Washing Machine

Service Manual
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Model:
WM-75FL1

Model No: WM-75FL1

Version 1.0
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CONTENTS

SAFE SERVICING PRACTICES............................................................................................................ 4

BASIC PRINCIPLES OF WASHING MACHINE .................................................................................. 5

INSTALLATION & DISMANTLING ..................................................................................................... 7

ELECTRICAL DIAGRAM.................................................................................................................... 15

PROGRAMME CHART ........................................................................................................................ 16

WIRING ASSEMBLY ........................................................................................................................... 17

CABLE TABLE ..................................................................................................................................... 18

FEATURES OF WASHING MACHINE ............................................................................................... 19

FAULT DIAGNOSIS INDICATIONS ................................................................................................... 24

PART LIST............................................................................................................................................. 25

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SAFE SERVICING PRACTICES

To preclude the possibility of resultant personal injury, it is important that safe servicing practices be
observed. The following are examples, but without limitation, of such safe practices.

Before servicing, always disconnect the product from its electrical power source by removing the
product’s electrical plug from the wall receptacle or by removing the fuse (or tripping the circuit
breaker to OFF) in the branch serving the product.

Note: If a specific diagnostic check require electrical power be applied (e.g. a voltage or amperage
measurement, etc), reconnect electrical power only for the time required for such a check and
disconnect.

All electrical harness leads are properly dressed and secured away from sharp edges, high temperature
components (e.g. resistors, heater, etc) and moving parts.

Any non insulated current-carrying metal parts are secure and adequately spaced from all
non-current-carrying parts.

All electrical ground – both internal and external to the product are correctly and securely connected.

All water connections are properly tightened on appliance. All panels and covers are properly and
securely re-assembled.

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BASIC PRINCIPLES OF WASHING MACHINE

WASHING PROCESS:

Washing is a process of removal of dirt, soilage, perspiration, etc from clothes.

The degree of cleaning achieved in washing process is result of several interacting factors, which
provide energy to remove soil.

The 4 main factors are:

Mechanical energy during washing action
Amount of wash time
Chemical energy from the detergent, bleach and other additives
Thermal energy from the use of warm or hot water

An optimum balance of these energies provide acceptable cleaning performance. If any one of this is
decreased, the other factors must be increased to maintain the same cleaning results.

MECHANICAL ACTION

Mechanical action like thumping helps in dislodging the dirt from fabric.
Mechanical action helps to expose more surface for wetting and detergent action.
Mechanical action improves distribution of clothes inside the drum.
Mechanical action in Front Loading Machine allows to use lesser water for effective wetting of
clothes.

TIME

Time allows detergent to act chemically on dirt in fabric.

Improves wetting of clothes.
Bonding of dirt loosens.

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DETERGENT

Removes soil, lint and prevents it from re-depositing on fabric.

Detergent holds oil, dirt in suspension for limited period.
One end of detergent molecule attracts towards water whereas other end clings to dirt. Hence dirt
particle is pulled out from fabric.
Detergent reacts with dissolved salts in water and softens the water.

TEMPERATURE

At 40 – 50oC of water, active oxygen gets released from dissolved oxygen. This active oxygen
helps in pushing dirt particles from fabric.
Warmer water enhances detergent effectiveness. As the temperature of the water increases,
chemical reactions proceed at a greater speed.
Granular detergents are better dissolved in warm water.
The bacteria is killed at water temperature above 60oC resulting in hygiene washing
(disinfectant).
The temperature also expand, the mesh of fabric and loosens the grip over dirt particle embedded
within.

WASHING MACHINE

Washing machine is an equipment which does the process of washing clothes as per selected, set or
pre-set commands.

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INSTALLATION AND DISMANTLING

STRUCTURAL PARTS ASSEMBLY

The structural parts assembly has following major parts.

Moving parts:
Drum assembly
Tub Assembly
Springs
Dampers
Rubber sleeve
Motor pulley & belt

Stationary parts
Housing assembly
Door assembly
Facia & DD handle assembly
Rear upper beam assembly
Cabinet backwall
Top lid

The housing assembly is made up of galvanized sheet of 0.75 – 0.80mm thickness duly pretreated and
powder coated to 60 – 90 micron thickness. The housing assembly is reinforced by embossing on
sides, ribs on front, welded side upper beams, base sub assembly and bolted transportation beam
assembly. 4 Nos. Adjustable feet are provided with M10 threading for leveling the machine.

The housing assembly acts like an enclosure and supporting structure for other sub assemblies. P.P.
Corrugated sheet is fixed to cover the bottom. Filter door is hinged with a pin on the housing.

The Tub Assembly is fitted with Drum Bearing Bracket by 6 Nos. M8 Bolts Bearing Set with Sealing
Ring. The Drum Assembly is fixed inside the tub assembly by supporting it on the bearings.

The Drum Pulley is fitted on shaft splines and bolted by M8 bolt with spacer and washer at front and
back. Drum is driven by the motor through the Poly V Belt. The Poly V Belt runs over the grooved
pulley on motor and plane drum pulley.

The Tub Front Ring Assembly consisting of front ballast weight bolted by 3 Nos. on to stainless steel
SS430 tub front ring is clamped on tub assembly with tub front sealing ring by two holding ring half
bolted together by 2 Nos. Allen headed M8 bolts.

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The Motor Assembly with fittings like Buffers, Fixing Lug, Motor Holding Pins is fixed on Motor
Hanger by 2 Nos. M6/M8 bolts and Adjustable Plate.

The Tub Assembly holds water during washing process and supports drum with wash load. The tub
assembly is suspended in Housing assembly on three springs on top side and fixed with two friction
dampers on bottom side. The flexible rubber rubber sleeve is fitted on tub front ring assembly at one
end on housing assembly at the other end.

The drum assembly consist of rigid structure of a perforated drum with a drum backwall fastened to a
aluminium bracket which carries a shaft at the rear end and drum front ring on the front side. The
drum liner and drum front ring are mechanically seamed. The drum liner is fitted with plastic baffles
by S.S. Screws.

The drum assembly holds the wash load, rotated it at designated speed during wash/ spin process. The
perforation in drum and baffles allows better wetting of clothes. The baffles in the drum lifts the wash
load and drops down giving gentle thumping action, as well as baffles scoop the water and spary over
the cloths for better wetting.

The door assembly consisting of door frame, door glass with door gasket, hinge assembly, handle
assembly (optional) and door inner frame screwed together by 6 Nos. double start screws. The door
assembly is hooked on housing assembly and screwed with 2 Nos. self tapping screws 4.2 x 13. This
allows user to put wash laundry in the drum opening the door. It seals the front side on rubber sleeve
during washing when closed and restricts access to drum when machine operates. The Facia and DD
Handle is fixed on housing assembly as specified for the model.

The Rear Upper Beam assembly with fixed electrical parts is screwed on housing assembly by 4 Nos.
S.T. Screws 4.2 x 13. This acts as a panel fro mounting related electrical parts.

The cabinet backwall is screwed on housing assembly by 7 Nos. S.T. Screw 4.2 x 13 and 2 Nos. S. T.
Screws 4.2 x 9.5. This acts as a back cover for the machine.

The top lid is slide on the lid holders and screwed on back side with 2 Nos. S.T. Screws 4.2 x 13 with
washers. The top lid adds aesthetic value to the machine and acts as top cover for machine.

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HOUSING ASSEMBLY

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DRUM ASSEMBLY

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HYDRAULIC PARTS ASSEMBLY

Water supply hose

1 / 2 / 3 way solenoid valve assembly
Detergent dispenser assembly
Pressure switch (pressostat) assembly
Filter assembly
Pump and exhaust accumulator
Exhaust hose

Washing manichine is connected to water supply by fixed plumbing or tap adapter with water supply. Hose
having the nut (end cap) ¾” BS Parallel threads. Other end of hose is connected to Magnetic Valve fitted on
Rear Upper Beam with nut (end cap). The outlets of valve is connected to Detergent Dispenser box at respective
chamber by Dispenser inlet tube/s. The water from the DD box enters into tub through the tub hose.

The outlet of the tub at bottom is connected to folded hose through which water flows in Filter assembly. Rear
end connection of filter assembly and drain pump inlet is joined by filter nose. Filter assembly is having a
threaded opening to remove fluff filter for periodic cleaning. Drain hose fixed with drain plug is connected to
filter hose to inlet of drain pump. Gutter is provided on filter assembly, which can be pulled out to avoid spillage
of water during periodic cleaning.

The other end of the folder hose is joined to Air Trap Tube and elastic tube with plastic hose connector and
metallic connector. Elastic tube is connected to Pressostat. All the joint are clamped with suitable spring collars.

The Drain Pump, pump out the water through the corrugated PP Pump Hose to Exhaust Accumulator. Outlet of
it is connected to Exhaust Hose (corrugated PP) via the connecting elbow. The by-pass connection is provided
through Dispenser Hose to DD box. The Exhaust Hose drains water in drain pipe or wash basing as provided by
user.

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HYDRAULIC ASSEMBLY

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CONTROL PARTS ASSEMBLY

Power supply cable with fuse

Indicator lamp/ LED’s
Single level / 2 level pressure switch
2 / 3 button press switch
Motor/ Capacitor/ SSU/ SCU/ Potentiometer
Drain Pump
Wiring Harness
NTC sensor
Power board
On-Off switch cum temperature selector
Thermal door lock/ magnetic door lock
Programmer
1 / 2 / 3 way solenoid valve
Heater / Fixed or adjustable thermostats
R.F. Filter (optional)
Interface Board
Surge suppresser (MOV)

Washing machine gets power supply through 3 Pin – 15A Power Supply Cable (PSC) with moulded
plug head. Fuse of 13A is provided in the plug head. Power supply cable clamp fixed on RUB holds
the cable and avoids the tension on end connection fixed to cable connector. The earth terminal is
connected to earthing pin on PSC to pass on any leakage current to the ground.

Wiring harness connects the various electrical components used in washing machine and supplies
power depending on the position of switches as shown in electrical diagram.

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FACIA ASSEMBLY

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ELECTRICAL DIAGRAM

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PROGRAMME CHART

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WIRING ASSEMBLY

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CABLES TABLE

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FEATURES OF WASHING MACHINE

GENERIC FEATURES

1. Fully automatic and programmable

The preset washing process and optimum wash time can be selected from given set of
programmes. Once the selected programme is switched on, machine carries out the defines wash
process and stops.

2. Hot wash/ hygiene wash

Water temperature option to select 30 – 95oC is available. Temperature between 45 – 60oC
dissolves the granular detergent and activates it for effective chemical reaction. Temperature
above 60oC kills the bacteria and germs and gives hygienic wash (disinfectant).

3. Draining water at any height upto one meter ground level

Option available to customer to drain water in fixed drain pipe at ground level or in wash basin.
The drain point in the machine is kept at height of one meter and water is drained by pumping it
out. Fixed quantity of water is retained in drain line to act as a barrier for preventing detergent
entry into the drain hole of the tub.

4. Auto selection of in-take water

Water filling in tub through the appropriate chamber of detergent tray is carried out by energizing
individual coil of magnetic valve. The programme does not index until first level of water is
filled in tub.

5. Dry tap protection

Wash cycle does not advance without ensuring adequate quantity of water. Even in case of low
water pressures, amounts of water required during washing and rinsing is ensured. No “soapy”
feeling of clothes after drying.

6. Fail safe heating

Heater is switched “ON” through the Programmer only when water to first level is filled in the
tub. Once the set temperature is attained, thermostat/ NTC regulates the temperature of water by
switching “OFF” and “ON” heater to the required timing.

7. Door inter locking with programme

The power supply to electromechanical Programmer/ Interface board and Pressure Switch/ Power
board is routed through Door interlock. This ensures availability of power supply only when door
is locked mechanically and electrically.

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8. Cool down cycle

At the end of main wash, hot wash is cooled down by taking additional cold water automatically.
This reduces the concentration of detergent thus ensuring better rinse quality and eco friendly
environment. This also eliminates harmful effects of hot water draining. In case of Electronic
programmer, the cool down occurs only if the temperatures of water is high.

9. Water overflow protection

During water filling, if the Pressure Switch (Pressostat) fails to detect water levels and doesn’t
stop in-take of water, the water level in the tub increases. The increased water level gives high
pressure and triggers the overflow switch in Pressostat and pump starts draining water and
reduces water level in the tub.

10. Vibration damping

Uneven distribution of wash load in the tub leads to imbalance of load. The reactive forces are in
proportion to the imbalance load, square of speed of rotation and radius of rotation. Variable
reactive force generate vibrations which are absorbed by spring and dampened by dampers. The
folds in rubber sleeve prevent transfer of vibration to cabinet.

11. Liquid siphon for additives

Normally fabric conditioners like fabric softener, whitening agent, enzyme, disinfectants,
bleaching agent are in liquid form. Such fabric conditioners are mixed up in water at the
beginning of additive cycle and then siphoned to the tub. This ensures uniform mixing abd
application of additives to wash load.

12. Draining during emergencies

In case of long power failure during a programme run, the water can be drained through the drain
hose. This will avoid spillage of water on the base parts and eliminate chances of rusting.

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ADD-ON FEATURES

1. Eco program/ button

This option/ program gives and environmental friendly and energy saving operation of washing.
In this program, the mechanical tumbling action during wash is increased in such a way that at
lower temperature and power consumption, the same quality of wash is achieved as that with
high temperature and less mechanical action.
This action can be used for washing cotton/ synthetic clothes such as whites, cottons and coloreds,
average soiled cottons, bed sheet, curtains, under garments, towels, shirts, trousers, etc.

2. Water plus
“Water Plus” provides option for using 15-30% additional water during wash cycle. This option
is suitable for load more than 3 kg of light and medium soiled clothes, which are normally not
washed daily or having highly water obsorbing fabrics which are washed after relatively longer
duration of use like curtains, bed sheets, jeans etc.

3. Soak
Soaking facilitates action of detergent to dislodge the dirt particles from the clothes for better
wash quality. Upon pressing this button, the clothes remain stationary (soaked) in soapy water.
This option is used when the cotton/ synthetic clothes being washed are highly soiled or stained.
Soaking option is inbuit in woolen program.

4. Rinse hold
Rinse hold option gives flexibilities for delays in taking the clothes out sfter the end of
programme and minimizing formation of wrinkles, Rinse hold option holds water in tub at the
end of additive rinse cycle. Before taking the clothes, the button to be released for spin drying
operation.

5. Pre wash
The clothes are given a preliminary wash before main wash. At the end of the pre wash, the dirty
water is pumped out automatically. This option can be used when the cotton/ synthetic clothes
being washed are highly soiled, long wearing for e.g. outdoor sport wear, kitchen wear, jean etc.

6. Quick wash
With this option, the total duration of washing cycle is reduced by 20 to 35 mins approximately
depending on the program chosen. Also one rinse is skipped. Cotton & synthetic clothes which
are lightly soiled, once worn, undergarments, shirts, blouses, guest towels or less quality of
clothes (max 3 kg) are suited to be washed with this option.

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7. Intensive wash
On pressing this button, the mechanical tumbling action during washing is increased to give more
vigorous action on clothes in cotton program. This option is suitable when the cotton/ synthetic
clothes being washed are highly soiled and long garments washed after long duration of use for
e.g. bed sheets, pillow covers.

8. Additional rinse
On pressing this button, an additional rinse is executed by the program to wash out any left over
detergent to give a better feel to the fabric. This option can be used in places of soft water or for
highly soiled clothes or rinsing delicate fabric, net curtains.

9. Time delay
Time delay indicates the time after which the program will start. This option is used when
delayed washing is preferred at your convenient time. The delay time can be set from 30 mins to
24 hrs. After time delay is over, the washing machine will automatically start the chosen program
and time required for completing the chosen program would be displayed.

10. Start/ pause

By pressing this button, the washing machine will start the washing cycle. This button has to be
pressed after selecting the program and optional buttons. If you want to modify the program
selected, then washing machine can be brought into “pause” state by pressing the same button
again.

11. Door open

This button is used for opening the door before and after the washing cycle. The “Door open”
LED will be ON indicating to the customer that door can be opened before the start of washing
cycle or at the end of the washing cycle. After pressing the “Strat/ Pause” button i.e. after
commencing the washing cycle, the door can be opened only after completing the full washing
cycle. Please note that the door can not be opened if there is a power failure. In case of
emergency, pull the emergency lever provided on the base of the washing machine on the front
right hand side.

Also to prevent any untoward incidents to you, additional protection is provided in which the
door can not be opened even if paused when the water temperature in drum is above 50oC or if
the washing machine is in rinse mode or if the washing machine is in spinning operation.

12. Digital display

This is an exclusive feature whereby you get the complete feedback from the washing machine
during the setting of the program, state of the washing cycle, fault indications if any etc.

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13. Child lock safety

This is an exclusive feature to prevent the tampering of programs of washing machine during
washing cycle. This option is to be selected after starting the washing cycle. Once set, all the
buttons are inoperable during washing cycle. The “child lock” feature can be disabled by again
pressing the same button. The “Child lock” symbol in the digital panel will not be seen.

14. Spin speed selection and spin cancellation

This feature provides optional of deleting the spin or selecting spin speed. When the wash load is
rotated at the selected spin speed, the centrifugal force is generated. This force squeezes the
clothes and removes water. It is preferable to selected spin speed based on circumstances and
requirements. Higher spin speeds should be selected when necessary to avoid undue stressing of
clothes, bearings and joints.

15. Anti crease

Anti crease cycle is provided at the end of spin cycle. The clothes are tumbled anticlockwise and
clockwise direction to loosen the squeezed clothes during spinning. Anti crease cycle makes
clothes fluffy, gives soft feel and smooth surface to the fabric.

16. Showering system

The perforated baffles fitted on drum assembly scoops soap solution and showers it through
perforation on the fabric during rotation. This improves wetting of clothes and allows to use
lesser water to provide acceptable cleaning results.

17. Imbalance mass detection, correction and spin speed control

During tumbling, the rpm being low, the clothes keep falling down. However, as rpm increases,
the clothes get attached to the circumference of the drum. In this situation, uneven clustering of
clothes in segments of drum causes imbalance load. Formation of imbalance load is random in
nature and can not be predicted in advance.

The spin cycle (intermediate and final spin starts with distribution of clothes. During distribution
the drum rpm is 80 – 90 due to which the clothes are facilitated to get aligned evenly in the
segment of drum.

The extent of imbalance is detected by the speed control unit through pulses generated by
tachogenerator. The spin speed is selected as per preset speeds for a detected imbalance load. In
case of heavy imbalance, the machine rotates at preset lower spin speed.

This type of control avoids adverse effect of imbalance load during spinning like over stressing
of bearings, excessive vibration, noise, premature wear/ tear of moving parts.

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FAULT DIAGNOSIS & INDICATIONS

Digital display / Check if the machine is ON.

Indicator lamp does not Check for loose connections in plug/ socket.
glow. Check if the programme selector knob is in OFF position.
Check for blown fuse.
Machine does not start Check if machine is powered ON.
Check if the “Start/ Pause” button is ON. The LED will glow when it
is pressed.
Check water supply.
Porthole door no closed properly.
Check position of programme selector knob.
Indicator lamp not glowing.
Water does not enter Check water supply.
machine/ detergent not Porthole door not firmly closed.
being flushed into drum Water tap not turned on.
Bent inlet hose.
Sieve on inlet valve/ inlet hose clogged.
SUDS escaping from Detergent used is not a washing machine detergent.
detergent dispenser tray Excessive detergent used.
Drain line is blocked.
Water leakage from the Inlet / Outlet hose connection loose.
machine Fluff filter not screwed on properly.
Inlet hose leaking.
Drain plug not fixed properly onto Drain hose.
Machine does not drain Fluff filter clogged.
Outlet hose end above 1m from floor level.
Machine does not spin Check if the spin speed selector knob is set on spin cancel position.
Rinse hold button is pressed.
Fluff filter clogged partially.
Clothes not loaded as instructed.
Machine vibrates Machine not leveled properly.
strongly during spinning Clothes not loaded as instructed.
Water not drained completely.
Motor noise It is normal for noise to be heard while motor is running. However
wash load, belt tension and motor mounting bolt should be checked for
specified limits
Pump noise It is normal for noises to be heard from the pump during the start-up
and final stage of draining. However, check for fluff filter clogging.

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PART LIST

NO PART NAME
1 Snap lock
2 Lock pin
3 Lock spring N.L.
4 Door handle white N.L.
5 Door frame white N.L.
6 Door gasket
7 Door glass pc
8 Hinge (plated)
9 Pin
10 Inner door frame N.L.
11 Lock shim
12 Spring ring
13 Lock plate
14 Filter door pin
15 Filter door painted
16 Adjustable foot assly M10
17 Door lock (L)
18 Expansion nut (MOD)
19 Power supply cable (FL series)
20 Motor speed control unit
21 PR upper beam (ver.slot) plated
22 Housing assy add PTD (SENATOR)
23 Trans. Beam assly painted
24 Table top LID (SDX)
25 Cabinet backwall painted
26 Rubber sleeve
27 Rubber sleeve O ring
28 Front ballast wt.
29 Screw M8 x 50 DIN 931-8.8
30 Tub front ring sub assembly
31 Square nut M8 DIN 557-5
32 Screw M8 x 45 DIN 912-8.8/12.9
33 Tub front sealing ring
34 Holding ring half (PLTD)

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NO PART NAME
35 DAMP. Element (M-bush)
36 Screw M10 x 45 DIN 933-10.9
37 Drum assy 24 (single BKWALL)
38 Fixing lug assy (SENATOR)
39 Plate
40 Motor UNIVERSAL 220V 1100RP
41 Heating element holder
44 Heating element 1900W – 220V
45 Poly V belt 1333 J6
46 Tub assy (modified) senator
47 Upper ballast WT. CEMENT
48 Large spring
49 Small spring
50 Shaft liner 29
51 Drum B. sealing ring 29
52 Ball bearing 6206-2RS/2RSR-C3
53 Drum bearing BKT (SENATOR)
54 Screw M8 x 25 DIN 933-10.9
55 Ball bearing 6205-2RS/ 2RSR-C3
56 INT. CIRCLIP B52 x 2.00 DIN 472
57 Drum pulley 29
58 HEX screw M8 x 30 DIN 933-10.9
59 Baffle DELUX
61 Spring washer (plastic)
62 Filter cover
63 Filter washer
64 Filter sealing ring
65 Filter
66 Filter housing
67 Gutter
68 Folder hose
69 Plastic sleeve connector
70 Air trap tube
71 Mettalic hose connector
72 Elastic tube
73 Sponge ring
74 Pressostat 2 level – (SENATOR)

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NO PART NAME
75 Shell lower part natural
76 Shell assly with flaps
77 Dispenser inlet tube 315mm
78 Triple solenoid valve – 180 DEG
79 Water supp. Hose C.L. (white)
80 Filter hose (H)
81 Plastic hose connector
82 Drain hose
83 Drain plug
84 Hose (rubber tube) exe
85 Pump base plated
86 Synchronous pump (I)
87 Pump hose
88 Exhaust accumulator assly
89 Dispenser hose
90 Exhaust hose complete
91 D D handle 75FL1 (printed)
92 Detergent dispenser tray
94 Indicator lamp RED
98 Adjustment TH. assly (I)
100 DD handle 75FL1 (PRINTED)
101 Button type – 1 (STR)
102 Button type – 2 (STR)
103 Button type – 3 (STR)
104 Button type – 4 (STR)
105 Potentiometer knob (STR)
106 Therm. Knob assy (PRTD) – STR
107 Prog. Knob base (PRTD) (STR)
108 ASY – Knob Cov & Body (SENATOR)
109 Facia 75FL1
110 Indicator lamp green
111 Programmer (SENATOR)
112 Potentiometer (SENATOR)
113 P-Switch MOD DY11KS50H000
114 P-Switch MOD DY11KS60C000
115 P Switch MOD DY1KS10C

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