Fisher & Paykel ecosmart GWL15 Service Manual Download Page 52

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517792A

Note: The outer bearing will be proud of the housing by approximately .07in /3mm.

10.3 Shaft

Bearing

Assembly

(a) The bearings must be inserted separately with the

inner bearing fitted first

and pulled down

with the bearing tool onto the shoulder in the bearing housing.

IMPORTANT

: There must be no gap between the bearing outer race and the shoulder of the

aluminum extrusion. Remove the insertion tool at this point and check that the inner bearing is
fully home.

(b) Fit the bearing spacer and press in the outer bearing using the bearing tool. Check the spacer

has no end float but has slight sideways movement to allow for shaft insertion.

.07 in / 3mm

Summary of Contents for ecosmart GWL15

Page 1: ...517792A ECOSMARTTM PHASE 7 ELECTRONIC WASHING MACHINES ...

Page 2: ...A NOVEMBER 2005 2 The specifications and servicing procedures outlined in this manual are subject to change without notice The latest version is indicated by the reprint date and replaces any earlier editions ...

Page 3: ...AYKEL PHASE 7 ELECTRONIC WASHING MACHINES Covering the following product codes GWL15 US 96200 Fisher Paykel Appliances Inc 5800 Skylab Road Huntington Beach California CA92647 USA Ph 888 936 7872 F P Ph 888 396 2665 DCS ...

Page 4: ...r Temperature Sensing 11 2 5 Water Valves 12 2 6 Water Level Measurement 12 2 7 Motor 14 2 8 Pump 17 2 9 Lid Lock 17 2 10 Inner and Outer Baskets 17 2 11 Agitator 19 2 12 Lint Removal System 19 2 13 Fabric Softener Dispensing 19 3 SIZE SETTING MODE 21 4 DIAGNOSTIC MODE 21 4 1 Last Fault Data 21 4 2 Drain Pump Test 21 4 3 Water Valve Test 21 4 4 Restart Feature 22 4 5 Recycle Feature 22 4 6 Hot Bas...

Page 5: ...The Cabinet 46 9 16 Removal of Rotor 46 9 17 Removal of Stator 47 9 18 Removal of Rotor Position Sensor 47 9 19 Removal of Pump 48 10 SPECIALISED SERVICE PROCEDURES 49 10 1 Blocked Pump Procedure 49 10 2 Shaft Bearing Replacement 50 10 3 Shaft Bearing Assembly 52 11 WASH PERFORMANCE INFORMATION 54 11 1 Creasing 54 11 2 Soiling 54 11 3 Linting 54 11 4 Detergent Residue 54 11 5 Black Marks on Clothe...

Page 6: ... 39 6 gal 150 liters Eco Rinse 27 7 gal 105 liters 1 Deep Rinse 43 5 gal 165 liters 2 Deep Rinse 56 79 gal 215 liters Note Approximate water consumption for a high water level load for each rinse option offered 1 4 Water Fill Temperature Approximate Factory Settings Supply Water Fill Temp Hot 140o F 60 o C Hot Warm 122 o F 50 o C Warm 104 o F 40 o C Warm Cold 95 o F 35 o C Cold Plus 68 o F 20 o C ...

Page 7: ...chine is not in use 1 8 Thermistor NTC type temperature sensor Thermistor Resistance 10 000Ω 77 o F 25o C 1 9 Cabinet Pre painted steel 1 10 Lid ABS plastic co injected 1 11 Top Deck Polypropylene 1 12 Inner Basket Stainless steel Grade 430T Basket base and balance ring Polypropylene The inner bowl on the large machine has a series of small bumps around the base of the inner bowl These bumps are d...

Page 8: ...ator Polypropylene 1 16 Fabric Softener Dispenser Dosage 75cc 1 17 Electric Supply Operating Voltage 110 120V AC 60Hz Maximum Current 7 0 amps 1 18 User Information User Guide 420900 Compact Disk 420353 1 19 Lid Lock Resistance 63Ω 10 68o F 20o C Note Normally low voltage potentially 110V if harness is grounded on the cabinet 1 20 Control Panel EcoSmartä ...

Page 9: ... with great accuracy over spin speed agitate action fill temperature and water level Having such control insures the wash cycle selected provides the optimum soil removal combined with appropriate gentleness for the washing and care of the clothes load The Motor Control Modules for the Phase 7 Washers are air cooled in the same way as the Phase 5 and 6 machines are and are colored brown the same c...

Page 10: ...the power point 2 3 Out of Balance Detection Bump Detect Past electronic machines have used a lever connected to a mechanical switch to detect if the load in the inner basket is out of balance On Phase 7 machines this system has been replaced with electronic sensing known as Bump Detect Bump Detect is software written into the Motor Control Module which looks at specific feedback from the Rotor Po...

Page 11: ...ress light will increase the wash temperature If the ADVANCE button is kept pressed the light will scroll back to the coldest setting available for that wash temperature 2 4 2 Controlled Cold If the cold water temperature is very low below 68 o F 20 o C a very effective wash will not be obtained The controlled cold option solves this problem by adding a small amount of hot water to raise the tempe...

Page 12: ...Measurement The machine is fitted with a pressure sensor which can control the fill to any water level The pressure sensor is incorporated within the Motor Control Module and cannot be removed The pressure tube connects from the Motor Control Module to the air bell at the bottom of the outer basket and is part of the harness assembly Care must be taken when removing or refitting the pressure tube ...

Page 13: ...vel 59in 15mm 2 6 2 Auto Water Level The machine automatically selects the appropriate water level for the load when AUTO Water Level is selected and will choose one of the pre existing 5 water levels low medium low medium medium high and high During fill the machine pauses occasionally to sense the water level The machine checks if the water level is correct by using a series of 2 different agita...

Page 14: ...r 36 Poles Curved pole tips Wiring Diagram 32 32 32 16 1 6 1 6 RED BLUE YELLOW STAR POINT 2 7 1 1 Testing the Stator If the stator needs to be tested we would first recommend testing the resistance of the windings from the harness that is connected to the Motor Control Module Refer to Section 7 Note Ensure that the Rotor or basket is stationary when measurements are made Testing the stator from th...

Page 15: ... Rotor The rotor is also unique to the Phase 7 machines It has 16 blocks containing 3 individual magnets as opposed to 14 blocks containing 4 magnets for Phase 5 and Phase 6 machines The rotors between Phase 7 and previous Phases of machines can physically be interchanged however electrically they are incompatible If a Phase 7 rotor is fitted to a Phase 6 or earlier machine fault code 240 will occ...

Page 16: ... powered by a 9V battery To test the RPS of a Phase 7 Washer it will also require an adaptor harness part number 420892 The tester has 3 LEDs and the pattern of these LEDs will change as the magnetic field of the Rotor passes the hall sensors Connect the RPS tester to the RPS harness Turn the basket and note the pattern of lights A valid pattern is a pass A fail will indicate a failure of either t...

Page 17: ...rced upwards and out of the lock Note This is the only time in which we would recommend doing this If the harness is damaged the complete lid lock assembly will need to be replaced If the power supply is cut during the spin cycle the machine will keep the lid locked until the rotor has ceased to turn 3 to 10 secs Only then will it release the lock The motor is acting like a generator and allows th...

Page 18: ...hen the chosen water level is reached and before the agitate cycle is started the machine will carry out inner basket float checks basket check The inner basket will stop and commence a number of small agitate type actions During this action the machine determines if the inner basket has floated If it has the machine will determine the required water level and check if the operator has selected th...

Page 19: ...ing in the separation of lint from the wash water As the agitator moves the specially designed vanes on the bottom create turbulence The agitator acts as a centrifugal pump circulating the wash water As a result of the agitator action lint and wash water are sucked into the agitator stem and down to the base where they are directed into the cavity between the inner and outer baskets The extruded h...

Page 20: ...eventually cause a build up within the outer basket This can result in black flakes present in the wash load that can stain garments To remove scrud follow the procedure below Step1 Add a full cup of a good quality dishwashing powder in to the machine Step 2 Set the machine to a Heavy Duty cycle select a Hot Wash temperature High Water level and allow the machine to agitate for 10 minutes Step 3 L...

Page 21: ...press POWER until the machine gives 2 short beeps and lights up 3 Release the buttons after the beeps as the beeps indicate diagnostic mode has been entered 4 1 Last Fault Data When in diagnostic mode the last fault can be found by pressing the SPIN SPEED UP or DOWN buttons until the HOLD and SLOW lights are illuminated Binary can then be read from the wash progress lights 4 2 Drain Pump Test GW W...

Page 22: ...diagnostic mode press and hold ADVANCE down at the same time as pressing WATER LEVEL DOWN A long beep will acknowledge the setting has been retained in EEPROM Press POWER to retain selection as with size switching To remove from the permanent memory repeat the above procedure Note This feature is designed as a service aid only and should be left on in the customer s home To return to normal operat...

Page 23: ...Care Manual 4 8 1 Hot Water Temperature LED Flashing Insufficient Hot Water Possible causes 1 Check that the hot water is connected and that the tap is turned on 2 Check that the water temperature is not too low The water temperature may need to be 140oF 60oC for a hot wash 3 Check that the hot water inlet hose is not connected to the cold water supply 4 Check that there are no kinks in the inlet ...

Page 24: ...ion rod 3 Check the suspension is not catching or bouncy If so replace all four suspension rods 4 Check both balance rings on the inner basket contain water The most accurate way is to check the weight of the inner basket Refer to Section 1 12 5 Check that the holes on the inner basket have been punched through or are not blocked 4 8 6 Suds First Rinse LED is flashing or Final Spin LED is flashing...

Page 25: ...ed to obtain the last fault data Use the chart below to identify which was the last user warning Binary Count User Warning 0 No warning 1 No taps 2 Overload 3 OOB 4 Suds 5 No Hot 6 No Cold 7 Agitate overloaded Diagnostic mode 1 Last User Warning Cycle Position To find out which stage in the cycle the last user warning occurred use this level A LED on the wash progress LEDs will identify the stage ...

Page 26: ...t has no thermistor Diagnostic mode 9 10 Cycle count low byte high byte These levels work in the same way as for Diagnostic levels 5 6 which allows the Service Technician to establish how many cycles the machine has completed Note A completed cycle is counted at the end of the spin cycle Diagnostic mode 11 Motor Speed RPM Add up the LEDs on the wash progress and multiply this figure by 10 The resu...

Page 27: ...517792A 27 5 WIRING DIAGRAM ...

Page 28: ...RMS multimeter 2 Supply voltage 230 VAC 3 Wash Motor No accurate readings are possible 4 Pump Motor 5 RPS 6 Display Module 7 Lid lock 8 Thermistor 1 3 4 110V AC 0 5 V DC Pulses up to 30V when locking when locked sits at approx 10V DC 5 6 7 8 2 5 V DC Should always be 15V DC C B A Individual phases will be 15 or 0 volts will change as motor turns ...

Page 29: ...ter Valves 64 Ω 10 2 Wash Motor 3 Pump Motor 4 RPS Unable to be tested with multimeter 5 Lid lock 6 Thermistor 7Ω Pulses up to 30V when locking when locked sits at approx 10V DC 63Ω 10 68o F 20o C 32Ω across any two windings 10 000Ω 77o F 25oC 1 3 5 4 2 6 ...

Page 30: ...6 177 178 179 180 181 182 183 YOYYY 184 185 186 187 188 189 190 191 YYOOO 192 193 194 195 196 197 198 199 YYOOY 200 201 202 203 204 205 206 207 YYOYO 208 209 210 211 212 213 214 215 YYOYY 216 217 218 219 220 221 222 223 YYYOO 224 225 226 227 228 229 230 231 YYYOY 232 233 234 235 236 237 238 239 YYYYO 240 241 242 243 244 245 246 247 YYYYY 248 249 250 251 252 253 254 255 The above table shows the 8 ...

Page 31: ... The Motor Control Module has encountered an error when writing to an EEPROM address Primary Source Motor Control Module Action Replace Motor Control Module 3 00000011 Motor Control Module Fault The Motor Control Module has found a memory error Primary Source Motor Control Module Action Replace Motor Control Module 9 00001000 Size Switch Error The Display size switch setting does not match that wh...

Page 32: ...er valves have stuck on and are letting water in at a flow rate that is higher than the pump can handle or the pump is blocked and can t remove the excess water Primary Source Water Valves Action If the water valves are on continuously check that the water valves turn off mechanically remove power from machine Secondary Source Pump system Action Check the pump for blockages and drain hose for corr...

Page 33: ... hose is not blocked 5 If the basket contains water then service the pump from the top of the machine by removing the top deck and inner basket Bail out the water remove the pump cap and hood and clear the restriction Secondary Source Wiring Action 1 Check the pump harness is connected correctly to the pump 2 Check continuity of the pump harness Tertiary Source Motor Control Module module Action A...

Page 34: ...in the sensor line This fault is only applicable in the GW models Primary Source Thermistor Action 1 Check the connection from the thermistor the Motor Control Module 2 Check the resistance of the thermistor Resistance should be 10kW 77 o F 25o C or 12 5kW 68o F 20o C Replace if faulty 3 Replace the Motor Control Module 45 00101101 Display Memory Check Fault On power up the display has checked its...

Page 35: ...ve fault and both will need to be replaced 52 00110100 Diverter Top up Fault More than 6 attempts have been made to top up the water level in the basket This then signifies the valve has not closed and is diverting to drain or the top up was not increasing quickly enough suggesting the valve has a blockage and is also draining Primary Source Diverter valve Action Remove the diverter valve and chec...

Page 36: ...ine should physically be able to measure This suggests that the pressure sensor has been disconnected from the Motor Control Module damaged or not actually placed on the PCB Primary Source Motor Control Module Action Replace Motor Control Module 69 01000101 Pressure Transducer Error Zero Too Low The pressure sensor is zeroed in the factory but to compensate for zero drift during the life of a prod...

Page 37: ...s reset when it should not have This can be due to a Motor Control Module supply disturbance or microprocessor failure Primary Source Motor Control Module Action Replace Motor Control Module 109 01101101 AC Pump Triac Over Temperature This fault occurs when the electronics have detected that the temperature of the pump Triac has exceeded what would be expected under normal conditions The most like...

Page 38: ...eplace Motor Control Module Quaternary Source Rotor Action Ensure the correct rotor for this phase of machine has been fitted Refer to Section 2 7 2 136 10001000 Motor Stall The Motor Control Module has been unable to start the motor Possible causes of this fault are Faulty motor harness faulty or jammed motor seized bearings or seals faulty Motor Control Module faulty Rotor Position Sensor or har...

Page 39: ...ary Fault Motor Control Module fault Action Replace Motor Control Module 234 11101010 Lid Lock Open Circuit Check Harness to Lid Lock and connections at the Motor Control Module and lid lock ends Primary Fault Connector to the harness either end could be at fault Action Replace Harness Secondary Source Lid Lock has failed to be activated Action Replace Lid Lock Tertiary Source Motor Control Module...

Page 40: ...Error faults See fault code130 for directions 241 11110001 Function Time Out Display crashed Primary Fault Display Module has failed Action Replace Display Module Secondary Fault Motor Control Module has failed Action Replace Motor Control Module 243 11110011 Stepper Test Failure Rotor Position Sensor fault The Motor Control Module has attempted a motor step test and found the motor has not steppe...

Page 41: ...d by law must be carried out 9 1 Removal of Lid a Open the lid fully then lift off vertically Reassembly Refit in reverse manner ensuring that the hinge lugs on the lid are vertical 9 2 Components in Console Area a Remove the lid Refer to Section 9 1 b Remove the two screws at the rear of the console securing the console to the top deck c Tilt the console forward Reassembly Refit in reverse manner...

Page 42: ...t in reverse manner ensuring when refitting the thermistor that the thermistor is pushed until it comes to a stop against the back wall of the elbow 9 6 Removal of Motor Control Module a Follow procedures for removal of Display Module Refer to Section 9 2 b Disconnect all wiring harnesses to the Motor Control Module c Remove the pressure tube by squeezing on the legs of the spring clip Pull gently...

Page 43: ...odule c Remove Motor Control Module from the top deck Refer to Section 9 6 leaving all remaining harnesses connected d Remove wiring cover from top deck e Carefully remove the two lid buffers from the front side top of the deck by levering upwards taking care not to damage the top deck f Remove the two screws under the buffers securing the top deck to the cabinet g Lift the top deck upwards and re...

Page 44: ...fit in reverse manner Note The inlet nozzle can be removed when the top deck is lifted 9 10 Removal of Neck Ring a Follow procedures for removal of lid Refer to Section 9 1 b Carefully remove the two lid buffers from the front side top of the deck by levering upwards taking care not to damage the top deck c Remove the two screws under the buffers securing the top deck to the cabinet d Lift the top...

Page 45: ... the reverse manner 9 13 Removal of Clutch Mechanism Spline Drive Spline Driven a Follow procedures for removal of Inner Basket Refer to Section 9 12 b Remove the 3 screws securing the spline driven to the inner basket Reassembly Refit in the reverse manner Ensure that the screws are tightened sufficiently with out over tightening 9 14 Removal of Pump Hood a Follow procedures for removal of Inner ...

Page 46: ... be unclipped from the suspension rod first g With the suspension rods removed from the cabinet carefully lift the outer basket assembly out of the cabinet taking care not to cut the drain hose on any sharp edges of the cabinet Reassembly Refit in reverse manner 9 16 Removal of Rotor a Lay machine down or against a wall If leaning the machine against a wall ensure that the machine is stable and ta...

Page 47: ... four bolts and only tighten to a torque of 5nm Note The Stator should have a slight radial movement of approximately 0 5 1mm when correctly tightened and should have a maximum axial rocking movement of 0 5mm 9 18 Removal of Rotor Position Sensor a Follow procedure for removal of Stator Refer to Section 9 17 b Disconnect the harness plug to the RPS c Unclip the RPS by releasing the tabs on either ...

Page 48: ...rn until the pump disengages Note Approximately 250mls of water remains in the pump sump after pump out and will spill when the pump is removed Take care not to spill this water over electrical connections by using a towel or small container to catch the water Reassembly a Locate the bayonet fixture correctly then turn the pump in a clockwise direction until you hear the locking tab clicks into pl...

Page 49: ... is to carry out the procedure below which leaves the pump undisturbed This way the object causing the obstruction can be identified as well as the integrity of the pump remains in tact a Follow procedure for removal of pump hood Refer to Section 9 14 b Remove pump cap c Locate object and check for free movement in both directions of the impellor d Refit pump cap and pump hood ensuring that the se...

Page 50: ...machine with the internal thread a Follow procedures for Removal of Outer Basket From Cabinet Refer to Section 9 15 b Lay the outer basket on its side before removal of the shaft This ensures that the shaft does not fall directly onto the floor Note The shaft can only be removed towards the inside of the outer basket Remove the shaft If the shaft is difficult to remove use a puller and a mandrel R...

Page 51: ... serious damage to the bearing housing or outer basket may result Use the bearing removal tool as illustrated d Remove the seal with the aid of a screwdriver handle levering from side to side e Remove inner bearing using the bearing removal tool Insert the threaded rod and extractor washer up from the bottom of the outer basket Place the collar and large locating spigot on the threaded rod and ext...

Page 52: ...ing tool onto the shoulder in the bearing housing IMPORTANT There must be no gap between the bearing outer race and the shoulder of the aluminum extrusion Remove the insertion tool at this point and check that the inner bearing is fully home b Fit the bearing spacer and press in the outer bearing using the bearing tool Check the spacer has no end float but has slight sideways movement to allow for...

Page 53: ...n nut Use the spline tool and spanner to tighten the shaft retention nut e Invert the outer basket Take care not to damage the shaft or flooring Fit the assembly thimble sleeve onto the shaft before fitting the seal Lubricate the seal outside diameter with liquid detergent and then slide into position by pressing down on both sides of the seal Note The seal should be flush with the lip on the base...

Page 54: ...abrics attracting lint 11 4 Detergent Residue Over loading the washer can result in detergent residue being caught in the creases of the fabrics If this occurs decrease the load size Some detergents need to be pre dissolved Check the instructions for the detergent Cold ambient temperatures cold washes or short agitation times may not let the detergent dissolve properly In these cases pre dissolve ...

Page 55: ...by too much incorrect use of or poor quality detergents Has the correct water level been selected for the clothes load Too much water for the clothes load will cause water to splash Check that the size setting is correct Check that the high water level is acceptable Acceptable limits are 10 110mm from the top of the agitator to the water If it is less than 10mm then splashing may be a problem Empt...

Page 56: ...top and respin 4 times This is due to suds build up between the baskets and normally will sound a User Warning A more likely cause of slow spinning is the Hot Basket Flag Refer to Section 4 6 12 5 Siphoning Typically this occurs when the Standpipe height is too low The minimum is 33 46in 850mm from the floor This is 3 54 in 90mm ABOVE the drain hose outlet on the machine With a very low standpipe ...

Page 57: ...517792A 57 Notes ...

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