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Bosch WFL 2060UC Training Program

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WFL 2060UC & WFR 2460UC
WFL 2060UC & WFR 2460UC
Washer Training Program
Washer Training Program
LED display model - WFL2060UC
Digital display model - WFR2460UC
1st Edition/Revision 5 (1/20/04)

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Summary of Contents for Bosch WFL 2060UC

  • Page 1 WFL 2060UC & WFR 2460UC WFL 2060UC & WFR 2460UC Washer Training Program Washer Training Program LED display model - WFL2060UC Digital display model - WFR2460UC 1st Edition/Revision 5 (1/20/04)
  • Page 2 WFL 2060 & WFR 2460 Training Program WFL 2060 & WFR 2460 Training Program • Features and Benefits • Features and Benefits • Product Description • Product Description • Warranty • Warranty • Installation • Installation • Operation • Operation •...
  • Page 3 Features and Benefits Features and Benefits • Larger door • Larger door 25% larger vs. WFK 2401 25% larger vs. WFK 2401 • Larger opening • Larger opening 15% larger vs. WFK 2401 (easier 15% larger vs. WFK 2401 (easier loading and unloading) loading and unloading) •...
  • Page 4 Extra Features and Benefits Extra Features and Benefits WFR 2460 WFR 2460 • Continuous cycle notification digital display • Continuous cycle notification digital display • Sensotronic II Plus electronic control • Sensotronic II Plus electronic control • Accurate water level control independent of water pressure •...
  • Page 5 Product Description Product Description • Electronic Sensotronic controls • Electronic Sensotronic controls • UL listed (U.S. & Canada) • UL listed (U.S. & Canada) • Larger capacity & door opening • Larger capacity & door opening • Drain hose & cord holders •...
  • Page 6 The warranties provided by BSH Home Appliances ("Bosch") in this Statement of Warranties apply only to Bosch clothes washers and dryers sold to the first using purchaser by Bosch or its authorized dealers, retailers or service centers in the United States or Canada.
  • Page 7 5 Year Limited Warranty On Motor Bosch will repair or replace, free of charge, any pump or component part of the pump that proves defective under conditions of normal home use for a period of five years from the date of original installation, labor charges excluded.
  • Page 8 Warranty Warranty Serial # Label Serial # Label The serial # label, located on the rear of the washer, shows necessary warranty information. Serial # label Factory serial # - Can convert • Model # - “WFR2460UC/01”. factory serial # to FD # for warranty use.
  • Page 9 Installation Installation Reprint of Installation Instructions Reprint of Installation Instructions (“utility knife”) Flat (blade) screwdriver. Be sure to follow all “Mains” Cold & hot water connections NOTE: HINT: HINT: national & local codes. European term for “power”, are clearly marked on the rear of the so “mains cable”...
  • Page 10 Installation Installation Reprint of Installation Instructions Reprint of Installation Instructions To avoid damaging washer, don’t move it HINT: while the feet (leveling legs) are extended. 1st Edition/Revision 5 (1/20/04)
  • Page 11 Installation Installation Reprint of Installation Instructions Reprint of Installation Instructions Loosen transport HINT: (shipping) bolts just enough to remove them from the washer -- don’t unscrew them completely HINT: To eliminate possibility of leaking, so the bushings fall from the bolts into the washer frame.
  • Page 12 NEMA 6-15R outlet (receptacle). Bosch dryers include a NEMA 6-15R outlet which the HINT: “Mains” is the European term for HINT: washer NEMA 6-15P 240V, 15A, 3-wire plug can be plugged into. “power”, so “mains cable” = “power cord”.
  • Page 13 Be sure to remove the transport (shipping) bolts! When moving an existing HINT: washer, screw in the feet (leveling legs) first so they won’t be damaged. Bosch dryers HINT: include a NEMA 6-15R outlet which the washer 240V, NEMA 6-15P HINT: “Earth”...
  • Page 14 Operation Operation Fascia Panels Fascia Panels WFL 2060UC WFR 2460UC 1st Edition/Revision 5 (1/20/04)
  • Page 15 Operation Operation Controls Controls Both have Regular/Cotton, Permanent Press, Delicates, Hand Washables, Temperature Boost & Power Temperature Boost settings. WFL 2060UC Spin Speed Selector knob Special Wash Buttons Digital Display WFR 2460UC 1st Edition/Revision 5 (1/20/04)
  • Page 16 Operation Operation Sensors (1) Sensors (1) 1A. Load Sensor (WFL2060UC) At a predefined points during the initial fill, the washer determines if it needs more water using a pressure switch. This is due to differences in the absorption of the laundry and the size of the loads. 1B.
  • Page 17 Sensors (2) 1A/1B. Load & Dynamic Load Sensors Mechanical Pressure Switch - (WFL 2060UC & WFR 2460 UC) measures the water level after the first fill. If the water level is high (like for smaller loads), the pressure increases and the pressure switch does not provide more water.
  • Page 18 Operation Operation Sensors (3) Sensors (3) 1A/1B. Flow Meter Exact monitoring of water inflow. Ensures exact control of water inlet valves so that there is always the right amount of water for wash and rinse cycles. Together with the pressure switch, there is a continuous adjustment of wash time, water and energy in relation to the load size.
  • Page 19 Operation Operation Sensors (4) Sensors (4) 1A/1B. Flow Meter Water Propeller emits signals independent from water pressure An internal water clock monitors water inflow via soak compartment. Ensures exact control of water inlet valves - always right amount of water. Independent from water pressure.
  • Page 20 Operation Operation Sensors (5) Sensors (5) 2. Digital Temperature Sensor Both models are equipped with the Temperature Sensor deliver guaranteed wash temperatures Thermostat & Heating Element 1st Edition/Revision 5 (1/20/04)
  • Page 21 Operation Operation Sensors (6) Sensors (6) 3A/3B. Suds & Continuous Suds Sensors Detection during draining out after main wash WFR2460 immediate additional rinse & cancelling of 1st rinse spin Detection during 1st rinse spin WFR2460 immediate interuption of spin insertion of one or two additional rinses WFL2060 reduced agition during additional anti foam rinse Detection during any other rinse spin...
  • Page 22 Operation Operation Sensors (7) Sensors (7) 4. Unbalanced Load Sensor New 2-step detection Accurate measuring of unbalance by deviation of spin speed and slow down time of drum Infinite adapting of spin speeds Compensates reducing of spin speeds by prolonging spinning times Will attempt up to 15 times to redistribute a load Advantages: Reduction of noise...

  • Page 23: Operation Operation

    Operation Operation Sensors (8) Sensors (8) 4. Unbalanced Load Sensor New 2-step detection 1200 1000 max. 15 trials load distribution unbalance Spin speed (rpm) spinning profile good small 1200 (max.) After 4 attempts uneven medium 1000 (reduced) After 7 attempts 800 (low) After 14 attempts none...
  • Page 24 Operation Operation Cleaning Drain Pump Trap Cleaning Drain Pump Trap Larger objects such as coins and paper clips are collected in the drain pump trap so they won’t plug up or damage other parts of the washer. The drain pump trap can easily be cleaned by customers.
  • Page 25 Operation Operation WFR 2460UC Sales Demo Mode WFR 2460UC Sales Demo Mode IMPORTANT: CAUTION: When reselling any WFL2060 or WFR2460 washers from display To avoid danger of electrical shock, make sure the washer is unplugged floors, replace the white (or gray) drain pump connector so washers will run properly and replace the shipping bolts so washers won’t be damaged during shipment.
  • Page 26 Disassembly Disassembly Top & Rear Panels (1) Top & Rear Panels (1) Washers NOTE: have concrete counterweights (top & front) to dampen vibrations. When removing NOTE: top panel, don’t damage white plastic panel latches. To remove top panel to access control module, dispenser, inlet valves, pressure switch(es), drain reservoir, surge protector &...
  • Page 27 Disassembly Disassembly Top & Rear Panels (2) Top & Rear Panels (2) To remove rear panel to access drive motor and rear of drum, remove (7) T-20 & (4) T-30 Torx screws and gently lift panel up (off of tabs at top of panel). 1st Edition/Revision 5 (1/20/04)
  • Page 28 Disassembly Disassembly Drum (1), Top Panel Drum (1), Top Panel To access the drum, the front panel must be removed first. TO REMOVE FRONT PANEL (to access drum): • Remove top panel. • To remove fascia panel, first remove T-10 Torx screw on right endcap and T-20 Torx screws on either side of fascia panel.
  • Page 29 Disassembly Disassembly Drum (2), Front Panel Drum (2), Front Panel TO REMOVE FRONT PANEL (continued): • Carefully loosen door seal clamping rings (outer/inner), taking care not to tear seal. Loosen clamp and disconnect water fill tube from seal, then remove seal. •...
  • Page 30 Disassembly Disassembly Drum (3), Outer Drum (Tub) & Dampers Drum (3), Outer Drum (Tub) & Dampers “Jacket” weight is the concrete HINT: counterweight on the top of the outer drum. 13.2 x 300 mm drill bit # 340700 1st Edition/Revision 5 (1/20/04)
  • Page 31 Disassembly Disassembly Drum (4), Outer Drum (Tub) Drum (4), Outer Drum (Tub) Before disconnecting HINT: HINT: After removing wire harnesses from control crossbar screws, module, mark each one to remove crossbars by insure proper reassembly (as rotating bottom several connectors look them out from washer.
  • Page 32 Disassembly Disassembly Drum (5), Outer Drum (Tub) Drum (5), Outer Drum (Tub) When installing outer drum bolts, screw them in by hand HINT: onto the first thread. Do not overtighten or cross-thread them. WFL 2060 drums use a NOTE: separate gasket with bolts kit # 265964.
  • Page 33 Disassembly Disassembly Drum (6), Rear Bearing Drum (6), Rear Bearing When installing rear bearings HINT: for WFR 2460 models, replace the front outer drum with gasket and bolts as well. When installing outer drum bolts, screw them in by hand onto the first thread.
  • Page 34 Disassembly Disassembly Drum Drive Motor Drum Drive Motor 1st Edition/Revision 5 (1/20/04)
  • Page 35 Disassembly Disassembly Drain Pump Drain Pump …and that’s all there is to taking apart the washers! 1st Edition/Revision 5 (1/20/04)
  • Page 36 Reassembly Reassembly WFR 2460 Outer Drum WFR 2460 Outer Drum The WFR 2460 outer drum is provided by a different manufacturer than the WFL 2060 outer drum. Both the front and rear outer drums should be replaced at the same time (if one needs to be replaced). When installing outer drum bolts, HINT: screw them in by hand onto the first thread.
  • Page 37 WFL 2060UC Circuit Diagram WFL 2060UC Circuit Diagram 1st Edition/Revision 5 (1/20/04)
  • Page 38 WFL 2060UC Wiring Diagram WFL 2060UC Wiring Diagram “Mains” is the HINT: European term “power”, “mains suppressor” = “power (surge) suppressor”. 1st Edition/Revision 5 (1/20/04)
  • Page 39 WFR 2460UC Circuit Diagram WFR 2460UC Circuit Diagram 1st Edition/Revision 5 (1/20/04)
  • Page 40 WFR 2460UC Wiring Diagram WFR 2460UC Wiring Diagram “Mains” is the HINT: European term “power”, “mains suppressor” = “power (surge) suppressor”. 1st Edition/Revision 5 (1/20/04)
  • Page 41 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Ratings Ratings • Rated 240VAC, 15A, 60 Hz (uses 11A max.). • Hot & cold water inputs, 3/4” NPT • Two concrete vibration dampeners, top & front •...
  • Page 42 WFL 2060 Service Tips WFL 2060 Service Tips Configuring Configuring Replacement Control Modules Replacement Control Modules Replacement WFL 2060 control modules (# 481304) aren’t configured. Please follow these instructions to set on-board switches to configure replacement modules. If settings aren’t done correctly, CAUTION: washers can eventually be damaged! Switch S1...
  • Page 43 WFR 2460 Service Tips WFR 2460 Service Tips Configuring Configuring Replacement Control Modules Replacement Control Modules Sample Displays Replacement WFR 2460 control modules Max. spin speed (# 484014) aren’t configured. Please 42010011 T5: Variant 1000 RPM 1100 RPM follow these instructions to configure Push Menu button to select 1st #...
  • Page 44 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Drum Drive Motor Drum Drive Motor Note “RPM” HINT: European symbol for RPM. 1st Edition/Revision 5 (1/20/04)
  • Page 45 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Drain Pump Drain Pump 80 - 94 Ω 1st Edition/Revision 5 (1/20/04)
  • Page 46 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips NTC & Heater NTC & Heater 23.2 - 29.4Ω 1st Edition/Revision 5 (1/20/04)
  • Page 47 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Door Lock Door Lock 1st Edition/Revision 5 (1/20/04)
  • Page 48 WFR 2460 Service Tips WFR 2460 Service Tips Water Flow Meter Water Flow Meter 1st Edition/Revision 5 (1/20/04)
  • Page 49 WFR 2460 Service Tips WFR 2460 Service Tips Mechanical & Mechanical & Analog Pressure Switches Analog Pressure Switches Mechanical Analog The water level (pressure switch) system consists of a mechanical Pressure Pressure pressure switch and an analog pressure switch. Switch Switch Mechanical Pressure Switch The mechanical pressure switch (orange) has (3) switching...
  • Page 50 WFR 2460 Service Tips WFR 2460 Service Tips Polinox Outer Polinox Outer Drum (Tub) Drum (Tub) POLINOX TUB POLINOX TUB Lifecycle Test 2,500 washes = 10 years Highest spin 300 consecutive times (wash-spin, wash-spin, etc. - have tested up to 900 wash-spin cycles) Heat Resistant Up to 130°C (266°F) Stability Dropped from a great height, won’t dent like Stainless Steel...
  • Page 51 WFR 2460 Service Tips WFR 2460 Service Tips Low Spin Speeds Low Spin Speeds If the WFR 2460 control doesn’t allow spin speeds > 800 RPM, then the Reduced Ironing setting has been turned on. HINT: To exit the Reduced Ironing mode: When indicating light...
  • Page 52 WFL 2060 Service Tips Test Program (1) Test Program (1) The WFL 2060UC washers have test programs enabling the washers to self-diagnose problems, including listing the last fault code. To enter component test program for WFL 2060 washers to test individual parts or check last wash fault): ♦...
  • Page 53 WFL 2060 Service Tips WFL 2060 Service Tips Test Program (2) Test Program (2) Test parts individually as follows: ♦ Motor – To start test, rotate cycle selector knob to Regular/Cotton Hot (not through Off position), then push Start button. To end test, rotate cycle selector knob out of Regular/Cotton Hot position or rotate spin speed knob.
  • Page 54 WFL 2060 Service Tips WFL 2060 Service Tips Test Program (3) Test Program (3) To enter comprehensive test program for WFL 2060 washers to test entire washer or check last wash fault): ♦ Rotate cycle selector knob to Off position and rotate spin speed knob to 1000 RPM. ♦...
  • Page 55 WFL 2060 Service Tips WFL 2060 Service Tips Test Program (4) Test Program (4) Flashing Program Fault Fault Possible Causes Lights Occurred Door left open. Door open or Door locked Wash Rinse/Spin Faulty door latch or door lock. won’t lock Wash Water shut off.
  • Page 56 WFL 2060 Service Tips WFL 2060 Service Tips Test Program (5) Test Program (5) Comprehensive Test Sequence Chart HINT: “n” = spin speed & n max. spin speed of 1000 RPM. HINT: Before leaving, make sure door isn’t locked. To drain washer to HINT: Rinse/Spin light goes out when max.
  • Page 57 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (1) Test Program (1) The WFR 2460UC washers have test programs enabling the washers to self-diagnose problems, including listing the last 8 fault codes. Rotate selector switch to Off position. Press & hold Menu &...
  • Page 58 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (2) Test Program (2) The last 8 fault codes are stored & displayed! HINT: # of errors reads “0” for faults which didn’t occur. Look at # of errors, not error #, to see HINT: Scroll thru all errors if faults occurred.
  • Page 59 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (3) Test Program (3) HINT: Do not use this test applies to European models requiring VDE safety testing. NOTE: Test takes ~ 1 minute, 20 seconds to complete. HINT: Using the test program can greatly cut down repair times & NOTE: “...
  • Page 60 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (4) Test Program (4) HINT: Start/Pause light turns yellow when drum speeds up to 1200 RPM and slows down. “RPM” HINT: European symbol NOTE: Test takes > 10 minutes to run. RPM.
  • Page 61 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (5) Test Program (5) - for replacement modules ONLY Select “RPM” HINT: HINT: This test shows washer European symbol for RPM. configuration (42010011), meaning max. spin speed is 1200 RPM, it uses hot water doesn’t have European Aqua-Stop feature.
  • Page 62 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (6) Test Program (6) (~ 50 sec.) P01 for Regular/Cotton •Power Wash Cold). •Rinse Plus •Quick Wash Select (when held down) HINT: Test takes ~ 50 seconds to (when held run.
  • Page 63 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (7) Test Program (7) Display Display HINT: HINT: shows T8:NIVEAU1 shows T9:NIVEAU2 HINT: “W controller” is the mechanical pressure switch. HINT: Start/Pause light turns yellow when water reaches N level. 1st Edition/Revision 5 (1/20/04)
  • Page 64 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (8) Test Program (8) HINT: Test runs ~ 15 seconds. HINT: Test runs ~ 1 minute, but doesn’t end. Press Menu button when HINT: Turbidity sensor appears only on European models. shows on display.
  • Page 65 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (9) Test Program (9) To save time with Tests Tests T13 - T16 fill until n256 HINT: HINT: T13 - T17, press Menu to stop test pressure switch reading appears. When when the washer stops filling (tests display reads n256, press Menu to stop test.
  • Page 66 WFR 2460 Service Tips WFR 2460 Service Tips Test Program (10) Test Program (10) HINT: To save time with Test T18, On Test T18, the water NOTE: press Menu to stop testing after level rises until N , which is the the temperature has gone up heating water level.
  • Page 67 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Troubleshooting of Minor Faults Troubleshooting of Minor Faults (Customer Self Help) (Customer Self Help) 1st Edition/Revision 5 (1/20/04)
  • Page 68 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Troubleshooting of Minor Faults Troubleshooting of Minor Faults (Customer Self Help) (Customer Self Help) 1st Edition/Revision 5 (1/20/04)
  • Page 69 WFL 2060 Service Tips WFL 2060 Service Tips Resistance Resistance Measurements from Control Module (1) Measurements from Control Module (1) Disconnect & measure white 5-pin connector (with 3 Disconnect & measure blue black wires) to measure dual cold water valve. Valve connector (with...
  • Page 70 WFL 2060 Service Tips WFL 2060 Service Tips Resistance Resistance Measurements from Control Module (2) Measurements from Control Module (2) Disconnect & measure white 6-pin connector Disconnect & measure white 3- (with wires) to measure drum drive motor. blue pin connector (with wires) blue Motor should read (pin 1 is at far right):...
  • Page 71 WFR 2460 Service Tips WFR 2460 Service Tips Resistance Resistance Measurements from Control Module (1) Measurements from Control Module (1) Disconnect & measure white 6-pin connector (with wires) to blue Disconnect & measure blue 2-pin measure drum drive motor. Motor should read (pin 1 is at far right): connector (with wires) to blue...
  • Page 72 WFR 2460 Service Tips WFR 2460 Service Tips Resistance Resistance Measurements from Control Module (2) Measurements from Control Module (2) HINT If necessary to access connectors, Disconnect & measure white 2-pin connector (with carefully pry control module tabs and black wires) to measure hot water valve. Valve remove module from fascia panel.
  • Page 73 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Troubleshooting (1) Troubleshooting (1) Symptom Problem Solution Washer won’t start. Electricity is disconnected Make sure washer is connected to an appropriate 240V, 60 Hz or has been turned off. circuit (according to local codes).
  • Page 74 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Troubleshooting (2) Troubleshooting (2) Symptom Problem Solution Drum won’t rotate. Drum rear bearing Check how drum rotates. If drum wobbles or won’t move, has failed. replace faulty rear bearing. Motor drive circuit Check voltage at motor connectors when motor is energized.
  • Page 75 WFL 2060 & WFR 2460 Service Tips WFL 2060 & WFR 2460 Service Tips Troubleshooting (3) Troubleshooting (3) Symptom Problem Solution Washer overheats. Control module has Check voltage to heater. If voltage is present when heater failed. shouldn’t be on, replace faulty control module. NTC failed.
  • Page 76 WFL 2060 Service Tips WFL 2060 Service Tips WFL 2060 Not Running WFL 2060 Not Running NOTE: WFL2060 Occasionally, washers have been set up for sales demonstration and not reconfigured for normal use when they were sold. WFL2060 drain pump is located at washer right front corner...
  • Page 77 WFL 2060 Service Tips WFL 2060 Service Tips Fascia Panel Parts Fascia Panel Parts Surge suppressor NOTE: Complete fascia panel Use & Care Manual 366766 includes knobs dispenser drawer gasket. Dispenser 240V, 15A, door front 484011 is not included and must be bought separately. 3-pronged plug with cord (NEMA...
  • Page 78 WFL 2060 Service Tips WFL 2060 Service Tips Frame & Door Parts Frame & Door Parts Shipping bolts NOTE: Parts are subject to change without notice. To obtain an updated parts list (updated monthly), please purchase a parts CD subscription. Shipping bolts Door latch...
  • Page 79 WFL 2060 Service Tips WFL 2060 Service Tips Drum Parts Drum Parts Concrete top counterweight Parts NOTE: Polinox subject change rear outer without notice. drum obtain an updated parts Polinox front list (updated monthly), outer drum ss inner please purchase drum parts CD subscription.
  • Page 80 WFL 2060 Service Tips WFL 2060 Service Tips Pump Parts Pump Parts Water inlet valves (hot & dual cold) Pressure switch Cold Water inlet hoses (hot & cold) Drain reservoir Dispenser Air dome Parts NOTE: Ball check subject change sump Drain pump without notice.
  • Page 81 WFR 2460 Service Tips WFR 2460 Service Tips Fascia Panel Parts Fascia Panel Parts Parts NOTE: Surge subject change suppressor without notice. Use & Care Manual obtain an updated parts list (updated monthly), 240V, 15A, 3- pronged plug please purchase Control with cord parts CD subscription.
  • Page 82 WFR 2460 Service Tips WFR 2460 Service Tips Frame & Door Parts Frame & Door Parts Shipping bolts NOTE: Parts are subject to change without notice. To obtain an updated parts list (updated monthly), please purchase a parts CD subscription. Shipping Door latch bolts...
  • Page 83 WFR 2460 Service Tips WFR 2460 Service Tips Drum Parts Drum Parts Polinox rear outer drum Concrete top counterweight NOTE: Rear outer drum gasket & screws are not Polinox front available separately) NOTE: When replacing rear outer drum (with outer drum, replace front outer gasket &...
  • Page 84 WFR 2460 Service Tips WFR 2460 Service Tips Pump Parts Pump Parts Main pressure switch Cold Analog pressure switch Drain Hoses reservoir Hoses Water inlet valves (hot & dual cold) Dispenser Parts are NOTE: subject to change without notice. Water inlet Air dome obtain an updated hoses (hot...

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