
or insufficient compression force of the holddown spring of the valve. In this case, he
should replace the spool or the holddown spring of the valve.

Example 18
Failure symptom: Drain valve leaks when the washing machine is in non-drainage condition.
Analysis and repair:
① There are foreign matters within the valve body, for example, thread pieces, coins,
barrettes, etc., which make the valve spool fail to fully close. In this case, he should
open the back cover, remove the split pin, loosen the valve cover, take out the valve
spool and remove the foreign matters.
② Valve leaks due to longer service time, aging, shortening, hardening of valve spool or
insufficient compression force of the hold-down spring of the valve. In this case, he
should replace the spool or the hold-down spring of the valve.

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