Service Manual - McCulloch Spares, Parts & Accessories
Contents
1. Fan motor Condensation solenoid valve Thermostop electromagnet Automatic drying button Drying pilot light Discharge pump Timer motor Electronic speed control Commutator motor 20 TIMER TIMING DEVICE CONTACTS Door delay Drying Timing device power supply Energetic heating Heating Automatic drying Drying thermostop Automatic drying Direct timer power supply Discharge pump Motor control signals Reverser When the drying cycle and drying time are selected and the main switch 1 is pressed the door delay device 2 is powered via the door delay contact 21 and all the components in the appliance are powered The main pilot lamp 3 and the drying pilot lamp 16 which receives its signal from timer contact 28 light immediately The power supply to the drying circuit and the timing device motor 11 is received via the contact of the pressure switch 4 in the empty position via timer contact 22 via contact 23 of the timing device the power supply is controlled by the manual reset thermostat 5 One branch of the drying heater 9 is powered by contact 24 of the timing device the other is controlled by the drying thermostat 7 The circuit is completed by the safety thermostat 10 and contact 25 of the timing device The fan motor 12 condensation solenoid 13 thermostop electromagnet 14 and timing device motor 11 are powered at the same time as the heating elements The timer motor is2. foil and held in position by two fastening bands The duct is fastened to the front casing by a screw A steel wire band is used to fasten the duct to the bellows seal 10 DRYING CONDENSER 11 The drying condenser consists of a plastic body which is fixed to the base of the appliance The bottom end of the condenser is connected to the tub by means of a rubber hose coupling The upper extremity is connected to the fan by a gasket The humid air enters the lower end of the condenser while a jet of cold water is introduced from the upper end The shape of the condenser is designed to create a turbulence between the flow of humid air and the jet of cold water This causes the humidity in the air to condense asa result the fan receives cold dry air which is then re circulated and passed through the heaters The cooling water and condensation fall to the bottom of the tub and are drained off by the discharge pump Condenser self cleaning process 1 Circulation pump 2 Condenser 3 Pump condenser hose During drying the fluff suspended in the water tends to accumulate in the bottom of the condenser Jetsystem washing machines are fitted with a hose which connects the circulation pump to the condenser During the washing cycles therefore water flows constantly between the condenser and the tub and fluff is therefore carried to the condenser During the discharge phase the fluff is deposited on the discha
3. knob assembly c Detach the mechanism from the detergent dispenser d Remove the two screws which fasten the timer to the timer support e Remove the connectors f Slide the timing device out Replacing the knob Replace the spring and the knob cover before refitting the knob assembly Check that the knob is correctly aligned with the indicator window inside the control panel 28 7 SOLENOID a Remove the intake hose b Remove the screw from the contact board support and remove the bracket which fastens the solenoid to the dispenser c Remove the screw and detach the rear wire clamp d Detach the hoses from the manifold e Remove the solenoid duct assembly from the dispenser and remove the connectors f Remove the hose that connects the solenoid and the manifold g Remove the solenoid from the manifold Replacing the solenoid Fit the sealing gasket before replacing the solenoid 8 MANIFOLD Access to the manifold between the drying solenoid and the dispenser may be gained by dismantling the detergent dispenser or by following the procedure outlined below a Use a sharp blade to cut the duct on two sides as shown in the figure b Remove the manifold from the dispenser 29 ph 2 re ACCESS FROM THE REAR SHELL Dm A gt KO s Venen E pw y r s NX AN Ex lt 4 LA DADA TE LAN y AT FA I IT Heater casing Fan
4. lt EEK dO Sl 28 RE gt IF a ab Q e pari gt ka Q A k I Publication 599 32 00 00 P6000 series Washer dryers 1 a r h AN ET ON 4 lt w it e lt ky m 452 my d 4 4 4 re Y YE a k SS i mas ee I i Va NCT in Ba l 05 91 Date INDEX Purpose of this Manual DRYING CIRCUIT OPERATING PRINCIPLES AND STRUCTURAL CHARACTERISTICS Drying circuit Fan Heater casing Duct Drying condenser Hydraulic drying circuit Jetsystem Direct Spray washing system ELECTRICAL COMPONENTS Timer Timers with timing devices operating diagram Dual knob timers operating diagram ACCESS TO COMPONENTS Access from the top Access from the rear shell Access from the porthole door Page 10 11 13 15 19 20 22 27 30 33 PURPOSE OF THIS SERVICE MANUAL This Manual is intended for use by service technicians who already have the basic training required for the repair of washing machines and contains information relative to the drying system used in P6000 series washer dryers NEXUS line The structural characteristics and the washing system are described in Service Manual n 599 31 74 50 Separate Service Notes relative to each specific model contain more detailed information such as technical characteristics electrical diagrams timer diagrams exploded diagrams and spare parts lists DRYING CIR
5. powered by contact 29 which also provides the power supply for the electronic speed control 19 of the motor 20 operation of the motor is governed by the various motor speed selection contacts and reversers 31 32 The discharge pump is powered by timer contact 30 The timer remains in the drying position since the coil of the thermostop 14 prevents its advance When energetic drying is selected both branches of the heating element are switched on During delicate drying contact 24 of the timing device is open thus switching off one branch of the heating element 9 Each heating element absorbs 700 W The drying thermostat 7 which is normally closed is set to open the contact at 106 C and to reclose the contact at 90 C This thermostat is designed to control the heating of the resistances during the drying phase especially when the user selects excessively long drying times and when the power supply voltage is abnormally high The safety thermostat 10 which is normally closed opens at 98 C and recloses at 75 C This thermostat is positioned further away from the heating element than the drying thermostat and intervenes if a malfunction occurs in one of the components of the electric fan the belt breaks if the drying thermostat 7 malfunctions if the water supply is closed etc Eight to ten minutes before the end of the drying cycle the timing device opens contact 25 and switches off the heating elements Ho
6. C and to reclose at 75 C The manual reset thermostat 3 is normally closed and opens at 150 C thus disconnecting the entire appliance from the power supply This thermostat intervenes only in the case of a simultaneous fault in the safety thermostat 9 and any of the other components of the ventilation circuit Eight to ten minutes before the end of the drying cycle timer contact 20 opens and switches off the heating elements However the fan continues to operate until the cooling phase is completed At the end of the drying cycle the timer advances to the stop position When the user desires to select automatic drying at the end of the washing cycle it is necessary to press the automatic drying button 12 which via timer contacts 21 and 22 automatically causes the timer to skip the stop immediately preceding the drying phase 23 ACCESS TO COMPONENTS REPAIR PROCEDURES 25 ACCESS FROM THE TOP 33 8 ac 2 wt bp 34 SS BEDE bn S ZO bas 353588 8 0009 CERROS RA e ee e j 9 B O s AUN T u NO D oo ON O m vd en 27 A L 77 Remove the two rear screws push the top towards the rear of the appliance and remove from the cabinet This gives access to TIMER ADJUSTABLE THERMOSTAT if fitted PUSHBUTTONS FAN BELT DRYING TIMER a Use a small screwdriver or a blade to lever off the knob cover b Lift the locking tab which fastens the knob to the spindle and remove the
7. CUIT OPERATING PRINCIPLES STRUCTURAL CHARACTERISTICS DRYING CIRCUIT O a 2 o 2 O tou O lt 2 Y S Log E O gt 3 Y d bn a 545 753 So 528 20 4 8 P 532 8 83 RL 4 e e BG e Z q w w pel al w w Fi mr EE MEN ve LO r O va L a 2 ci lt 3 8 f E O ka EL HAS V 0 6 o 2 TD N L A E O Pwa 3 0 EEEE 020 3 3323533323 ka oi Nado w The drying system is based on forced air circulation with a water jet condensation circuit The drying capacity is approximately half the maximum load of dry washing If a full load is washed then drying must be carried out in two stages However if a half load is washed the drying cycle can be set to start automatically at the end of the washing cycle During the drying phase the drum rotates at low speed in alternate directions The air is warmed by the heater and ducted by the fan to the interior of the drum where it removes the humidity from the damp washing When the jet of cold water comes into contact with the humid air the resulting heat exchange causes the humidity to condense The cooled dry air is redirected to the fan re heated by the heater and is then recirculated into the drum The cooling water and condensation are drained off by the discharge pump During the last few minutes of the drying cycle the heaters are switched off while the fan continues to operate until the coo
8. Condenser Circulation pump Motor Electronic speed control Tub Detergent dispenser Cold water and condensation solenoid Hot water solenoid After removing the rear shell care must be taken when moving the appliance When the rear shell is removed the appliance must never be laid on its side or on the rear as this might seriously damage the internal structure 30 1 REAR CABINET SHELL a Remove the top b Remove the screws which fasten the shell to the base c Remove the screws which fasten the shell to the fan This gives access to 2 FAN ASSEMBLY a Remove the screws which fasten the fan assembly to the cross brace b Fold back the coupling gasket between the fan and the heating elements c Lift the fan from the condenser d Detach the manifold Replacing the fan assembly Reposition the O ring seal on the fan 31 puen a E E R This gives access to 3 FAN MOTOR a Remove the three fixing screws CONDENSER a Disconnect the hoses from the condenser b Push the condenser upwards and remove from the base HEATER CASING a Detach the connectors from the heater and the thermostats b Fold back the fan coupling gasket c Remove the screws which fasten the casing to the duct and the two screws which fasten the casing to the cross piece d Remove the casing This gives access to all the thermostats DRYING AND SAFETY THERMOSTATS a Remove the casing from the washing machine b Remove
9. ck to the door during the first few drying cycles 35 c The clamp used to fasten the circulation hose if fitted should be positioned as shown in the figure SNS AP dak MAMA A MAL LA ASS d Fit the duct to the heater casing Use pliers to align the two tabs as shown in the figure e Replace the screws which fasten the duct to the cabinet 36
10. ling phase is completed FAN 1 Fan assembly 2 Fan motor 3 Belt The fan ducts the air from the condenser to the heater casing The fan is actioned by the fan motor and driven by a V belt 00 OMB e a 1 Cover oa HER 7 2 Ventilation scroll N NOG DER BAZ Mi m 5 Seegerring RS 6 Pinlock 7 Driven pulley 8 Fan HEATER CASING 1 Casing 2 Manual reset thermostat 3 Drying thermostat 4 Drying heater 5 Safety thermostat The heater casing consists of two half shells constructed in aluminium alloy The two shells are fastened together by screws and sealed with a silicone based sealant The casing is insulated by two shells in rockwool which are covered in aluminium foil and held in position by two fastening bands The air is heated by two heating elements When the delicate drying cycle is selected one of the heating elements is switched off The casing houses one functional thermostat and two safety thermostats Upper shell Lower shell Silicone seal Fixing screws Heating element pin Thermostat housing DUCT 1 Duct 2 Fixing screw 3 Bellows seal 4 Steel wire band Nur The front duct routes the warm air coming from the heaters through the bellows seal and directly into the drum The duct consists of two aluminium alloy tubes which are fastened together by screws and sealed with silicone The duct too is insulated by two layers of rockwool covered in aluminium
11. old Detergent dispenser JETSYSTEM DIRECT SPRAY WASHING SYSTEM Jetsystem models feature the direct spray system in which the water is introduced directly into the tub through a duct in the upper section of the bellows seal In this way the water goes directly to the washing without passing through the drum perforations as in the original Jetsystem washing machines However the basic principles of operation remain unaltered This system reduces the dispersion of water and heat 15 DRYING CIRCUIT ELECTRICAL COMPONENTS 17 TIMER Two types of timers are fitted to these washer dryers a Conventional timers connected to a simple timing device which governs the drying time The timing device controls the electromagnet of the timer s thermostop device so that it is maintained in operation during the drying phase b Timers with built in timing devices This type of timer features two knobs The first knob sets the cycles the second selects the drying time The following pages show two examples illustrating the operation of the timers during the drying phases 19 TIMERS WITH TIMING DEVICES OPERATING DIAGRAM DRYING PHASE L r 2 pi ome mu eo a s A O ee m sei m e m m a a atab a Ge stab JEN v s a an am Main switch Door delay Pilot light Pressure switch Manual reset thermostat Timer Drying thermostat Drying heater Drying heater Safety thermostat Timing device motor
12. rge filter This system effectively prevents the fluff from blocking the drying circuit In traditional washing machines the water flows automatically into the condenser as the water intake during the wash cycle takes place at a higher level In this case too the fluff suspended in the water is then discharged Regular cleaning of the filter is extremely important 12 HYDRAULIC DRYING CIRCUIT Solenoid valve Solenoid valve manifold hose Manifold Manifold condenser hose Dispenser tub hose Vapor discharge hose Qu f 0 N The condensation water is loaded by a section of the cold water solenoid valve which has a delivery of about 0 4 litres per minute The solenoid valve is connected by a hose to a manifold a narrow tube then routes the water from the manifold to the upper section of the condenser A small hole inside the manifold introduces a very small quantity of water into the detergent dispenser In this way there is always water in the siphon of the tube which connects the detergent dispenser to the tub thus preventing vapor from escaping from the tub and the detergent dispenser during drying 13 Vapor discharge hose A plastic hose between the condenser to the manifold ducts the vapor which builds up during the heating process in the wash phases into the detergent dispenser This vapor condenses as it comes into contact with the internal walls of the detergent dispenser Condenser Vapor discharge hose Manif
13. rge pump 15 Timer motor 16 Motor 22 In this type of timer the duration of the drying cycle is determined by the timer knob When the drying cycle and drying time have been set and the main switch 1 pressed the door delay device 4 is powered via contact 17 and the manual reset thermostat 3 and all the components in the appliance are powered The main pilot lamp 2 and the drying pilot lamp 13 light immediately The power supply to the drying circuit is received via the contact of the pressure switch 5 in the empty position The heating element 7 the fan 10 and the condensation solenoid 11 are powered by contact 19 of the timer The other heating element 8 1s powered by contact 18 of the timer and switched on when energetic drying is selected Heating is governed by the drying thermostat 6 the safety thermostat 9 and contact 20 of the timer x Each heating element absorbs 700W The fan 10 and the condensation solenoid 11 are powered at the same time as the drying heaters The timer motor is powered by contact 24 which also provides the power supply for the motor 16 operation of the motor is governed by the various reverser contacts 25 The discharge pump 14 is powered by contact 23 of the timer In this case too the drying thermostat 6 which is normally closed is set to open the contact at 106 C and to reclose the contact at 90 C the safety thermostat 9 is set to open at 98
14. the screws which fasten the thermostat to the casing and remove the thermostat DRYING HEATER a Detach the connectors b Remove the two screws which fasten the heating element to the casing c Remove the heating element Replacing the heating element When inserting the heating element ensure that it is positioned correctly on the support inside the casing 32 Q E wn i ACCESS FROM THE PORTHOLE DOOR Door Bellows seal Duct Fixing screw Wire clamp 33 1 BELLOWS SEAL AND DUCT a Remove the top b Remove the screws which fasten the duct to the heater casing c Open the door and remove the screw which fastens the duct to the cabinet d Remove the bellows from its surround e Detach the circulation hose from the gasket Jetsystem models only f Remove the wire clamp which fastens the bellows to the duct and detach the gasket w g Remove the bellows seal and the ring by pulling downwards 34 Replacin il l a When replacing the bellows seal ensure that the reference mark is aligned with the hole for the screw which fastens the duct to the panel eam b When replacing the wire clamp check that it is correctly positioned in the seat of the bellows seal then proceed as shown in the figure N B If a new bellows seal is fitted lubricate the external surface i e the part that comes into contact with the porthole door using silicone oil in order to ensure that the seal does not sti
15. wever the fan continues to operate until the cooling phase is completed When the timer reaches the end of the cycle stop contacts 23 open thus disconnecting the coil of the thermostop this allows the timer to advance to the stop position within two minutes The manual reset thermostat 5 intervenes only if the safety thermostat 10 malfunctions and simultaneously one of the ventilation components breaks down This thermostat is normally closed opening at 150 C to disconnect the drying circuit and the electromagnet of the timer s thermostop which as a result passes to the stop position When the user desires to select automatic drying at the end of the washing cycle it is necessary to press the automatic drying button 15 which via contact 26 of the timing device and contact 28 of the timer automatically causes the timer to skip the stop immediately preceding the drying phase 21 DUAL KNOB TIMER OPERATING DIAGRAM DRYING PHASE 1 Main switch TIMER TIMING DEVICE CONTACTS 2 Pilot light 3 Manual reset thermostat 17 Door delay 4 Door delay 18 Energetic heating 5 Pressure switch 19 Heating 6 Drying thermostat 20 Heater timing device 7 Drying heater 21 Automatic drying 8 Drying heater 22 Automatic drying 9 Safety thermostat 23 Discharge pump 10 Fan motor 24 Direct timer power supply 11 Condensation solenoid valve 25 Reversers 12 Automatic drying button 13 Drying pilot light 14 Discha
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