Daewoo DW-3000 Series Installation guide

Table of contents
Chapter I : Twin Tub Washing Machine
1. Technical point of some key parts ----------------------
-
2
1-1. Spin Timer --------------------------------------------------------- 2
1-2. Drain Pump -------------------------------------------------------
-
2
1-3. Pressure Switch -------------------------------------------------
-
3
1-4. Safety Device of Motors --------------------------------------
-
3
1-5. Safety Device of Spin Dryer ---------------------------------
-
3
1-6. Gear Housing ----------------------------------------------------
-
5
1-7. Spin Bellows Assembly ---------------------------------------
-
5
2. Specification of some key parts -------------------------- 6
2-1. V-Belt & Pulley Motor ------------------------------------------
-
6
2-2. Timer ----------------------------------------------------------------
-
7
3. Improvements of New Models ----------------------------
-
9
3-1. DW-160C(170C) --------------------------------------------------
-
9
3-2. Others 1, 2 --------------------------------------------------------- 16
4. Trouble Shooting Guide ------------------------------------- 23

Chapter II : Fully Automatic Washing Machine
1. Specification of New Models ------------------------------
-
29
1-1. DWF-100M's ------------------------------------------------------
-
29
1-2. DWF-900,160,170's ---------------------------------------------
-
30
1-3. DWF-750, 800's --------------------------------------------------
-
31
2. Sequence Chart of New Models --------------------------
-
32
2-1. DWF-100M's, 100C's, 1098's, 1094's, 1089's ------------ 32
2-2. DWF-900's, 160's, 170's, 174W's ---------------------------
-
34
2-3. DWF-750's, 800's ------------------------------------------------
-
36
3. Sequence Chart of Electrical Parts ---------------------
-
38
All New Models
4. Main Function of PCB ---------------------------------------
-
39
All New Models
5. The Principle of Load Sensing ---------------------------- 44
6. Trouble Shooting Guide ------------------------------------- 45
7. Testing(Demonstration) Mode ----------------------------
-
48
All New Models
8. Radical Function ----------------------------------------------- 57
9. Gear Mechanism ----------------------------------------------- 62
9-1. Wash & Spin Mode ---------------------------------------------
-
62
9-2. Structure -----------------------------------------------------------
-
63
9-3. Concerning Clutch Spring -----------------------------------
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64
10. Technical Report ---------------------------------------------
-
71
10-1. Air Bubble -------------------------------------------------------
-
71
10-2. Pulley Motor ----------------------------------------------------- 72

Chapter I : Twin Tub Washing Machine
1

1. Technical point of some key parts
1-1. Spin Timer
Function
Structure and Principle of Activation
1-2. Drain Pump
The Spin Timer is the switch providing to the Spin Motor(Drain Pump Motor) during the set
spin dry time, and is a spring-type time switch comes on upon turning and those contact
points comes off after the set time.
1) The main shaft turns due to the unwinding force when the spin timer is turned and the
spring timer wound, with that force being delivered through each gear and the spring slowly
unwinding at a speed finally controlled by the angle assembly.
2) The contact point turns ON and the assembly angle is set in motion, which is in the CAM
groove in the OFF state, comes off the groove when the MAIN SHAFT is turned to wind the
spring. The contact point turns OFF, return to CAM groove when the spring unwind
completely.
Drain pump is designed to drain the water in selecting drain, spinning and water level being
high. Draining capacity is 18l/min. when the drain hose is 1.5m height.
a) Drain : The Drain Pump is turned on when the Drain Selector Knob is set to "DRAIN" while
the Wash Timer is ON. In this case the Drain Select Knob open the Drain Valve and drain
time can be controlled by Wash Timer.
b) Spinning : The POWER is provided to Spin Motor and the Drain Pump Motor by Spin
Timer so that the water is drained simultaneously with spinning.
2

1-3. Pressure Switch
1-4. Safety Device of Motors
1-5. Safety Device of Spin Dryer
c) water level being high : The Drain Pump is turned on when the water level reaches
approx. 9.5cm above level High. It is then turned off when the water level returns to level
High. It is operated automatically so that the water level maintains between level High and
approx. 9.5cm above level High.
I
n case excess
i
ve stra
i
n
i
s p
l
ace
d
on t
h
e motor
d
ue to excess
i
ve e
l
ectr
i
c
i
ty, over
h
eat
i
ng, or
overloading so that the temperature of motor reaches to about 135℃the thermal protector
attached to the motor shuts off the motor automatically. In this case the motor does not
operate, and is activated only after about an hour when motor temperature drops to about
85℃.
Note : Some
p
roducts do not offer this o
p
tion.
The Spin Dryer is an apparatus which eliminates the water from laundry through centrifugal
separation generated by rapid revolution(approximately 1,600 revolution per minute for
frequency of 60Hz). Accordingly, there are a Door Switch to cut off the power going into the
Spin Motor when Door Spin *0 is operated and a brake system to stop the rotating Spin
Dryer.
Drain Pump Motor
Drain Pump Motor is a shaded pole motor with a pump impeller, rotate about 2650 rpm to
operate the pump fan to drain.
As a mechanical switch, Pressure Switch turns ON by air pressure when the water level
reaches approx. 9.5cm above level High so that the Power is provided to the Drain Pump
which designed to drain the water to prevent overflow out the tub.
3

Door Switch
When the Door Spin *0 is operated during spin drying the Lever of the Door Switch which
sites the Door Spin *0 falls off the contact, and cuts off the Power going into the Spin Motor.
Brake System
When the Door Spin *0 is opened, the Plate Control Wire which sites separately atop and
Door Spin *0 drop down and loosens the Link Wire and Link Brake. And when the Brake
Band touches the Drum coupling Assembly and stops the Spin Dryer as it is pulled by the
spring in the Brake Fix Assembly.
4

1-6. Gear Housing
(at 60Hz)
1-7. Spin Bellows Assembly
Brake Band Gap Control Method
The Band Brake works best when the gap between it and the Drum Coupling is about 2mm
when the Door Spin *0 is closed. The Spin Dryer stops slowly if the gap is larger in which
case the screw of the Wire Guide may be loosened and adjusted upwards. If the gap
between the two is too narrow, the Spin Dryer revolution is affected and the Wire Guide may
be adjusted downward to maintain the Brake Band gap adequately.
The initial deceleration following the activation of the Wash Motor takes place through the
Motor Pulley and the Agitator Pulley, and the secondary deceleration is done by the gears in
the Gear Housing which also increases their revolution strength. This revolution speed and
strength is delivered to the Agitator, which is then able to cause water current that is strong
yet soft so that wash loads are not damaged.
The wrinkled rubber device on the
bottom of the spindryer is called
Spin Bellows assembly. It has a
waterseal and a oilless metal
inside to prevent leakage and so
that the Spin Dryer may work
smoothl
y
.
WASH MOTOR
(MOTOR PULLEY)
about 1600 RPM
AGITATOR PULLEYS
about 271 RPM
AGITATOR
about 65 RPM
4.18:1
5.91:1 V-BELT
GEAR HOUSING
ASS'Y
5

2. Specification of some key parts
2-1. V-BELT & PULLEY MOTOR
TYPE PART CODE TYPE(IN) PART CODE
50Hz M32 450M700020 Ø31 3618431700
60Hz M31 3616590400 Ø24 3618431600
50Hz M32 450M700020 Ø31 3618431700
60Hz M31 3616590400 Ø24 3618431600
50Hz Ø31 3618431700
60Hz Ø24 3618431600
50Hz Ø31 3618431700
60Hz Ø24 3618431600
50Hz Ø31 3618431700
60Hz Ø24 3618431600
50Hz ----
60Hz M24 3616590700 Ø26 3618432700
450M700020
DW-4000's
DW-800C's
MODEL
DW-500M's
DW-170C's
DW-3000's
PULLEY
M25 4504B00020
DW-160C's
V-BELT
A36.6 3616500800
M32
6

2-2. TIMER
1) WASH TIMER
TYPE RESIN PART CODE TYPE RESIN PART CODE
110/60 S-K30A UL-94(HB) 3619910741
220,240/50 S-K30AP UL-94(HB) 3619910701 S-K30A UL-94(HB) 3619910741
100/50,60 S-K30AS UL-94(HB) 3619910721
220/60 S-K30AS UL-94(HB) 3619910721
110/60
220,240/50 S-K30A UL-94(HB) S-K30AP UL-94(HB) 3619910701
100/50,60
220/60 S-K30A UL-94(HB)
110/60
220,240/50 S-K40A UL-94(HB) 3619905401 S-K40A UL-94(HB) 3619905401
220,240/50 S-K40B UL-94(V0) 3619905501
100/50,60
220/60 S-K40A UL-94(HB) 361995401
110/60 S-K80NT UL-94(HB) 3619910941
220,240/50 S-K80NT UL-94(HB) 3619910941 S-K80NT UL-94(HB) 3619910941
220,240/50 S-K80NT UL-94(HB) 3619910941 S-K80NT UL-94(HB) 3619910941
100/50,60 S-DT15TJ UL-94(HB) 3619911140
220/60 S-K80NT UL-94(HB) 3619910941
110,120/60 S-DT15NT UL-94(HB) 3619911100 S-DT15NT UL-94(HB) 3619911100
220,240/50 S-DT15NT UL-94(HB) 3619911100
220,240/50
100/50,60
220/60
110,120/60 S-DT15NT 3619911100 S-DT15NT UL-94(HB) 3619911100
220,240/50
220,240/50
100/50,60
220/60
DW-170C's
PUMP N0N PUMP
DW-800C's
DW-160C's
DW-3000's
DW-500M's
DW-4000's
MODEL
7

2) SPIN TIMER
TYPE RESIN PART CODE TYPE RESIN PART CODE
110/60
220,240/50
100/50,60
220/60
110/60
220,240/50
100/50,60
220/60
110/60
220,240/50 S-4000A UL-94(HB) 3619910011 S-4000A UL-94(HB) 3619910011
220,240/50 S-4000B UL-94(V0) 3619910021
100/50,60
220/60 S-4000A UL-94(HB) 3619910011
110/60 S-800CA UL-94(HB) 3619911000
220,240/50 S-800CA UL-94(HB) 3619911000 S-800CA UL-94(HB) 3619911000
220,240/50 S-800CA UL-94(HB) 3619911000 S-800CA UL-94(HB) 3619911000
100/50,60 S-800CA UL-94(HB) 3619911000
220/60 S-800CA UL-94(HB) 3619911000
110,120/60 S-160CA UL-94(HB) 3619911200 S-160CA UL-94(HB) 3619911200
220,240/50 S-160CA UL-94(HB) 3619911200
220,240/50
100/50,60
220/60
110/60 S-160CA UL-94(HB) 3619911200
220,240/50
220,240/50
100/50,60
220/60
DW-3000's
DW-500M's
DW-4000's
DW-800C's
MODEL
PUMP N0N PUMP
DW-160C's
DW-170C's
8

3. Improvements of New Models
3-1. DW-160C(170C)
No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
1 DRAIN SELECTOR KNOB is hard to New made CONTROL LEVER 2000. 8. Proper path with short arm and easily
rotate. rotated.
- Arm length : short - Arm length : long
- Abnormal path for maximum stroke - Normal path is enough for valve stroke
FRICTION
LONGER
ARM
9

No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
2A. Vibration when Spinning is too severe. Number of supporting points : 3→42000. 8. New designed BRACKET MOTOR
B. Swing of SPIN TUB - No. of dampers : 4ea - No. of dampers : 3ea
- No. of dampers : 3ea - Diameter : Ø226 - Diameter : Ø220
- Diameter : Ø166
- Simple RING BASKET (200g) - BALANCER with salt water (380g) 2001. 7. - BALANCER with salt water (380g)
- Thickness of the SPIN BELLOWS
increased
RING BASKET
SALT WATER inside
1.5mm→2.0mm
10

No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
3Loosening of the DRUM COUPLING bolt Reinforce the fixing torque by changing 2001. 5. Redesign the DRUM and BOLT
- BOLT : M6 bolt and nut (M6→M8) - DRUM : Iron casting→Press & Bush
- Unbalance weight of DRUM itself - Unbalance weight of DRUM itself - BOLT : M8 & SILOCK bond
4 Shaft deformation by impact and A. Increase diameter of the SHAFT 2000. 9. Ø14 SHAFT and Round from the beginning
FIXING PLATE crack B. Rounding the edge
M6 BOLT & NUT M8 BOLT & NUT M8 BOLT & SILOCK
BUSH & Press
DRUM
Ø12
EDGE
(CRACK)
Ø14
ROUND
Ø14
ROUND
11

No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
5 Water leakage through the TUB holes Add the TUB CUSHION (2ea) 2001. 3. Redesign the TUB mold (Slide cores)
6 SPIN DOOR hinge is separated from Add a LOCK not to be taken out 2000. 9. A. Add a LOCK not to be taken out
the TUB B. Increase distance between HINGES
(130mm→154mm; Disperse the force)
7 KNOB crack Change the material (HIPS→ABS) 2000. 4. ABS KNOB from the beginning
8 WASH DOOR crack Additional ribs inside the WASH DOOR 2000. 8. Additional ribs from the beginning
HOLE TUB CUSHION LOCK
DOOR LOCK
DOOR LOCK
12

No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
9 INNER COVER crack Additional ribs and roundings 2001. 3. A. Additional ribs from the beginning
B. Increase the diameter of HINGE
ROUNDING AT
EVERY CORNER
ADDITIONAL RIBS
ROUNDING AT
EVERY CORNER
ADDITIONAL RIBS
Ø6 HINGE Ø7 HINGE
8010 160C
13

No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
10 WATER SELECTOR KNOB is not No countermeasures Smooth when starting by Rounding edge
smooth when starting
11 STOPPER of BRACKET PANEL broken Reinforce the ribs 2001. 1. Extend the RIBS to the ends
when enforce rotating (Connected between inner & outer sides)
(WATER ACTION, DRAIN SELECTOR)
SHARP EDGE ROUND EDGE
STOPPER
STOPPER
14

No Problems of DW-7510 Improvements of DW-7510 Date Improvements of DW-160C
12 OILLESS BEARING stick to the shaft Change the material (Fe→Cu) 2001. 6. Cu BEARING from the beginning
(Especially in Dominica)
13 LEAD WIRES cut by vibration & touch Using WIRE CLAMP 2000. 9. Using WIRE CLAMP
Fe (White) Cu (Yellow) Cu (Yellow)
TOUCH & WIRE CLAMP WIRE CLAMP
15

Problems Models Supposition of Cause Solution Date
1. Water leaks DW-2520 1. We found the surface of the shaft was 1. We made the smoothness of surface as a 01-09-01
between shaft DW-3633 a little rough, especially where water seal control point. Roughness should be under
and oil seal. DW-5010 is located. 6.3㎛.
3-2. Others
Smooth surfaceRough surface
16

Problems Models Supposition of Cause Solution Date
2. Another reason is lack of grease inside 2. Increased the grease on WATER SEAL. 01-09-01
the WATER SEAL. (Weight of grease : 0.5g)
2. Pulsator pulley DW-2520 1. The center part of P-Pulley was little 1. A little reinforced. (To prevent crack 98-06-19
is worn out. DW-3633 weak. and deformation when tightening bolt.)
So it vibrates DW-5010
up and down.
More Greased
Round shaped
Reinforced
17