Page 2
478182 JAN 2010 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. Fisher & Paykel Appliances Ltd Fisher & Paykel Appliances Inc 78 Springs Road, 5900 Skylab Road East Tamaki,...
Page 3
478182 FISHER & PAYKEL ELECTRONIC WASHING MACHINE Covering the following models Market Model Number Product codes North America WL37T26CW2 96108 96109 WL37T26DW2 96112 96113 WL37T26KW2 96100 96104...
478182 CONTENTS SPECIFICATIONS.......................7 Model Information ......................7 Dimensions ........................7 Maximum Capacity (AS/NZS 2040.1:2005) ..............7 Water Consumption ......................7 Water Fill Temperature (Approximate Factory Settings)..........7 Wash Motor........................8 Pump Motor........................8 Water Valves........................8 Thermistor ........................8 1.10 Cabinet..........................8 1.11 Lid ........................... 8 1.12 Top Deck.........................
Page 5
478182 4.9.7 SLR Feature ......................22 4.9.8 Testing the Pump Stator ..................23 4.9.9 Testing SmartPump™ Stator from the Console............. 23 4.9.10 SmartPump™ Test Routine ................... 24 4.9.11 Bypassing ......................24 4.10 Lid Lock ........................25 4.11 Neck Ring ........................26 4.12 Inner Basket and Outer Tub ..................
Page 6
478182 10.12 Removal Of Dispensing Hoses ..................63 10.13 Removal of Straps......................63 10.14 Removal of Neck Ring ....................63 10.15 Removal of Low Profile Agitator..................64 10.16 Removal of Inner Basket....................66 10.17 Removal of Clutch Mechanism (Spline Drive / Spline Driven) ........66 10.18 Removal of Pump Hood &...
478182 SPECIFICATIONS Model Information AquaSmart™ introduces the new Fisher & Paykel model numbering system, which provides a clearer description of the product and its features. The new model numbering system will come in to affect with each new model released. The model identification is explained below.
478182 Wash Motor Electronically commutated 36 pole direct drive 3 phase brushless DC motor. Motor Resistance @68 F (20 C): 19.5Ω +/- 10% (39Ω +/- 1.95Ω across any two phases) Pump Motor The motor is a fully electronically controlled 325V, 3 phase, 6 pole, brushless DC motor. The speed of the motor will vary depending on whether it is draining or re-circulating the water.
478182 1.24 Lid Lock Resistance: 63Ω +/- 10% @ 68 F (20 Note: Normally low voltage, potentially 110V if harness is grounded on the cabinet! 1.25 Control Panel LCD Model 1.26 Control Panel Triple Dispensing LED Model 1.27 Control Panel Non Dispensing LED Model 1.28 Important Screw / Bolt Torque Settings Below are the important screw torque settings on the AquaSmart™...
478182 THE UNIQUE AQUASMART™ WASH The AquaSmart™ is a EcoSmart™ based washing machine that has two modes of washing, High Efficiency & Conventional. It is essentially a front loader (high efficiency mode) and a top loader (conventional mode) washer in one. Both washing modes start the same way, with a detergent activating wash.
478182 CONTROL PANEL LCD Model Power On/Off button. High-Efficiency mode On/Off. When off, the machine uses the conventional wash mode High-Efficiency LED used also for data download (refer to Section 6.3). Start/Pause button LCD Screen. Left arrow (used when scrolling through options on the LCD screen). Right arrow (used when scrolling through options on the LCD screen).
Page 13
478182 LED Model Power On/Off button. Service Spanner LED. Lid Lock LED. Regular button. Heavy button. Delicate button. Sheets button. Colours button. Bulky button. 10. Easy Iron button. 11. High-Efficiency mode On/Off. When off, the machine uses the conventional wash mode 12.
478182 TECHNICAL OVERVIEW This Service Manual contains information on the Product Specifications, Diagnostic Mode, Detailed Fault Codes and the complete disassembly and assembly instructions for the AquaSmart™ washing machines. Electronics 4.1.1 Motor Control Module The Motor Control Module used on the AquaSmart™...
478182 Water temperature Sensing The thermistor for sensing the water temperature is located in the back of the outlet elbow on the valve assembly, and is connected directly to the Motor Control Module. Details for adjusting the wash temperature, Refer to the Use & Care Book. Specifications NTC-type temperature sensor (Thermistor) Resistance 10,000Ω...
478182 4.6.1 Detergent Dispensing During fill, the detergent valve is also energised. This allows a proportion of the inlet water to flow into the detergent dispenser. The flow rate through the detergent valve is dependent on the inlet water pressure, but it is less than the flow rate of water entering the machine.
478182 The Softener valve can be tested in diagnostics (refer to Section 6.1.2 for LCD models, or Section 7.2 for LED models). 4.6.4 Inlet Nozzle In addition to its design, which ensures excellent rinse water distribution, the nozzle shares an important relationship with the inlet valve assembly and the dispensing system as described above.
478182 Testing the Stator If the stator needs to be tested we would first recommend testing the resistance of the windings from the harness end that is connected to the Motor Control Module. (Refer to Section 5.2). Note: Ensure that the Rotor or basket is stationary when measurements are made. Testing the stator from the console The resistance of each individual winding is approximately 19Ω, however when testing the stator from the console we are testing across two windings therefore the resistance should be approx.
478182 Current Black Previous White 4.8.3 Rotor Position Sensor One of the inputs that the Motor Control Module needs in order to determine which switches to turn on is the position of the rotor. The rotor position sensor (RPS) supplies this information. The rotor position sensor (RPS) is a printed circuit board that contains three Hall Sensors, which detect the magnetic field of the individual...
478182 Note: This tester does not test all the functionality of the RPS. It tests the 3 outputs but cannot indicate all faults, for example if a capacitor on the RPS is cracked. The rotor may also be tested with a RPS Tester. A complete rotation will test all the magnets. If the rotor has cracked or chipped magnets it will work fine, and does not need to be replaced.
478182 4.9.4 Rotor and Stator The rotor and stator magnetically interact with each other in order to convert electrical energy into rotational movement of the rotor Rotor The rotor assembly is a complete unit that is permanently fixed into the pump housing. The resulting cavity is charged with water, which acts as a lubricant.
478182 4.9.6 SmartPump™ Spare Parts The following spare parts service kits are available for SmartPump™. Hood And Cap (SmartPump™) Kit Flapper (SmartPump™) P/N 479418 P/N 420403 Seal (SmartPump™) Housing Pump Assembly (SmartPump™) Kit P/N 479420 P/N 479417 Connector cover Note: The pump assembly is supplied with the connector removed from the stator shield.
478182 4.9.8 Testing the Pump Stator SmartPump™ Wiring Diagram WHITE BLUE 16.2Ω 16.2Ω 8.1Ω 8.1Ω 8.1Ω 16.2Ω The stator resistance can either be tested from the harness at the motor controller or at the connections to the stator itself. 4.9.9 Testing SmartPump™...
478182 4.9.10 SmartPump™ Test Routine Use the following procedure to test the SmartPump™. It is equally important to test both the drain and recirculation modes. In diagnostic mode the lid lock is disabled, which allows the technician to visually inspect both aspects of the pump. Enter diagnostic mode.
478182 4.10 Lid Lock AquaSmart™ uses the same lid lock that is used on previous machines, and is locked during the complete cycle. The Lid Lock symbol (padlock) appears in the top right hand corner of the screen on LCD models, and in the centre left next to the power button on the control panel on LED models, letting you know at a glance if you can open...
478182 4.11 Neck Ring The neck ring incorporates wells used for the fabric, detergent and bleach dispensing. The neck ring is clipped in place to the outer bowl. It also restrains the re-circulating nozzle. It is important that the neck ring is secured correctly to the outer bowl, as it affects bump detect (out of balance detection).
478182 4.12.1 Detection of Inner Basket Float Off Point – Basket Check During fill the inner basket will rotate to ensure that the clothes are evenly saturated with water. When the chosen water level is reached, and before the agitate cycle is started, the machine will carry out inner basket float checks (basket check).
478182 4.13 Suspension Rods The suspension rods on AquaSmart™ need to be more robust than the suspension rods used on previous EcoSmart™ machines. The top bracket has lugs to which the straps from the neck ring attach. A rubber washer sits midway down the rod, this helps detergent residue from running down the rod and into the grease filled damper.
478182 4.14 Agitator Low Profile The unique low profile agitator works well in both the High Efficiency and Conventional modes. In the High Efficiency mode, the clothes have greater contact with the agitator due to the low water level, and the agitator ensures a high level of clothes turnover. In Conventional mode, the clothes are completely submerged in the water and the curving steep side walls and raised shoulders of the wash plate vanes create enough inward and upward movement to keep the clothes turning over even when there is reduced contact with the agitator.
Page 30
478182 PCB and Housing – LCD Model The PCB, which contains the capacitive touch buttons and LCD, is mounted within a plastic housing. The PCB housing is clipped into the console at the bottom, and secured with four screws along the top. Facia –...
478182 VOLTAGE AND RESISTANCE READINGS FROM THE CONTROLLER Voltage Readings 1. Water Valves Display Module Varies between 13 – 22V DC Note: Accurate voltages can only be obtained by using a True RMS multimeter. 2. Supply voltage 110V AC 0 – 5 V DC 3.
478182 Resistance Readings 1. Water Valves 64 Ω +/- 10% 5. Lid lock 2. Wash Motor 63Ω +/- 10% @ 68 F / 20 39Ω across any two windings 3. Pump Motor 6. Thermistor 10,000Ω @ 77 F / 25oC 16.2Ω...
478182 DIAGNOSTIC MODE – LCD MODEL Press and hold the HI-EFFICIENCY and SELECT buttons for 2 seconds To enter the DIAGNOSTIC MODE, turn the power on at the power point and off at the console. Press and hold the HI-EFFICIENCY and SELECT buttons. Keep the buttons pressed for at least 2 seconds, after which time two beeps will sound and the screen below will appear.
478182 6.1.2 Machine Status Screen In the top half of the screen it displays the following information. Size is the size of machine, (650mm = Large) HVDC is for on line testing in the factory. WL displays the water level in mm. T is the actual temp of the inlet chamber water.
478182 6.2.2 Restart Feature The LCD AquaSmart™ leaves the factory with the RESTART set to the ON position, which is indicated in the screen by the word RESTART highlighted. To turn the RESTART feature OFF, push the Left scroll arrow. This will remove the highlight from the word RESTART. When the machine is being serviced, it is more convenient to turn the RESTART feature OFF.
478182 6.2.5 Restart/Recycle Features Permanently Programmed It is possible for the Restart Feature to be disabled, or the Recycle Feature to be enabled, or a combination of both to be permanently programmed into the memory of the electronics so that in the event of a power cut the electronics will remember the setting.
478182 Showroom Mode Press and Hold START/PAUSE, then press the SELECT button Showroom mode will play the introduction and repeat it continuously, until the machine has been isolated from the power supply. To access the showroom mode follow the steps below. Turn the power supply to the washing machine on.
478182 DIAGNOSTIC MODE – LED MODEL This washer has a diagnostic system to help diagnose faults. Use Diagnostic Mode 2 for non- dispensing LED models. For all other models use Diagnostic Mode 1. To enter DIAGNOSTIC MODE 1 for dispensing models; •...
478182 If this appears you need to set the dispensing type of the LED AquaSmart™: Press and hold down the TEMPERATURE button, then press the POWER button until three beeps are heard. Press the TEMPERATURE button to scroll through the ‘dispensing type’ options stopping at desired ‘dispensing type’...
478182 To turn RESTART on: • Enter the COMPONENT TEST MODE by pressing and holding the HI EFFICIENCY button, and then press the power button until two beeps are heard. • Press the SPIN button until all the spin LEDs are illuminated. •...
478182 Restart/Recycle Features Permanently Programmed It is possible for the Restart Feature to be permanently disabled, or the Recycle Feature to be permanently enabled, or a combination of both to be permanently programmed into the memory of the electronics so that in the event of a power cut the electronics will remember the setting. The factory settings are: •...
478182 For more information on resolving the binary coded value from the Data Download Wash Cycle LEDs, refer Section 8 START/PAUSE DATA DOWNLOAD LED POWE WASH PROGRESS INDICATOR To enter the Data download mode Press and hold the HI EFFICIENCY button, then press the POWER button until the machine beeps. Press the START/PAUSE button.
Page 43
478182 Diagnostic mode 1: Wash Cycle Position of Last User Warning Number The Wash Cycle position of the last user warning is primarily displayed on the wash progress indicator. E.g. Wash, Rinse or Spin. In addition to this, the exact stage of the wash where the warning occurred is displayed via the Wash Cycle LEDs.
478182 7.10 Showroom Mode Press and hold ADVANCE, then press the POWER button Showroom mode will play the introduction and repeat it continuously, until the machine has been isolated from the power supply. To access the showroom mode follow the steps below. •...
478182 FAULT CODES (00000001) Motor Control Module Fault The Motor Control Module has encountered an error when writing to an EEPROM address. Primary Source: Motor Control Module. Action: Replace Motor Control Module. (00000011) Motor Control Module Fault The Motor Control Module has found a memory error. Primary Source: Motor Control Module.
Page 46
478182 (00011000) Dispensing Type Not Set The Motor Control Module has found that the dispensing type needs to be set. Reselect the dispensing type for the machine by using the DISPENSING TYPE SETTING. Action, LED Machines: To set the dispensing type, turn the power on at the power point and off at the console.
Page 47
478182 (00100100) Water Leak Fault The Motor Control Module has needed to top up the water level more than 4 times during agitate. This is excessive, as normally only one or two top ups are required to replace the air that has escaped from a full load during agitate. The most likely cause is that the machine is siphoning.
Page 48
478182 (00100110) Pressure Sensor Fault The Motor Control Module has detected and recorded an empty water level while agitating. The water level must have been greater than empty for the machine to start agitating initially. Primary Source: Mechanical. Action: Check the pressure tube is attached and has not been cut. Secondary Source: Motor Control Module.
Page 49
478182 (00110000) Hot and Cold Valve Coil Faulty The Motor Controller module has measured voltages from the valve diagnostic circuit that indicate both the hot and cold valves are faulty. Primary Source: Wiring. Action: Check the valve harnesses are correctly fastened to the valves or the pins are not bent backwards.
Page 50
478182 (00111100) Motor Control Memory Check Fault On power up, the Motor Control Module has checked its memory against a known reference and found differences. Primary Source: Motor Control Module. Action: Replace Motor Control Module. (01000100) Pressure Transducer Error – Count Too High (01000101) Pressure Transducer Error –...
Page 51
478182 112. (01110000) Motor Current Sense Too High The motor current sense circuit is faulty. Primary source: Motor Control Module. Action: Replace Motor Control Module. 113. (01110001) AC Pump Thermistor Short Circuit The AC Pump thermistor is faulty or damaged. Primary source: Motor Control Module.
Page 52
478182 160. (10100000) Basket Engaged In Agitate The bowl has re-engaged itself during agitate. Primary Source: Mechanical. Action: 1) Check that the rotating basket assembly is not jammed to the agitator with any foreign object that may be caught under the agitator skirt.
Page 53
478182 235. (11101011) Lid Lock Short Circuit. Lid Lock fault, not activated when instructed to by the Motor Control Module. Primary Fault: Lid Lock mechanism has jammed or failed. Action: Check resistance across the connections, this should be 63 ohms +/- °C.
Page 54
478182 Secondary Source: Motor. Action: Check continuity of motor phases. Check the bridge terminal on the stator is not open circuit or burnt. Replace Stator. Tertiary Source: Rotor Position Sensor. Action: Check the Rotor Position Sensor patterns with a RPS Tester. If faulty fit new Rotor Position Sensor.
Page 55
478182 (11111000) SmartPump Top Up Fault. More than 6 attempts have been made to top-up the water level in the bowl during recirculation. Primary Source: Poor Flapper Seal. Action: 1. Clean any foreign objects out of the pump, concentrating especially on the flapper and drain/re-circulating port areas.
Page 56
478182 250. (11111010) SmartPump Loss of Sync. This fault is normally as a result of the pump not starting and is usually caused by an object that has got into the pump, and is either under or on top of the impeller, which is causing the motor to stall when trying to start.
478182 SERVICE PROCEDURES Note: Prior to carrying out any service procedures, ensure that the machine has been isolated from the power supply. 10.1 Accessing Components in Console Area (a) Remove the lid. (b) Remove the two screws at the rear of the console securing the console to the top deck. (c) Tilt the console forward.
478182 10.4 Removal of Inlet Valve Assembly (a) Follow procedures accessing components in console area (refer to Section 10.1). (b) Remove screw securing the valve body to the top deck. Disconnect wiring harness from each coil. Disconnect Thermistor harness from motor control module.
478182 10.6 Removal of the Cord Set (a) Follow procedures for removal of Inlet Valves Assembly. (Refer to Section 10.3). Slide (b) Disconnect the mains plug to the Motor Control Module. (c) Slide the strain relief to the left and slide out.
478182 10.8 Raising Top Deck (a) Remove the lid. (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.
478182 10.10 Removal Of Softener and Bleach Funnel (a) Lift the lid. (b) To remove the cap, lift it upwards. Reassembly: Refit in the reverse manner ensuring that the funnel is clipped fully home to ensure that the bleach dispenser functions correctly. 10.11 Removal Of Detergent Cover Note: Only remove the cover if it is essential to do so.
478182 10.12 Removal Of Dispensing Hoses (a) Follow procedures for removal of inlet valve assembly. (refer to Section 10.3). (b) Follow procedures to raise the top deck (refer to Section Error! Reference source not found.). (c) Remove hose clips from the hoses located at the front of the top deck.
478182 The top of the nozzle must be dry before refitting the neck ring Reassembly: (a) Prior to fitting the neck ring, ensure the recirculating nozzle is fitted to the outer bowl correctly. (b) Fit the straps to the neck ring. (c) Fit the neck ring to the outer bowl, ensuring that all the clips are engaged.
Page 65
478182 Reassembly: (a) Refit the agitator, ensuring that it is pushed as far down as it can go. (b) Insert the bolt into the shaft. Hand tighten until the first click has been felt, then using the open-ended or adjustable spanner, tighten a further 4 more clicks.
478182 10.16 Removal of Inner Basket (a) Follow procedures for removal of Straps. (Refer to Section 10.13). (b) Follow procedures for removal of Neck Ring (Refer to Section 10.14) (c) Follow procedures for removal of Agitator. (Refer to Section 10.15). (d) Lift inner basket upwards and clear of machine.
478182 10.18 Removal of Pump Hood & Cap (Impeller & Flapper Inspection) (a) Follow procedures for removal of neck ring (refer to Section 10.14). (b) Follow procedures for removal of low profile agitator (refer to Section 10.15). (c) Remove the inner bowl by lifting the inner bowl upwards and clear of machine.
478182 10.19 Removal of Stator (SmartPump™) – Testing / Inspection Purposes Only Note: The stator is not available as a separate spare part, Use this procedure for inspecting and testing the stator only. (a) Tilt the rear of the machine carefully against Alignment arrows the wall ensuring that the machine is stable and locked in position, take necessary...
Page 69
478182 Reassembly: (a) Fit the Housing Pump O-ring to the Outer Bowl. When replacing or refitting the pump housing, a new O-ring must be fitted. (c) Refit the Pump Housing. Note: This should be done with the Pump Cap & Hood in place, but it is not essential.
478182 10.21 Removal of Recirculation Hose (a) If the bowl is full of water drain or bail as much of the water as possible from the machine prior to continuing. To assist with bailing the water, the inner bowl can be removed.
478182 10.22 Removal of outer Tub From The Cabinet (a) Follow procedures for removal of the Top Press tab and rotate fixture carefully Deck. (Refer to Section.10.9). (b) Follow procedures for removal of Inner Basket. (Refer to Section 10.16). (c) Thread the drain hose back in to the cabinet.
478182 10.24 Removal of Stator (a) Follow procedures for removal of Rotor. (Refer to Section 10.23). (b) Unscrew the four bolts securing the Stator to the outer basket. (c) Lift Stator off the base of the outer basket and clear of the shaft. (d) Disconnect the wiring to the terminals.
478182 SPECIALISED SERVICE PROCEDURES 11.1 Pump Housing - Stripped Bolt Procedure On the pump housing there are two bolt hole positions. These positions are used when the housing is assembled to the base of the outer bowl in the factory. On servicing, should either or both bolts strip in the outer bowl, the other ‘blanked off’...
478182 Note: If there appears to be a foreign object trapped under the impeller and it cannot be freed by using the above procedure, it may be possible to clean out under the impeller area by holding it under running water while spinning the impeller. To do this the pump housing must be removed from the machine.
Page 75
478182 WARNING: Make sure the Stator clamp plate is flat before reusing. If in doubt, replace. (c) Remove the outer bearing using the bearing removal tool. WARNING: Do not remove the bearings with a hammer and drift as serious damage to the bearing housing or outer basket may result.
478182 .07” / 3mm Note: The outer bearing will be proud of the housing by approximately .07in /3mm. 11.4 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 aluminium extrusion.
Page 77
478182 (c) Ease the shaft through the bearings from inside the outer Tub. Take care the shaft is fitted with the threaded retaining nut section facing downwards in the direction of the base. (d) Fit the shaft retention nut. Use the spline tool and spanner to tighten the shaft retention nut. (e) Invert the outer basket.
478182 SOLVING WASH PROBLEMS Listed below are possible causes and solutions to some common wash problems. Creasing: • Was the washer or dryer overloaded? • Selecting the Easy Iron cycle will minimise creasing. • Try not to leave wet clothes in washing machine or laundry basket. Linting: •...