ELECTRONICALLY

CONTROLLED DOMESTIC
APPLIANCES

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 STUDENT’S NAME:

MAINTAINING AND REPAIRING AN ELECTRIC FAN

INFORMATION SHEET 1.1

Learning Outcome 1: Identify the functions of the parts of an electric fan.

Assessment Criteria:

1. The operation of an electric fan is explained.

2. The parts of and electric fan are identified.
3. The functions of its part are explained.

Operation of an electric fan, parts and its functions

 OPERATION OF AN ELECTRIC FAN

Electric Fan – is an air moving machine used to cool with an AC Motor connected to the 60 Hz power
source which converts electrical energy to mechanical energy in order to generate a moving air. It is a
power driven machine capable of providing high air flow parallel to the axis of the motor shaft where
an axially mounted impeller or fan blade agitates the air. The air velocity/delivery of the electric fan is
controlled by a mechanical speed selector switch for old models and electronically controlled speed
selector switch for new models. Timer is also included for fully automatic operations.

 PARTS OF AN ELECTRIC FAN


Front
Guard
a protective metal mesh wire used to prevent the fan blade
from any physical contact with foreign objects.

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  Guard Mark a logo of the manufacturer of the electric fan which is
mounted at the center of the front guard.
 Switch Box a panel board for the controls of the electric fan.

 Inner Pipe a metal tube inserted into the outer tube intended for
proper height adjustment of the electric fan.

 Outer Pipe a metal tube attached to the base stand of the electric
fan.

 Base Stand the bottom or lowest part of the electric fan where it
stands as a foundation.

 Blade a propeller made out of plastic or metal which is

attached in to the motor shaft and agitates air when the motor rotates.

 Remote Control a transmitter device used to control the electric fan

from a distance.
Block Diagram of Electronically-Controlled Electric Fan (ECEF)

 Power Controller – It is a circuit that controls the amount of power supplied to the motor.

 Sensor – It is the input receiver that detects input signal coming from remote control.

 Manual Control – It is a push button switch that controls manually operation of the electric fan.

 Timer – It is use to switch on or switch off automatically with predetermine time.

 Comparator – It is a processing circuit that accepts the input signal coming from remote control,
manual switch or timer switch. This circuit provides the triggering voltage to the power
controller.

 AC Motor – A rotating electric machine which changes applied electrical energy or power into
mechanical output energy or power.

 AC Plug – It is a connector intended for connecting to the main source 220V.

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 OPERATION SHEET 2.1
Learning Outcome 2: Diagnose an electric fan and troubleshoot the defects
found.

ASSESSMENT CRITERIA:

1. Pre-testing procedure is performed based on the manufacturer’s manual.

2. System defects/fault symptoms are identified using appropriate tools and equipment.

3. Identified defects and faults are explained to the responsible person.

4. Results of diagnosis and testing are documented.

5. Troubleshooting is performed in accordance with the service manual.

Procedure and Techniques In Pre-Testing An Electronically-

Controlled Electric Fan (ECEF)

 PROCEDURES IN PERFORMING PRE-TESTING OF AN ELECTRIC FAN

1. Determine what the problem really is.

a. Ask questions to the owner/operator of the electric fan to identify the problem for you.
b. Ask for a description of the problem and how long it has been going on.
c. Ask for a comparison of how long the electric fan is operating at the present time.
d. Inquire whether the electric fan has done this in the past and how it is supposed to
operate.
2. Be sure you understand how the electric fan is supposed to operate.
a. If you have worked on it before, check it out to see if it still operates in the same
manner.
b. Try to determine if anyone has modified it since you were last involved with it.
c. Review the operating manual if you are not overly familiar with the model of the electric
fan.
d. Review the service literature for the unit prior to any testing regardless of your previous
knowledge about the electric fan.
3. Perform preliminary inspection to locate where the problem originated.
a. If possible, attempt to operate the electric fan to gather information about the problem
whether or not the system of the unit is functioning.
b. While operating the electric fan, listen for unusual noises and look for smoke or other
visual signs of trouble.
c. Do not forget to use your sense of smell to assist in the diagnosis process.
4. Perform closer inspection into the suspected parts or components.
a. Prepare the tools needed and remove the cover ready for inspection.
b. Apply careful physical inspection of the suspected parts/components.
c. Look for burned and broken components.
d. Inspect for loose connections or broken wires.
5. Plan your approach to the repair problem.
a. List the tools and measuring instrument, where to use them and what you expect to
find when you conduct the test.
b. Modify your plans as you obtain additional information during the testing process.

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  TROUBLESHOOTING PROCEDURE

A. MECHANICAL FAULTS

PROBLEM/SYMPTOMS CHECKS TO MADE SYSTEM DEFECTS/FAULTS

1. Doesn’t rotate A. Check for Bent Shaft Defective rotor
B. Verify if Shaft is seized Defective rotor and end belts
2. Starts to rotate by Defective Motor
A. Check if the Motor is binding up
manually
3. Rotation is slow A. Check if shaft is slightly bent Defective rotor

Defective Rotor Inadequate

B. Check for an Oil and dirt build up lubricant with accumulated
dirt
C. Verify if oil is sufficient Poor lubrication

4. Noisy operation Defective yoke or motor metal

A. Check for any Worn bearing
cover
B. Check for Loose guard mark Loose guard mark screw

C. Check Loose guard fitter Untighten guard mark fitter

D. Check for Improperly balanced Effective fan blade

blade or broken blade

E. Check for Loose spinner Untighten spinner

F. Check if there is too much front to Worn out shaft washers

back play in the motor shaft
Poor lubrication with
G. Check for an Oil and dirt build up
accumulated dirt
H. Check if oil is sufficient Inadequate lubricant

I. Check for any improper mounting Misaligned front and rear

of the front and/or rear guard guards
J. Check if there are Loose screws Untighten screws

K. Check for rotor rubbing against Misaligned and dirt buildup in

housing insulation or wiring the rotro
5. No oscillation or A. Check for broken, stripped or bent Defective clutch assembly or
unsteady oscillation part in clutch or knee joint system knee joint system
B. Check for Slippage or wear of Defective worm wheel
worm wheel
C. Check for Disengagement of clutch Untighten clutch cover
cover
D. Check for Disengage oscillating Untighten oscillating rod set
rod set screw screw
E. Check for Broken oscillating rod Defective knee joint upper part
pin assembly
F. Check for Disengage and loose Untighten gear set screw
gear set screw
G. Check for Bent oscillating rod Defective oscillating rod
H. Check for Disengaged and loose Defective clutch shaft
clutch ball
I. Check for Bent yoke (frame) shaft Defective yoke shaft
J. Check for Worn rotor shaft worm Defective rotor

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 6. Imperfect oscillation A. Check for Tight operation of Defective oscillating switch
(clutch lever system) oscillation switch
B. Check for Excessively high outer Misaligned fitting in the high
wire position outlet wire position
C. Check for Loosen outer wire set Untighten outlet wire set screw
screw
7. Unsteady oscillation A. Check for worm wheel Defective worm gear
B. Check for Excessive thrust Misaligned thrust
C. Check for Bent yoke (frame) shaft Defective shaft
D. Check for Loosen oscillating rod Untighten set pin and calk pin
set pin
E. Check for Loosen oscillating rod Untighten rod set screws calk
screw screws
F. Check for Excessive oscillating rod Defective oscillating rod
bore
G. Check for Worm gear shaft metal Defective cover
H. Check for Disengaged gear set Untighten gear set screws
screws
I. Check for Excessive gear thrust Misaligned thrust
8. Unsteady or A. Check for Clogging of free stop Misaligned bushing
imperfect vertical bushing
movement

B. ELECTRICAL FAULTS
PROBLEM/SYMPTOMS CHECKS TO MADE SYSTEM DEFECTS/FAULTS
1. Doesn’t rotate A. Check for Open stator Defective stator
B. Check for Open AC cord or wiring Defective wiring/AC cord
C. Check for Open AC line fuse Defective fuse
D. Check for Open thermal cut-off Defective thermal cut-off
(inside the motor)
E. Check for Open speed selector Defective switch/electronic
switch system control
F. Check for Defective system Defective module(system
control control)
2. Starts to rotate by A. Check for Shorted capacitor Defective capacitor
manually turning the B. Check for Open start winding Defective stator
shaft

 TOOLS AND EQUIPMENTS NEEDED IN TROUBLESHOOTING

1. Mechanical Pliers
2. Long nose pliers
3. Side-cutting pliers
4. Set of Philip Screw Drivers
5. Set of standard Screw driver
6. Volt-Ohm Milliammeter

 POSSIBLE FAULTS AND CORRESPONDING REMEDIES

TROUBLE POSSIBLE FAULTS CORRESPONDING

REMEDIES
Bent shaft Replace (Note 1) motor
assembly
Doesn’t Rotate Open switch Replace switch
Shaft is seized Replace rotor and end bell
(Note 1)
Rotation Open stator Replace (Note 2) motor
assembly
Open AC cord or wiring Repair or replace
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 Starts to rotate by Start winding is open Repair lead wire to winding
manually turning or replace stator
the shaft Shorted capacitor Replace capacitor
Motor is binding up See Note 3
Bent shaft Replace (Note 1) motor
Rotation is slow assembly
Oil and dirt buildup Clean and lubricate
Lack of oil Lubricate
Worn bearing Replace yoke or its cover
(Note 4)
Noise Noisy Loose guard mark Fasten guard mark screw
Loose guard fitter Tighten
Improperly balanced or Replace Blade
broken blade
Loose spinner Tighten
Too much front to back Adjust by adding shaft
play in the motor shaft washers (Note 4)
Oil and dirt buildup Clean and lubricate
Lack of oil Lubricate
Improper mounting of Re – adjust
the front and/or rear
guard
Loose screws Tighten
Rotor rubbing against Disassemble, clean and
housing insulation or adjust if necessary
wiring
Oscillation No oscillation or Broken, stripped or Visually inspect and repair
Unsteady bent part in clutch or or replace as necessary
oscillation knee joint system

Note 1: If the shaft of model C30TK is bent, replace the rotor.

2: If the stator of model C30TK is opened, replace the stator.
3: Experience has shown that tapping the end bells and motor housing with a wooden or plastic
mallet will free up motors of this design. If this steps fails to free up the motor replace it.
4: Replace motor assy.

TROUBLE POSSIBLE FAULTS CORRESPONDING

REMEDIES
Slippage or wear of Replace worm wheel
worm wheel
Disengagement of Tighten clutch cover
clutch cover
Disengaged rod set Tighten or calk screw
Automatic screw
oscillation Broken rod set pin Replace knee-joint
system Non-oscillation upper part assembly
Disengaged and loose Tighten screw
gear set screw
Bent rod Adjust or replace rod
Disengaged and loose Replace clutch shaft
clutch ball
Bent yoke (frame) shaft Adjust or replace
Poor gear rotation Adjust or disassemble
and clean
Worn rotor shaft worm Replace rotor
Imperfect oscillation Tight operation of Replace oscillation
(clutch lever system) oscillation switch switch
Excessively high outer- Adjust fitting

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 wire position
Loosen outer-wire set Tighten screw
screw
Worn worm wheel Replace
Excessive thrust Adjust thrust
Bent yoke (frame) shaft Adjust shaft
Unsteady Loosen rod set pin Tighten and calk pin
oscillation Loosen rod set screw Tighten and calk screw
Excessive rod bore Replace rod
Worm gear shaft metal Replace cover
Disengaged gear set Tighten screw
screw
Excessive gear thrust Adjust thrust with
washer
Height Unsteady or imperfect Clogging of free stop Adjust bushing
adjustment vertical movement bushing
of standing
fan
External Scratch, stain or Scratch Touch up with lacquer
appearance breakage Dirt Wipe off with cloth or
soap and water

PERFORMANCE TEST 2.1

Direction: Given a set of hand tools, multi-tester and defective electric fan with manufacturers service
manual perform the procedure and techniques in pre-testing and troubleshooting an electric fan.
Provide a work report/write-up after completing the task. Write your answer on a separate sheet of
paper.
STUDENT WRITE-UP A
Common Symptoms / Defects of an Electric fan

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

1. PROBLEM/S & SYMPTOM/S :

_____________________________________________________________________________________________

_____________________________________________________________________________________________

STUDENT WRITE UP B
Diagnosing Faults and Remedies in ECEF

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

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2. POSSIBLE CAUSE:
____________________________________________________________________________________________________
____________________________________________________________________________________________________
Teacher’s Initial: ___________

INFORMATION SHEET 3.1

Lesson Outcome 3: Maintain and repair an electric fan.

ASSESSMENT CRITERIA:

1. Personal Protective Equipment is used in accordance with Occupational Health and Safety
practices.
2. Electro-static discharge (ESD) protection procedure is followed.
3. Defective parts/components are replaced with identical or recommended appropriate
equivalent ratings.
4. Repaired or replaced parts/components are soldered/mounted at the specified location.
5. Control settings/adjustments are performed in conformity with service-manual
specifications.
6. The unit is cleaned after the maintenance and repair activity.

A. HOW IS ESD GENERATED

Static charge is a form of electricity at rest. It can be generated by simple friction that is,
rubbing two objects together.
A simple method of generating a static charge is to rub a plastic ballpen case on a nylon cloth.
Once generated, the static electricity will remain on the ballpen for as long as it is not placed on any
other charged materials.
If ever the ballpen comes in contact with another object, the static electricity can move to or
from the ballpen to equalize the charge between the two objects. The transfer of static electricity from
any of the two objects is called electro-static discharge.
One inexhaustible source of electrons that can supply or accept them without any effect is the
earth. Whatever charged object brought into it is immediately discharged.
This simple illustration does not necessarily mean that static electricity can be generated
intentionally. The truth is that static electricity can be generated in a multitude of possible ways.
Rubbing of hands or arms on a table can result in the generation of up to about 3000 volts of
static electricity.
Sliding of the IC pins in a plastic box can result in the generation of up to 12000 volts of static
electricity.
A person walking across a vinyl floor can generate about 13000 volts of static electricity.
The amount of static electricity varies with the environment and it depends primarily on the
prevailing relative humidity. The moisture in the air offers a readily present conductive path to ground
fro static electricity and hence avoiding any static build-up.

B. ESD wrist straps

ESD wrist straps are also called conductive wrist straps or bands. They are usually made of
elastic cloth but contain conductive strands that touch your skin and so bleed off any static electricity
on your body. Some straps are made of conductive rubber. The wire attached to the strap contains a
large value resistor, usually one megohm (1,000,000 ohms) that allows any charge on your body to be
slowly transferred to an electric fan ground point. This build in resistor also limits the amount of
current to a safe level in case the other end of the wire touches a power supply voltage.
Some ESD kits also contain a conductive pad on which you can place components, like circuit
boards and ICs, when they’re out of the switch box of an electric fan. Often there’s an additional clip

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on the wire leading from the wrist strap that you can attach to this conductive pad, so that any charge
on the pad will also flow to the electric fan ground point.

C. ELECTRO-STATIC DISCHARGE (ESD) PROTECTION PROCEDURE

1. Purchase an antistatic kit from a computer or electronics supply store. Kits vary, but the main
component is an ESD wrist strap with a wire several feet long having an alligator clip at the
other end.
2. So to start off when troubleshooting electric fan, get an ESD wrist strap and wear it wherever
you go under the covers or handle ICs and circuit boards.
3. Put the adjustable strap around your wrist (usually the left wrist if you’re right handed).
Wearing an ESD wrist strap connected to frame or chassis ground drains static charges off
your body, preventing damaging ESD.
4. Attach the clip at the end of the wire to an electrical ground connection or metal framework of
the electric fan.
5. If you must work on an electric fan without a conductive wrist strap, touch an electrical
appliance such as a lamp or the screw in a wall outlet cover plate, before touching the PCB
circuit. An electrostatic discharge of just a few hundred volts is too small to feel in most cases,
but can be usually deadly to ESD sensitive devices.
6. When you are working with a switch box of an electric fan, touch a ground point, like the metal
extension pole, before touching anything else. This should ground out any static charge on
your body. Also avoid wearing clothes that easily produce a static charge, such as, knits and
wools and limit your movements as much as possible, especially on carpets, while working on
electronic circuits of an electric fan.

JOB SHEET 3.1

 COMPONENT REPLACEMENT
1. Determine the description of the values and ratings of the individual defective parts from the
manufacturer’s service manual
2. Identify the sources of replacement components/parts
 Original replacement components from the original factory sources
 Universal replacement components from independent factory sources
 Always consider the physical size of the replacement part
3. Consider the factors in the selection of specific part
 Quality – the ability to provide exact value or specification to
replacement part
 Tolerance – the ability to provide exact value or acceptable parameters
to replacement parts
 Availability – local access to parts and whether the parts are available
 Price – it refers to the affordability of the replacement parts at a
reasonable price
4. Disconnect or remove properly the electrical/mechanical parts of an electric fan
5. Install correctly replacement part/components in existing electric fan

 MAINTENANCE OF ELECTRIC FAN

1. Turn off the electric fan and remove the cord from the source of voltage
2. Apply lubricant to mechanical parts of the electric fan that requires lubrication through a
drop of oil or grease to assure smooth operation without grinding or squeaks.
3. Replace the bushings or end bells for squeaks with the use of appropriate tools if squeaks
cannot be corrected by applying lubricants.
4. Apply or spray anti-rust lubricants to all mechanical parts of the electric fan to drive out
moisture, protect corrosion, loosen rusted metal parts and even frees sticky mechanism.
5. Clean and check cooling louvers for any obstructions to avoid cutting off the air flow.
6. Clean or wipe dust and foreign particles at the PC Board and metal parts of the motor.
7. Replace worn or frayed AC cord and electrical wires

 SOLVENTS FOR CLEANING

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 1. Use mild soap and damp cloth or rug when cleaning plastic front panel and cover. They are
susceptible to immediate and long term damage from solvents.
2. Apply denatured alcohol as the safest solvent to use for plastic front panel and cover with
heavy stain. It should be used only as a last resort and applied to areas with heavy stain.

 PROCEDURE IN REPAIRING AN ELECTRIC FAN

1. Once the specific electrical/mechanical problem is located:
 Consider the techniques for the proper removal of the defective component or parts
 Anticipate what to do if the replacement part does not correct the problem
 Check the installation of the replacement or original part for any improper mounting in
the mechanical assembly or circuit board
2. Examine carefully the mounting of the replacement of original parts of the system
 Check the placement of the wires or leads of the replacement component
 Consider significant factors used in the original installation such as insulating washer,
silicon grease and locating mark for pin connections
 Observe proper placement of the component leads for electrical parts
3. Perform the techniques for the proper soldering of electrical parts
 Be careful not to damage adjacent components
 Be careful not to lift the copper conductive path from circuit board base material
 Avoid any solder bridges between board path
 Do not destroy the component being removed in case it is still functional and be careful
not to damage the component being installed
4. Verify all connections and harness
 Be sure that all components pre-positioned in a manner that will avoid the possibility of
adjacent component short circuit conditions
 Be sure to check or inspect all insulators and barriers between sections after working
on any model/brand of electric fan
 Check for frayed or broken insulation on all wiring including the AC line cord
 Be sure to replace fuses, resistors and capacitors with special designation such as
flame proof to components equal to the original value for both safety and liability
purposes
5. Once the repair is completed, perform an AC leakage test on all exposed metal parts of an
electric fan to eliminate the possibility of electric shock
 Perform complete retesting of the electric fan to ensure the correctness of the actual
repair
 Connect the electric fan into the 60Hz power to allow the time period required to let the
new parts settle in and operate as they are designed to work with each other.
 Recheck or inspect if the repair was done correctly and the unit functions properly to
ensure successful completion of the repair
6. Clean the electric fan before it would be returned to the customer
 Be sure that the blade, front and rear guards of the electric fan are properly cleaned
 Be sure that proper cleaning is given to the control panel or switch box of the electric
fan
PERFORMANCE TEST
Direction: Given a set of hand tools, multi-tester and defective electric fan with identified faults or
defect, perform preventive maintenance and repair procedure. Provide a work report/write-up after
completing the task. Write your answer on a separate sheet of paper.

STUDENT WRITE-UP A
Maintaining an Electric fan

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

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 SYMPTOMS DEFECTIVE REMEDY
COMPONENT/PARTS

STUDENT WRITE UP B
Repairing an Electric Fan
Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

SYMPTOMS DEFECTIVE REMEDY
COMPONENT/PARTS

Teacher’s Initial: ___________

MAINTAINING AND REPAIRING FLAT IRON

INFORMATION SHEET 1.1

Learning Outcome 1: Identify the functions of the parts of a flat iron.

Assessment Criteria:

1. The functions of the parts of a flat iron are identified based on manufacturer’s service

manual.

2. Parts are handled in accordance with manufacturer’s service manual.

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Parts of Flat Iron

1. AC line cord Is used to connect the unit to power source.

2. Selector Switch A type of switch used to select the amount of heat required in ironing
different types of fabrics. It can be a rotary or slide type.

3. Thermal Fuse A safety protective device used to protect the unit from damage when
overheating and short circuit occur.

4. Heating Element A form of nichrome wire that assembles properly inside the flat iron to
provide heat.

5. Soleplate A base metal that serves as fabric pressing part made of metal.

6. Handle The part of a flat iron by which it is, carried or controlled.

7. Body/Case Is used to protect the internal parts of the flat

iron.

Specific instructions

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 To avoid a circuit from overload, do not operate another high wattage appliance on the same
circuit. If an extension cord is absolutely necessary a 10 A cord should be used with a 120V iron or
a 16A cord should be used with a 220V iron. Cords rated for less amperage may overheat. Care
should be taken to arrange the cord so that it cannot be pulled or rippled over.

Information Sheet 2.1

Learning Outcome 2

Diagnose and troubleshoot a flat iron.

Assessment Criteria:

1. Pre-testing procedure is observed in accordance with the manufacturer’s instructions.

2. System defects/fault symptoms are identified using appropriate tools and equipment and in

accordance with safety procedures.

3. Identified defects and faults are explained to the responsible person (teacher as in the case of

student) in accordance with enterprise or company policy and procedures.

4. Results of diagnosis and testing are documented accurately and completely within the

specified time frame.

5. Customers (Teachers) are advised/informed regarding the status and serviceability of the unit

based on the procedures.

6. Pre-testing procedure is followed according to the manufacturer’s specifications.

Diagnosing and Troubleshooting a Flat Iron

Troubles Possible Causes

1. Electric iron does not heat. Open circuit/terminal connection

Short Circuit

Terminal connections

Heat controller-selector switch

Blown fuse

2. Electric iron gives abnormal Grounded wire

temperature.

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 Loose contacts between terminals

Heating element

STUDENT WRITE-UP 2.1

Diagnosing and Troubleshooting a Flat Iron

Student: __________________________ ____ Date: _______________________

Year and Section: _____________________ Teacher: ____________________

ADMISSION SLIP

UNIT BRAND: _______________________________ Unit Model: _________________

Owner: ______________________________________ Address: ____________________

Directions: interview the owner of the unit regarding their complaints.

1. PROBLEM/S & SYMPTOMS/S: ____________________________________________

____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
Teacher’s Initial: ________________
JOB SHEET 2.1

Diagnosing and Troubleshooting a Flat Iron

Directions: From the given defective flat iron Fill-out the table with the necessary information.

Trouble/s identified Possible Causes Remedies to be made

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 INFORMATION SHEET #3.1

Learning Outcome 3:

Maintain and repair a flat iron.

Assessment Criteria:

1. Personal Protective Equipment is used in accordance with the Occupational Health and

Safety Practices.

2. Defective parts and components are replaced with identical or recommended appropriate

equivalent ratings.

3. Repaired or replaced parts/components are soldered/mounted at the specified location.

4. Control settings/adjustments are performed in conformity with the service manual

specifications.

5. The unit is cleaned after the maintenance and repair activity.

Proper care to a Flat Iron

1. Prevent the iron fro falling on heavily padded board.

2. Avoid excessive scratches on iron plate due to direct contact from buttons, hooks, zipper, etc.
3. Cool iron before storing. Do not wrap cord around iron especially when it is still hot.
4. Put iron on a safe place to cool.
5. Always store iron in an upright position, on its heel rest, so that soleplate will not be scratched.
6. Clean brown stains in soleplate by heating the iron to a high temperature and iron it over to
salt in wax paper. A non-scratchy household cleaner may also be used.

To use a flat iron

1. Adjust the temperature selector to a minimum position before plugging cord into electrical
outlet.
2. Pre-heat the unit 2 minutes before using.
3. To improve dry ironing results, sprinkle garments evenly at least one hour before ironing.
4. Unplug iron by gripping plug and pulling it from the outlet. Never yank the cord!

To clean polished aluminum soleplate

1. Unplug the iron.

2. Make a paste of mild scouring powder and a little amount of water. Apply a small amount to
soleplate using a damp cloth and rub the soiled area. Wipe thoroughly.
3. Do not use metal scouring pads since they will scratch the soleplate.
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Store Iron

When iron has cooled, wrap cord loosely. To protect soleplate, always store iron on heel rest.

Mail/travel iron

When iron is cool, pack it carefully. The original cartoon box is not suitable for mailing, instead
provide a durable box.

Important:

When using an iron, basic precautions should always be followed including the following:

1. Read the instructions first.

2. Use the iron only for its intended use.

3. To protect against risk of electric shock, do not immerse any part of the iron in water or other
liquid.

4. The iron should always be turned to MIN position before plugging or unplugging from the
outlet. Never yank cord to disconnect from the outlet; instead grasp plug and pull it to
disconnect.

5. Do not allow the cord to touch hot surfaces. Let iron cool completely.

6. Do not operate iron if it has been dropped or damaged in any manner, as such may cause
temperature setting in occasion or electric shock. Do not assemble the iron; take it to the
dealer from whom the product was purchased for examination or any professional technician.
Incorrect assembly can cause electric shock when the iron is used.

7. Close supervision is necessary for any appliances being used by or near children. Do not leave
the iron unattended when plugged into the outlet or in an ironing board. Always position the
iron carefully to prevent it from falling if ironing board is accidentally knocked or if the cord is
pulled. When not in use, always stand the iron on heel rest.

8. Burn can occur from touching hot metal parts.

9. The use of accessory attachment not recommended or sold by the appliance manufacturer may
create a hazardous situation or damage to your flat.

10. Do not use the iron outdoor.

11. Do not operate in the presence of explosive and/or flammable materials.

JOB SHEET 3.1

Instructions:

1. Get the defective flat iron.

2. Identify the condition/trouble of the flat iron.
3. Identify the existing defect/s and their possible cause/s.
4. Record the information on the table.

Trouble Possible Causes Remedies made

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 MAINTAINING AND REPAIRING A RICE COOKER

INFORMATION SHEET 1.1

Learning Outcome1: Identify the functions of the parts of a rice cooker.

Assessment Criteria

1. Operation of a rice cooker is explained.

2. The parts of a rice cooker are identified based on the manufacturer’s

manual.

3. Functions of its parts are explained.

Rice Cooker
Rice Cooker

 This self-contained kitchen appliance, is used primarily

for cooking rice.
 It is used to prepare steamed rice and keep them warm
after cooking.
 It consists of an insulated case containing a
removable cooking pot.
 A heating element is located between the two
containers, usually controlled by a thermostat.
 The cooking pot is usually calibrated to ensure
proper proportions of the rice and water.

Application and Uses of Rice Cooker

Rice cooker are used both in home and commercial kitchens for various purposes:
 To cook rice
 To keep rice warm
 Could also be used as a steamer
 Cooks automatically

PROPER HANDLING OF A RICE COOKER

How to use a rice cooker?

Before using any other accessory, make sure that the power unit is on a suitable work
surface and switch to off. Put the protective cover over the drive that you will not be using rice cooker.
Page18
 How the rice cooker operates?
In most rice cookers, the rice and the water are poured in at the start of cooking. The
heater then brings the water to boiling point, during which the rice absorbs the water and
expands. After the present time, the rest of the water is boiled away and the machine either shuts
off or switches to ‘ keep warm” mode. Some models allow users to add flavorings before or during
the cooking.

Major Parts and their Functions

Power Cord - is a cord that temporarily connects an

electrical appliance to an electrical
power source. The term is generally used
for cables using a power plug to connect
to a single-phase.

Cast Heater - A part of a rice cooker that produces heat

to the aluminum pan. This serves as a
heating element of the rice cooker.

Mica heater- consists of an etched-foil sandwiched between

layers of mica. Installed by clamping to heat
sinks, mica heater provide the ultimate
temperature and wattage capability for fast
warm-up.

Thermal fuse – is a cutoff which uses a one-time fusible

link. Unlike the thermostat which
automatically resets itself when
temperature drops, the thermal fuse is
more like an electrical fuse.

Thermostat assembly- a device, as in a home heating

system that automatically responds
to temperature changes and activates
switches controlling the equipment.

Fluro pan- A part of a rice cooker where the rice is

placed.

Page19
 Outer Lid assembly - one of the major parts of a rice cooker and which
serves as a wife of an aluminum pan, because this part is responsible to
cover the bowl or an aluminum pan..

Body assembly- A part of a rice cooker in which the label are

Usually found and the holder of the outer lid
assembly.

Switch assembly - A part of a rice cooker that control

the whole operation automatically.

OPERATION SHEET 2.1

Learning Outcome 2: Diagnose and troubleshoot a rice cooker.

Assessment Criteria

1. Pre-testing procedure is performing in accordance with the manufacturer’s instructions.

2. System defects/fault symptoms are identified using appropriate tools and equipment.

3. Identified defects and faults are explained to the responsible person.

4. Results of diagnosis and testing are documented.

5. Troubleshooting is performed in accordance with the service manual.

Pre-Testing Procedure of a Rice Cooker

If………. Possible cause How to fix
 Unit cannot be turned  Is Ac power cord property  Visually check ac
on. plugged in? power cord if there
is loose connection
in the power plug.
 Unit does not operate  Is the plug connected  Plug-in properly.
when turned on. properly?
 Is the front cover properly  Push front cover/
closed? front lid properly
Page20
  Unit has light indicator  Visually check and
ON but cast heater  Does the cast heater continuously check.
doesn’t function. function normally? The cast heather
 Unit bogs down during
operation.  Follow instruction
 Does the thermal fuse for thermal fuse
active? protection.
 Poor boiling up  Replace the inner
pan or the cast
 Is the pan bottom heater.
 Excessive burning properly bring into  Replace the relay
contacted with the cast and replace the
heater? PCB completely
 Does the relay operates?

OPERATION SHEET NO. 2.2

Faults and Trouble of a Rice Cooker

Trouble Cause Inspection Remedy

No power  Overload Using multitasked  Refer to

 Rice cooker is check continuity of component
continuously the ff. parts testing
operated for more a.) fuse  Replace
than 3 hrs. b.) power cord defective parts,
without rest Refer next
Learning
outcome
repairing
procedure
Doesn’t light  Rice cooker lamp is Check rice cooker  Replaced busted
continuously lamp. lamp.
operated for more
than 3hrs.
With /power but  Foreign materials are Visually check by  Replace switch
doesn’t heat short to the circuit using multitester assembly.
board. check continuity.

With /power but  Defective Using multitester  Refer to component

doesn’t heat cast heater check continuity of testing procedure.
cast heater filament.  Explain to customer
Page21
 that the cast heater
is defective.

Tools Used in Pre-Testing a Rice Cooker

 VOM (multitester)
 Instructional/Operational Manual
 Screw Driver
 Pliers
 Side cutting pliers
 Long nose pliers

JOB SHEET 2.2

Faults and Trouble of a Rice Cooker

Trouble Cause Inspection Remedy

No power

Doesn’t light

W/power won’t
heat

W/power doesn’t
heat

Page22
 OPERATION SHEET 3.1

Learning Outcome 3: Maintain and repair a rice cooker.

Assessment Criteria;

1. Personal protective equipment is used in accordance with occupational health and safety

practices.

2. Defective parts/components are replaced are identical or recommended appropriate

equivalent ratings.

3. Repaired or replaced parts/components are soldered and mounted at the specified location.

4. Control settings/adjustments are performed in conformity with the service manual

specification

5. Repair activity is perform with in the required time frame

6. The unit is cleaned after the maintenance and repair activity.

OPERATION SHEET 3.1

COMPONENT CHECKING AND REPLACEMENT

PROCEDURE:
 Prepare all the tools and materials needed.

 Bubbling test
- Fill water until the center area of the pan bottom
is dipped and close the lid.
- When steam is produced while boiling. Remove
the lid immediately and check the bubbling condition on
the pan bottom.
- See right figure.
 Evaporation Test

- To check if it the bubbles is properly, and open the lid

and place weight and find out what happens

NOTE: to prevent plastic part from deformation caused by

Page23
 steam be sure to open the lid fully.
- Water on the pan bottom is completely evaporated
to be empty this timing is an follows:
Within 1 min. before the boiling switch is turn off.
Within 1 min. after the boiling switch is turn –of
The above condition are proper
 Heat reserving test
- put an approximately. 1 liter of water and the thermo
- meter in The pan. close the lid and turn on the
- boiling switch and when it becomes 70◦C, close
- the lid. after the warming heater is activated
- check the heart-serving temperature after one hour or more.

 Hinge cover removal (Hinge cover)

- Remove hinge cover with a mounting screw

- As shown in the figure, insert a narrow
flat screw driver from just below and pry
off the hinge cover.

 Inner enclosure and upper frame removal

- As shown in the figure, pry up three fastening hooks. Fixing the upper frame, turn the
inner enclosure in the arrow direction.
- The upper frame will be separated from the inner enclosure in the upper frame.

 Disassembling a control unit

- Pull-out the hinge shaft.
- Pull out wiring fir lid heater and then pulling
out outer lid assembly.

- Loosen a screw from button frame.

- Loosen a screw from P.C.B base (2 pcs).
Page24
 - Use a screwdriver to pry bottom frame.
- Pulling out body from upper frame.

- Pulling out a switch assembly.

- Loosen a screw for disassembling electronic parts.

 Disassembling Cast Heater and Thermostat Case Assembly.

- Loosen a screw for cast heater.

- Bend the leg of a thermostat.

- Lift a thermostat.

- Pulling out a side heater.

Page25
 INFORMATION SHEET 3.2
IDENTIFYING THE SPECIFICATION OF REPLACEMENT PARTS

PARTS LIST

Ref. no. Part name Part no.

1 OUTER LID ASSY. ARBO111935W9U

2 STEAM DOME ARB19T920-W9
3 STEAM VENT ARC00T920-W9
4 STEAM VENT HOLDING PACKING ARB82T920
5 HOOK LEVER ARE05H617-W9
6 HOOK LEVER SPRING ARE06H6167
7 HOOK LEVER BASE ARC31H617
8 HANDLE COVER ARB15T920-W9
9 HANDLE ARB10920W-9
10 LID CAUTION LEVEL ARB32H920
11 OUTER LID COMP ARB01T935-WU
12 FLURO PAN ARE50T935
13 CAST HEATER ASSY. ARL20909-0U
14 THERMOSTAT CASE ASSY. ARS24T908-OU
15 OUTER SPRING ARS62H616
16 UPPER FRAME ARE00A6171W-9

Page26
 17 HINGE SHAFT ARB74H616
18 PROTECTING FRAME ARE20T935
19 SIDE HEATER ASSY. ARL10P75200U
20 BODY ASSY. ARE10Y929Z3U
21 SWITCH ASSY. ARN01H935UHU
22 DECORATIVE PANEL ARN21H935-UH
23 HINGE COVER ARE40H6262W9
24 DEW COLLECTOR ARK20H616-0C
25 BOTTOM FRAME ASSY. ARH30T935W9U
26 FOOT RUBBER ARH90H66327
27 NAME PLATE ARY30H935-CS
28 POWER CORD ASSY ARQ14509943
29 INLET ARG10T9200U
30 STEAMING BASKET ARK53H617-W9
31 MEASURING CUP ASR7234R0-454BK
32 SCOOP ASR79WE281AK
A TAPPING SCREW XTB4+10GPJ
B SEMS SCREW XYN4+C10FNS
C SEMS SCREW XYM4+C7FNS
D SPRING WASTLE XWA4BPW
E TAPPING SCREW XTN4+8FFJ
F TAPPING SCREW ASR118-972-W
G TAPPING SCREW XTN4+16AZW
H TAPPING SCREW XPB4+25CFJ

MAINTAINING AND REPAIRING A BLENDER

INFORMATION SHEET 1.1

Learning Outcome 1: Identify the Functions of the Parts of a Blender.

Assessment Criteria

1. The operation of a blender is explained.

2. The parts of the blender are identified.
3. The functions of its parts are explained.

Page27
 Food Blender

What is a blender?
A food blender is…

 a motorized small appliance that blends, chops, and grates

food.
 a handy electrical gadget that makes chopping and mixing
food easier.
 a liquidizer or kitchen appliance used to mix ingredients or
puree food.
 a stationary, upright electrical device, which is to be
distinguished from a hand-powered or electric mixer that
may be used for similar purposes.

How a blender operates?

A blade inside a jar is connected to a motor shaft inside the unit. The blade speed is controlled
by varying electric current to the motor using one or more switches. The motor is operated by
supplying electric current to the motor.

Applications and uses of a blender

Blenders are used both in home and commercial kitchens for various purposes:

 to crush ice in drinks

 to make smooth purées of semi-solid ingredients, such as cooked vegetables and
meat
 to reduce small solids such as spices and seeds to powder or nut butters
 to blend mixtures of powders, granules, and/or liquids thoroughly
 to help dissolve solid into liquid

 Parts of a blender

Page28
 Blending container (jar)-made of glass, plastic, or stainless steel, and often has graduated
markings for approximate measuring purposes.
 At the top of the container is a lid to prevent ingredients from escaping during operation.

 At the bottom is a blade assembly, sometimes removable for cleaning purposes. In cases
where the blades are removable, the container should have an o-ring between the body of
the container and the base to seal the container and prevent the contents from leaking.

 The container rests upon a base that contains a motor for turning the blade assembly and
has controls on its surface. Most modern blenders offer a number of possible speeds.

 Selector switch is used to control the speed of the motor. It comes in different speed.

 The power train of a blender (motor). A fan-cooled electric motor is secured into the
housing by way of vibration dampeners, and a small output shaft penetrates the upper
housing and meshes with the blade assembly

Page29
 OPERATION SHEET 2.1

Learning Outcome 2: Diagnose a blender and troubleshoot the defect found.

Assessment Criteria:

1. Pre-testing procedure is performed in accordance with the manufacturer’s instruction.

2. System defects/faults symptoms are identified using appropriate tools and equipment.

3. Identified defects and faults are explained to the responsible person.

4. Results of diagnosis and testing are documented.

5. Troubleshooting is performed in accordance with the service manual.

Pre-Testing a Food Blender

Table for pre-testing a blender…

Proper Handling of a Blender

How to use a blender? Before using any other accessory, make sure that the power unit is on a
suitable work surface and switched to off. Put the protective cover over the drive that you will not be
using.

1. Before using the blender for the first time wash the blender bowl, cover, funnel and blade
assembly and gasket in warm soapy water. After washing, rinse well and dry before using.
Your blender is now ready for use.
Page30
 2. To assemble the blender, first press the gasket into the recess in the blade assembly base.
3. Then insert the blade assembly into the blender bowl from below and, using the lid as a
wrench, tighten the blade assembly into place. The blade assembly must be tightened
firmly to the bowl/jar to prevent leakage.
4. Place the blender on the high-speed (upper) drive and turn to the left (counter-clockwise) to
lock the blender in place.

INFORMATION SHEET 2.1

Faults and Trouble of a Blender

A. Table for possible faults and corresponding remedies

Page31
B. Tools used in pre-testing a blender

1. VOM (multitester)
2. Instructional/ operational manual
3. Screw driver
4. Soldering Iron
5. Pliers
6. Side cutting pliers
7. Long nose Pliers

OPERATION SHEET 2.2

Troubleshooting Procedure of a Blender

PROCEDURE:
1. Prepare all the tools and materials needed.
2. Unplug the blender and remove the jar. Undo the screw securing the base plate.
Separate the base plate and attached motor collar from the base housing.
3. Remove the switch housing; remove the decorative facing to get at the top screws.
Remove the lower screws from inside the blender base.
4. Hold the fan to keep the motor shaft from turning as you
unscrew the drive stud. Remove the shield and any
washers. Unscrew the fan nut to remove the fan.
5. Disengage the strain-relief fitting from the housing.
Remove the wire connector joining the power cord and the
lead to the brush housing.

Trouble shooting
6. Label and disconnect the lead wires from the switch
block. Remove the motor mounting bolts and lift out the motor if necessary.
7. To free brushes, remove the leads attached to the brush housing. Use a screw driver to
press lead terminal through the slot.
8. Conduct the following:
 Servicing the Multi-speed Switch: It's easy to see why the
multispeed switch is a critical component to the operation of
your food blender. Because of its high use and complexity, it is a
frequent culprit when things go wrong.

Multi-speed switch

 Servicing a fuse. Fortunately, most blenders include an in-line fuse that protects the motor
from overload. If excessive current is sent to the motor, the fuse will blow.
 Motor servicing is easy to test. Because there is a circuit
running from the appliance cord, through the multispeed
controls, to the motor, and back to the cord, an ohmmeter (part
of your multitester) can test the circuit.

 Tightening the Drive Stud: If the motor operates well, but the
blade in the blender jar doesn't turn as it should, the problem

Page32
 may be the drive stud. The most frequent cause is a loose drive
stud.

 Service the Blade Assembly: The blender's blade assembly is simple in function. It is rotated by
the drive stud, which blends or chops food within the jar. The most common problem is caused
by the jar leaking liquids. The solution is to tighten the base. If this doesn't solve the problem,
inspect and, if necessary, replace the gasket...

 JOB SHEET 2.1


 Results of Diagnosis and Testing a Blender

Directions: With the used of actual blender, diagnose its trouble and fill out the following table:

Blender model:_____________________________

Serial no: ___________________________________

Possible trouble Cause of trouble Affected Possible Remedy

components

1. ______________________

2. ______________________

3. ______________________

4. ______________________

Page33
 OPERATION SHEET 3.1

Learning Outcome 3: Maintain and repair a food blender.

Assessment Criteria:
1. Personal Protective Equipment is used in accordance with Occupational Health and
Safety Practices

2. Electro-static Discharge (ESD) protection procedure is followed.

3. Defective parts/components are replaced with identical or recommended appropriate

equivalents ratings.

4. Repaired or replaced parts /components are soldered/mounted in specified location.

5. Control setting/ adjustment are performed in conformity with service-manual

specification.

6. Repair activity is performed within the required time frame.

7. The unit is cleaned after the maintenance and repair activity performed in accordance
with standard procedures.
Components Checking and Replacement

 Exploded View and Replacement Part list

Page34
 Replacement Part List

Page35
Page36
 Components Checking

 Rubber Cap, Connector U (lower)

Page37
 OPERATION SHEET 3.2

Procedure in Maintaining and Repairing a Blender

 Servicing the Multispeed Switch:

Step 1: Remove the blender base.

Step 2: Attached the multi-speed switch is to the base with clips or screws accessed from underneath
the base's faceplate or from inside the base. Visually inspect the switch before removing it; in
many cases, the problem is a loose terminal. Otherwise, a blackened terminal or wire may
identify where the problem has occurred.

Step 3: Check the multispeed switch with a continuity tester or multitester.

Step 4: Because of its exposed location in front of the blender, the switch is susceptible to damage
from liquids. Use a can of compressed air or an electrical contact cleaner to clean the switch.

(Note: Before testing the switch, make sure to remove it from the blender)

 Servicing a fuse

Step 1: Remove the blender base and locate the fuse in the wire from the multispeed switch to the
motor.

Step 2: Disconnect the wire and use a continuity tester or multitester to check the fuse. If the circuit
is open, the fuse is blown.

Step 3: Replace the faulty in-line fuse with one of identical rating.

Page38
 Servicing the Motor

Step 1: Place a probe on each cord prong.

Step 2: Select a speed-control button or turn the speed controller slightly, then read the resistance on
the meter.

Step 3: Next, rotate the drive stud clockwise by turning it once. If the resistance reading (in ohms)
changes, the motor needs service. Take it to an appliance-repair service or replace the
appliance with a good one depending on cost.

 Tightening the Drive Stud

Step 1: Remove the base and turn the blender over. The other end of the drive shaft will protrude from
the bottom side of the motor.

Step 2: Grip the drive shaft with a wrench or pliers, and then turn the blender on its side to attach a
wrench to the drive stud.

Step 3: Hold the drive shaft steady as you turn the drive stud clockwise.

The other cause of drive stud problems is the rounding of its corners, requiring a new drive
stud. To replace a worn drive stud, reverse the instructions for tightening a drive stud, install
the new part, and tighten it.

 Service the Blade Assembly

The blender's blade assembly is simple in function. It is rotated by the drive stud, which
blends or chops food within the jar. The most common problem is caused by the jar leaking
liquids. The solution is to tighten the base. If this doesn't solve the problem, inspect and, if
necessary, replace the gasket.

JOB SHEET 3.1

Repairing a Blender

Directions: With the used of actual blender, fill out the following table:

Blender model:_____________________________

Serial no: ___________________________________

Trouble Cause Affected Description Possible Repairing

Page39
 of components of Remedy procedure
trouble Components

MAINTAINING AND REPAIRING A MICROWAVE OVEN

INFORMATION SHEET 1.1

Learning Outcome 1: Identify the functions of the parts of a microwave oven.

Assessment Criteria

1. Operation of microwave oven.

2. Parts of a microwave oven.
3. Functions of its parts.

Operation of Microwave Oven

Microwave oven

Is a kitchen appliance that can come in many different sizes and styles employing microwave
radiation primarily to cook or heat food.This is accomplished by using microwaves, almost always
emitted from a magnetron, to excite water (primarily) and other polarized molecules within the food
to be heated.

How the microwave operates?

Page40
Microwave ovens are generally used for time efficiency in both industrial applications such as
restaurants and at home, rather than for cooking quality, although some modern recipes using
microwave ovens rival recipes using traditional ovens and stoves, they have a central heated anode,
which is the source of electrons, several identical tuned cavities, a very strong magnet and a small
antenna to extract the energy. They are usually made from metal, but operate on the same principles
that glass thermionic valves do.

Major Parts and its Functions

High voltage Capacitor

A major concern in the operation of high voltage capacitors is
the failure mode at end of life. While progress has been made
in this area at lower voltages, little has changed for high
current capacitors operating above 30 kV in steady
state and pulsed power applications.

Magnetron
The magnetron is a device for producing microwave radiation from
electricity. A variation on this device, called the cavity magnetron is usually
used as the microwave energy source in your microwave oven. It can also
be used as the microwave source in a pulsed radar.

High voltage transformer

is the "muscle" of the microwave oven. With an input of
120 VAC (or 240 VAC in many commercial models) applied
to the primary winding, the high-voltage transformer
(also referred to as power or plate transformer) steps up
that primary voltage to a very
high voltage. This high voltage is then boosted even
higher by the voltage-doubling action of the capacitor and
diode

Varistor
is a type of resistor with a significantly non-ohmic current-voltage
characteristic. The name is a portmanteau of variable resistor*, which is
misleading since it is not continuously user-variable like a potentiometer or
rheostat, and is not a resistor but in fact a capacitor. Varistors are often
used to protect circuits against excessive voltage by acting.

Fuse
A wire, bar, or strip of fusible metal inserted for safety in an electric circuit. When
the current increases beyond a certain safe strength, the metal melts, interrupting
the circuit and thereby preventing possibility of damage.

Page41
 High voltage diode
A high voltage diode has a lamellar structured body of
semiconductor material. The lamellar structure is produced
by the thermal gradient zone melting process method of
migrating metal "wires" through the body to form a plurality
of spaced regions of conductivity opposite to that of the body.
The material of the spaced

Latch switch
A switch having a bimetal latch for locking a resilient
contact in a closed circuit position, and a heating coil for
activation of the latch to release the contact.

Oven lamp
A lamp which indicates that the unit has power.

INFORMATION SHEET 2.1

Learning Outcome 2: Diagnose a microwave oven and troubleshoot the

defect found.

Assessment Criteria

1. Pre-testing procedure is performing in accordance with manufacturer’s instruction.

2. System defects/fault symptoms are identified using appropriate tools and equipment.
3. Identified defects and faults are explained to the responsible person.
4. Results of diagnosis and testing are documented.
5. Troubleshooting is performed in accordance with the service manual.

Faults and Trouble of a Microwave oven

Trouble Cause Inspection Remedy

No power  Overload Using multitasked  Refer to component

 High voltage check continuity of testing
transformer is the ff. parts  Replace defective
continuously a.) fuse parts, Refer next
operated for more b.) diode Learning outcome
than 3 hrs. c.) high voltage repairing procedure
capacitor
Doesn’t light  Oven lamp is Check oven lamp  Replaced busted oven

Page42
 continuously lamp
operated for more
than 3hrs.
W/power no display  Foreign materials Visual check  Replaced digital
short to the circuit Using multitester programmer circuit
board check continuity assy.

W/power doesn’t  Defective magnetron Using multitester  Refer component

heat check continuity of testing procedure
magnetron  Explain to customer
the microwave
magnetron is un-
functional

Tools Used in pre-testing a microwave oven

 VOM (multitester)
 Instructional/Operational Manual
 Screw Driver
 Pliers
 Side cutting pliers
 Long nose pliers
Pre-testing procedure of a microwave oven

If………. Possible cause How to fix

 Unit cannot be turn on  is Ac power cord property  Visual check ac
plug in? power cord if there
is loose in the
power plug
 Unit does not operate
when turn on  Is the plug connected  Plug-in properly
properly?
 Is the front cover properly  Push front cover/
close front lid properly

OPERATION SHEET 2.1

Page43
 Troubleshooting Procedure of a Microwave Oven
Procedure:
Unlike many other appliances, the microwave oven is high voltage, high-current equipment.
Though it is free from danger in ordinary use, extreme care should be taken during repair.
Caution
1.) Serviceman should remove their watches whenever working close to or replacing the
magnetron.
Checking the earthing
2.) Do not operate on a 2 wire extension cord. The microwave oven is design to be used in a
completely earthed condition. It is imperative, therefore, to make sure it is properly earthed
before beginning repair work.

If the door lock, the door switch, the door seal or the door develops a malfunction,
be sure not to operate the oven until complete repairs are made
3.) If the oven is operated with any of these parts in imperfect condition, hazardous microwave
leakage might occur.
WARNING
Never operate the oven until the following are confirmed:
 The door is tightly closed.
 There is no broken hinge or door arm.
 The door seal is not damaged.
 The door is not bent or warped.
 There is no other visible damage.
Warning about the electric charge in the high voltage capacitor
For about 30 seconds after the oven is turn-off, an electric charge remains in the
high voltage capacitor. When replacing or checking parts, remove the power plug
from the outlet and the short terminal of the high voltage capacitor( terminal of lead
wire from diode ) to chassis ground with an insulated handle screwdriver to
discharge.
WARNING
4.) There is high-voltage present, with high current capabilities in the circuits of the high voltage
winding and filament winding of the high voltage transformer. It is extremely dangerous to work
on or near these circuits with oven energized.
DO NOT measure the voltage in the high voltage circuit including filament voltage in the high
voltage circuit including filament voltage of magnetron.

WARNING
5.) Never touch any circuit wiring with your hand nor with an insulated tool during operation

Page44
 When parts must be replaced, remove the power plug from the outlet.
 When the 10amp/2.5amp fuse is blown due to the operation of short switch

WARNING
5.) When the 10 amp/2.5 amp fuse is blown due to operation of the interlock monitor switch,
door switch, short switch and power relay B (RY1)

 When replacing the fuse, confirm that it has the appropriate rating for these models.
 When replacing faulty switches, be sure mounting tabs are not bent.

6.) Avoid inserting nails, wire, etc. through any holes in the unit during operation, because such
objects may work as an antenna and cause microwave leakage

Confirm After repair

7.) Make sure that all electrical connections are tight before inserting the plug into the wall
outlet and check any energy leakage of a microwave. Use caution not to become exposed to
radiation from the microwave magnetron or other parts conducting microwave energy.

Page45
 JOB SHEET 2.1

Result of Diagnosis and Testing

Fill-out the following table:

Brand: ___________________
Model #:__________________
Serial#:___________________

Trouble Possible cause Possible affected Possible remedy

of trouble components/parts

1._______________

2._______________

3._______________

4._______________

5._______________

INFORMATION SHEET 1.1

Learning Outcome 3: Maintain and Repair a Microwave Oven

Assessment Criteria

1. Personal Protective Equipment is used in accordance with occupational health and safety
practices. .
2. Defective Parts/ components are replaced with identical or recommended appropriate
equivalents ratings.
3. Repaired or replaced parts/ components are soldered /mounted in specified location.
4. Control setting/adjustment are performed in conformity with service manual specification.
5. Repaired activity is performed within the required time frame.

Page46
SPECIFICATION OF REPLACEMENT PARTS

Page47
Page48
 OPERATION SHEET 3.1

COMPONENT CHECKING AND REPLACEMENT

1.)PRIMARY LATCH SWITCH, (DOOR SWITCH AND POWER RELAY B

INTERLOCKS.
 Unplug lead connectors to primary latch switch and door switch
 Test the continuity of the circuit of door opened and closed position
Normal continuity readings should be as follows
Door open Door closed
Primary latch switch ∞ Ω (open) 0 Ω (close)
Door switch ∞ Ω (open) 0 Ω (close)
Power relay b ∞ Ω (open) ∞ Ω (open)
2.) SHORT SWITCH AND MONITOR
 Test continuity of switches at door opened and closed positions using the lowest scale of the
ohmmeter.
Normal continuity readings should be as follows
Door opened Door closed
0Ω 0Ω
3.)HIGH VOLTAGE TRANSFORMER
Normal resistance readings should be as follows:
Secondary winding Approx. 60 Ω-120 Ω
Filament winding Approx. 0 Ω
Primary winding Approx. 0 Ω - 2 Ω

4.) HIGH VOLTAGE CAPACITOR

 Normal capacitor will show continuity for a short time, and then indicate 9MΩ once the
capacitor is charged.

Page49
 5.) MAGNETRON
 A continuity check across magnetron filament terminals should indicate one ohm or less.
 A continuity check between each filament terminal and magnetron case should read open.

6.) DIODE
 Disconnect the two leads connected to the diode terminal and a normal diode’s resistance will
be infinite in one direction and several hundreds kΩ in the other direction.

Page50
 7.) PROTECTOR DIODE
 A normal protector diode’s resistance will be infinite in both directions. If it is faulty it shows
continuity in one or both directions.

OPERATION SHEET 3.2

MAGNETRON
After replacement of the magnetron
Tighten mounting screws properly making
Making sure there is no gap between
the waveguide and the magnetron to pre-
vent microwave leakage.

DIGITAL PROGRAMMER CIRCUIT (D.P.C) AND MEMBRANE KEYBOARD

 The membrane key board is attached to the escutcheon base with double faced adhesive tape.
Therefore applying hot air such as using a hair dryer is recommended for smoother removal.
 When installing new membrane keyboard, make sure that the surface of escutcheon base is
cleaned sufficiently so that any problemscan be avoided.
 Alignment position of membrane key board; membrane keyboard; right and upper edges
Escutcheon sheet: right and upper edges.
LOW VOLTAGE TRANSFORMER
 Be sure to ground any static electric charge built up on
your body before handling the D.P.C.
 Do not use soldering iron or disordering tool of more the
than 30watts on D.P.C contacts.

Page51
TEMPERATURE SENSOR (thermal protector)
 Remove 1 screw holding the temperature
sensor and replace with new one.
 Solder the lead wires securely
to the sensor terminals.

FAN MOTOR
 Remove 5 screws holding fan motor shaft by pulling it straight out.
 Separate the fan motor from the orifice.

DOOR ASSEMBLY
 After replacement of defective component parts of the door, be sure that the door assy. is
properly mounted, microwave power may leak from the clearance between the door and oven if
the door assembly is not mounted properly.

STIRRER MOTOR
 Removing and reinstalling the motor cover
Use 4x6 screw

Page52
FLOR SHELF AND/OR MOVING ANTENNA
 When replacing the moving antenna . make sure
the plastic stirrer spacers are correctly in place
they are necessary to stabilized the antenna by
gliding around the oven bottom as the antenna
turns.

JOB SHEET 3.1

Repairing a Microwave Oven

Fill up the following table:

Student Name: ______________________________
Blender model: _____________________________
Serial no: __________________________________
Direction: By using a defective microwave oven, fill-up the following table

Trouble Cause of Affected Description Possible Remedy

trouble components of
Components

Page53
 MAINTAINING AND REPAIRING A WASHING MACHINE

INFORMATION SHEET 1.1

Learning Outcome 1:

Identify the functions of the parts of a washing machine.

Assessment Criteria:

1. The operation of a washing machine is explained.

2. The parts of a washing machine are identified.
3. The functions of its part are explained.

 OPERATION OF A WASHING MACHINE

Washing Machine – is a domestic appliance that washes clothes and linens. It is a power driven
machine with an AC motors connected to the 60 Hz power source so that the electrical energy can be
converted into mechanical energy in order to facilitate an act of washing rinsing and spinning. It also
includes wash and spin timers for automatic operations.

 PARTS OF WASHING MACHINE AND ITS FUNCTIONS

TOP COVER WATER

SUPPLY
HOSE
PROGRAM
AC CORD
SELECTION
CONTROL

PULSATOR DRUM

SIDE COVER TUB

DRAIN HOSE

Function of each Part

 Top Cover – use to cover the tub.
 Pulsator – is a rotating part inside the tub. Responsible in making the water spin.
 Drain Hose – It served as a passage way out.

Page54
  Side Cover Tub – It is the main housing of the unit.
 Drum – It served as a washing tub.
 Water Supply Hose - It served as an inlet of water.

 Block Diagram of Electronically-Controlled Washing Machine

 Power Controller – It is a circuit that controls the amount of power supplied to the motor.
 Sensor – It is the input receiver that detects input signal coming from forward and reverse
motor. It detects any abnormality of the operation for automatic shut off.
 Program Selection Control – It is a push button switch that controls the operation of the
washing machine. This circuit has a timing sequence for low, medium or high.
 Comparator – It is a processing circuit that accepts the input signal coming from sensor,
program selection control. This circuit provides the triggering voltage to the power controller.
 Forward/Reverse Motor – A rotating electric machine which changes applied electrical
energy or power into mechanical output energy or power.
 Buzzer – It is a device used to generate sound, once the program operation is completed or
problem occurred.
 Input Command – It is a setting period of the user.
 AC Plug – It is a connector intended for connecting to the main source 220V.

Page55
 OPERATION SHEET 2.1

LEARNING OUTCOME 2: Diagnose a washing machine and troubleshoot defects / faults found.

ASSESSMENT CRITERIA:
1. Pre-testing procedure is performed based on the manufacturer’s manual.
2. System defects/fault symptoms are identified using appropriate tools and equipment.
3. Identified defects and faults are explained to the responsible person.
4. Results of diagnosis and testing are documented.
5. Troubleshooting is performed based on the service manual.

CONTENT:
 Procedure and Techniques in Pre-Testing a Washing Machine
 Troubleshooting Procedure
 Tools for Testing
 Possible Faults and Corresponding Remedies

 PROCEDURE AND TECHNIQUES IN PRE-TESTING AN ELECTRONICALLY-CONTROLLED

WASHING MACHINE

1. Determine what the problem really is.

2. Be sure you understand how the washing machine is supposed to operate.
3. Perform preliminary inspection to locate where the problem originated.
4. Perform closer inspection into the suspected parts or components.
5. Plan your approach to the repair problem.

 TROUBLESHOOTING PROCEDURES

ELECTRICAL FAULTS

1. Washer is not energized

Checks to be made Result of Check Possible Cause Remedy

Household Power
Supply

1. Check whether Poor contact Defect of the Change the

connection between electrical outlet electrical outlet
the plug and the
electrical outlet is poor
contact.
Approximate No defect
2. Measure voltage of voltage rating
the electrical
OV (No Voltage) Defect of AC 60 Hz Fix the 60 Hz power
household power supply line
supply
Wiring of the Washer

1. Measure resistance
between both end of Less than 1 Ω No defect
the power supply cord ∞Ω Open circuit of the Change the power
with both the plug power supply cord supply cord
pins short-circuited

Page56
 2. Check whether
every connector in the
bundle of connectors Poor connection Remove the cause
has a good connection Male & female to give strain and
connectors reconnect them
3. Check resistance of separated
every wire to find out
an open wire Change the lead
Wire is opened wire
∞Ω

Electrical
Component

1. Check resistance Less than 0.5 Ω No defect Change the Auto Off
with power relay More than 1.0 Ω Poor contact switch
switch turned on
10~14 V
2. Check the OV
secondary voltage of No defect Change the
the transformer Coil is open transformer
∞ Ω and motor is
3. Measure resistance hot
to check whether Testing Point blown Remove cause to
testing point of the out overload the motor
motor is blown out

4. Check whether the Open

fuse is open Change the fuse.
Defect of the fuse
Controller

1. If there are no Over 120% Change the

defects in the above, it voltage than controller if all the
should be defect of the rating check electrical parts have
controller no defects

2. If supply voltage is
120% higher than
rating, the varistar in
the controller may be
broken. Check supply
voltage

2. Defects on Displaying Function

Checks to be made Result of Check Possible Cause Remedy

Main Voltage

1. Measure main Less than 85% of Low voltage To explain that is it

voltage at the wall the rating is caused by low
outlet voltage in electric
supply and
recommend using a
transformer if
voltage has been
continuously low

Page57
 To use a
2. Measure voltage at Less than 85% of The diameter of the transformer having
the extended outlet the rating lead wire is smaller enough capacity if
that the washer is or many loads are using a transformer
plugged in if the connected at the
extended outlet is same outlet
used and voltage at
the electrical outlet is
normal in the above
Transformer

1. Measure the Less than AC 10V Defect of the Change the

secondary voltage of transformer controller
the transformer

Controller

1. Defect of LED Defect of controller Change the

2. Defect of LED controller
driving circuit
3. Defect of micom

3. Reset during Operation

Checks to be made Result of Possible Cause Remedy

Check
Main Voltage

1. Measure the voltage Less than 80% Main voltage is too Explain that it is
of the outlet that the of the rating low or size of a lead caused by a low
washer is plugged into wire is too small voltage in electric
during wash and spin main and
recommend using a
suitable size of
2. Reset symptom External noise leads.
happens at specific inrushed Explain it is caused
time zone repeatedly by using
environment (it
happens when
equipment with
high frequency is
3. Check whether a used around)
transformerlent power
cut happens. Explain it is a
(Fluorescent lamp is problem of electric
transformeriently supply environment
blinked)

4. Water doesn’t come into the wash bowl

Checks to be made Result of Check Possible Cause Remedy

Ball Pressure Sensor

1. Is there PE error on
the display which PE Error Connector is taken Reconnect the
means Ball Pressure displayed off or lead or coil is connector or change
Sensor Error open leads. Change the
Ball Pressure
2. Check frequency of Sensor if coil is
the Ball Pressure open
Page58
 Sensor without load if
wash is proceeding Less than 26.2 Defect of the Ball Change the
without filling kHz Pressure Sensor pressure switch
Controller

1. Defect of controller Change the

is highly possible if controller
inlet valve and Ball
Pressure Sensor have
no defects in the
above

5. Pulsator doesn’t rotate normally

Checks to be made Result of Check Possible Cause Remedy

Pulsator weakly
rotates

1. Check voltage at Less than 85% of Lower voltage Explain the causes
the power outlet rating and a transformer
where the washer is should be used if
plugged into necessary

2. Check capacitance Indicating needle Capacitor is normal

of the capacitor rises and
immediately
indicates ∞

The needle is Lack of capacitance Change the

stopped after it is of the capacitor capacitor
raised
Capacitor is fully
The needle discharged Change the
doesn’t move capacitor

6. Drain error happens while water drains normally

Checks to be made Result of Check Possible Cause Remedy

Ball Pressure Sensor

1. Check generation
frequency of the Ball Less than 26.3 Defect of the ball Change the Ball
Pressure Sensor kHz pressure sensor Pressure Sensor
without water

26.3~27.1 kHz Defect of the Change the

controller controller

7. Spin extraction is not proceeded

Checks to be made Result of Check Possible Cause Remedy

Motor

1. In the case that the There is motor Defect of the Change the
wash motor does not working sound capacitor or capacitor after
spin during spin mechanically locked checking defect of
extraction capacitor

Page59
 a. Check there is
motor working sound, Check whether the
washing clutch or
washing tub is
blocked if the motor
rotates after
removing the V-belt

Check whether the

motor is locked if
the motor does not
rotate even though
the V-belt is being
removed.

2. If there is no motor
– working sound
Change the Ball
a. Check frequency of Pressure Sensor
the Ball Pressure
Sensor, under no load, Defect of the Ball
or Less than 26.3 Pressure Sensor
kHz
b. Is placed the Explain “The lid is
magnetic in Lid-B. close during
Mistake in use operation”

The lid is open Change the Lid-B

Change the Ball

c. Check the Defect of Pressure Sensor
resistance of the magnetic in lid-B
motor Change the motor
Contact defect of
the Ball Pressure
Sensor Coil is open
∞Ω
Drain Motor/Clutch

1. In case the motor

rotates but the inner
tub does not rotate

a. Check resistance of
the drain motor if the
drain motor does not ∞Ω Coil is open. Change the drain
work Resistance is Defect of connection motor
normal part or defect of the
controller Change the
controller after
checking connection
parts

8. Spinning is going on even though the lid is open

Checks to be made Result of Check Possible Cause Remedy

Ball Pressure Sensor
Page60
 1. The magnetic is
placed on the wash Yes Read S/W is short Keep magnet away
by magnetic on the from the washer
washer

Read Switch Change the

No controller

9. Spin basket does not reach to full speed (normal rpm)

Checks to be made Result of Check Possible Cause Remedy

Main Voltage

1. Check voltage at Less than 85% of Tool low voltage Explain the cause
the power outlet rating and recommend
where the washer is using a transformer
plugged into if necessary

Starting Capacitor

1. Check the
capacitance of the Lack of Defect of capacitor Change the
starting capacitor acceptance capacitor

10. Power is not automatically turned off

Checks to be made Result of Check Possible Cause Remedy

Auto Off Switch

1. Check whether There is Remove it

there is something to something to
push the power press it
button

11. Power is automatically turned off during operation or immediately turning on the power
switch

Checks to be made Result of Check Possible Cause Remedy

Main Voltage

1. It is mostly caused Defect in main Explain the cause

by noise from main or (it happens
transformerient specially when a
power cut high frequency
equipment is used
around the washer
or in the case
voltage fluctuation
is big)
Auto Off switch or
Controller

1. Check whether Automatically Mechanical defect Change the auto

power is turned off of the auto off off switch
automatically turned switch
off when turning on
the auto off switch
after unplugging the

Page61
 power cord from the
outlet

2. It would be defect Change the

of the controller if the controller
power is
automatically turned
off immediately when
turning on the power
switch even though
there is no defect in
the auto off switch

MECHANICAL FAULTS

1. Water doesn’t come into the wash tub

Checks to be made Result of Check Possible Cause Remedy

Inlet Valve

1. If water doesn’t
come through the inlet
valve works (electric
sound occurs)

a. check whether
water main is cut Water main is cut Main is cut Explain

b. Check whether tubs Don’t turn on

are turned on Mistake of use Turn on the tap

c. Hot and cold tub Connected

are opposite opposite Wrong installation Correct their
connected locations and turn
on the tap
d. Wrongly select Selected opposite Mistake of use
water temperature Explain how to use
option
Filter blocked by
e. If there are no foreign substance Don’t clean Clean them by
problems in the above, brush and explain
check the inlet valve cleaning them
filters after regularly
disconnecting the
water supply hose

f. If there are no
problems in the above, Defect of the inlet Change the inlet
a diaphragm hole in valve valve
the valve is blocked by
foreign substance or
the plunger in it is
locked.

2. Water fills continuously or intermittently

Checks to be made Result of Check Possible Cause Remedy

Wrong
Page62
 Installation/Leakage

1. Check whether the Drain hose laying Wrong Installation The drain hose
drain hose is laying down should be hung on
down on the floor (For the stand-pipe or
pump model) the tub
Defect of the part
2. Check where water Water leaks from Change the part.
leaks a part Repair it
Ball Pressure Sensor

1. Check the pulsator It doesn’t rotate Water pressure is Check the tube of
if it is rotating when not sensed the Ball Pressure
water fills continuously Sensor, is it bent, or
blocked, repair it

2. If there is no defect Repair the blocked

in the Ball Pressure Blocked Air hole blocked hole
Sensor, check whether
the air hole of the
outer tub is blocked
Inlet Valve

1. Does water fills even Water fills Defect of the inlet Change the inlet
though it is not valve valve
energized (power is off)

3. Pulsator doesn’t rotate normally

Checks to be made Result of Check Possible Cause Remedy

Pulsator rotates at
one direction

1. The Pulsator rotates Clockwise Unusual operation Turn the power off
normally at the rotation locked and on again then
beginning of wash that symptoms
cycle, but does not disappears
rotate at clockwise Explain “don’t run
direction (locked) after wash only
some wash cycles continuously”
though there is motor-
working sound

2. In the case the

pulsator doesn’t rotate
either clockwise or
counter-clockwise from
the beginning of wash
cycle

a. Check resistance of
the wash motor if there
is no motor working Defect of controller Change the
sound Resistance is or poor contact of controller if there
normal connectors of motor are no contact
leads. defects in the leads
b. Check belt tension of the motor.
and whether the clutch
rotates normally if Loose the belt Adjust belt tension
there is motor-working by changing motor
Page63
 sound V-belt is loose fixing location and
change the belt if it
is impossible to
adjust belt tension

Change the clutch if

the clutch pulley is
locked when making
Defect of the clutch it rotate clockwise
and counter-
Clutch locked clockwise by hand

Adjust belt tension

3. The pulsator doesn’t or change the belt if
rotate at both it is impossible to
directions adjust

a. Check whether motor Loose the belt Remove the cause

rotates both direction locking the pulsator
if there is motor-
working sound when Motor rotates at Change the clutch
it’s energized both directions
Change the motor if
The pulsator locked the motor is locked
when having its
shaft rotated by
Defect of the clutch hand.

Defect of the Change the

capacitor (check the capacitor if there is
capacitor’s no contact defect in
capacitants) capacitor
Motor doesn’t ‘s lead
rotate at both
direction Change the motor
Defect of the motor
Remove the causes

Motor coil is open

2. Check resistance of Contact defect of

the motor if there is no the leads.
motor-working sound
∞Ω

Normal
resistance

4. Water does not drain

Checks to be made Result of Check Possible Cause Remedy

Drain Pump

1. Check whether There is pump Drain pump is Disassemble the

Page64
there is drain pump working sound blocked by foreign drain pump cap and
working sound objects remove the foreign
objects in the pump
casing

2. Check resistance Change the drain

between terminals if ∞Ω Its coil is open pump
there is no working
sound at the drain
pump

3. Check connection
parts of the leads if Repair defected
there is no working Defect in Defect in connection
sound and its connection part connection part
resistance is normal

Connection part Change the

has no defects Defect of the controller
controller
Drain Hose

1. Check whether the Kinked. Defect of Reinstall so that it

drain hose is put in a installation should not be
narrow space and kinked
kinked.

2. Check whether the Bent Defect of the drain Change the drain
internal drain rubber rubber assembly rubber assembly
assembly is bent (For
non-pump model)

3. Check whether the Defect of Reinstall so that it

end of the drain hose Submerged or installation cannot be
submerged into water higher than submerged or not
or higher than required higher than
required (for non- required
pump model)

4. Check whether the

drain hose is blocked Blocked hose Remove the objects
by foreign objects. It Blocked and reinstall so that
may happen in case it cant be kinked
the hose is a little
kinked
PV Case
(for non-pump model
only)

1. Check whether the Blocked Separate the drain

PV assembly is motor from the PV
blocked by foreign link, disassemble
objects PV cover and then
remove the foreign
objects within the
PV case

Page65
 Check the washer
works normally
after repair and
reassemble them
(PV link and drain
motor lever should
be assembled
accurately)

Drain Motor (for non-

pump model only)

1. Check resistance of
the drain motor if it ∞ Ω Drain motor coil is Change the drain
cannot pull the PV open motor
link Check the washer if
it works normally
after reassembling
(PV link and drain
motor lever should
be assembled
accurately)

Change the
controller if there is
no defects in the
Resistance is Contact defect in connection parts
normal connection parts or
defect of the
controller

5. Water drains though it is not the time of drain

Checks to be made Result of Check Possible Cause Remedy

Drain Motor
(for non-pump model
only)

1. Check whether the Blocked Defect of the drain Change the drain
drain motor is motor motor
normally returned
after turning power off
(it is considered
normal if the lever of
the drain motor is
fully pulled out by the
PV spring)
PV Case

1. If water drains Blocked Remove the objects

though the drain in the PV assembly
motor is normally
returned, check Change the PV
whether PV assembly Bellows deformed Defect of PV Bellows bellows (The bellows
is blocked by foreign may swell up if it
objects or the bellows contact petroleum
in the PV assembly is or petrochemical
deformed substance because
it is made of rubber)
Controller
Page66
 1. Check whether the works Defect of the Change the
drain motor or the controller (Triac controller
drain part works defect)
immediately after
power is turned on

6. Spin extraction is not proceeded

Checks to be made Result of Check Possible Cause Remedy

Drain Motor/Clutch

1. In case motor
rotates but the inner
tub doesn’t rotate

a. Check resistance of
the drain motor if the
drain motor does not ∞ Ω Coil is open Change the drain
work motor

Resistance is Defect of connection Change the

normal part or defect of the controller after
b. Check gap between controller checking connection
PV link and the break parts
lever if the inner tub Assembling defect
does not rotate while The clearance is of the drain motor Reassemble the
the drain motor works less than 2.0 mm or the clutch drain motor or the
or more than 3.5 clutch to keep the
mm clearance

Defect of the clutch

The gap is normal Change the clutch
(2.0-3.5 mm)

7. Spin basket doesn’t reach to full speed (normal rpm)

Checks to be made Result of Check Possible Cause Remedy

Clutch Assembling

1. Check the clearance

between the PV link The clearance is Adjust PV lever bolt
and the break lever less than 2.0 mm and paint it red
and clearance between or more than 3.5 Reassemble the
the clutch lever and mm drain motor or the
the adjustment bolt clutch

Bolt clearance is Adjust the bolt

out of range Defect of the clutch clearance
Blocked by foreign
objects

1. Check whether the Remove the foreign

PV assembly, the objects
drain pump and drain
hose are blocked by
foreign objects so that
Page67
 it makes water
splashing noise in the
tub

8. Vibration, Noise or Unbalance Error happens during spin

Checks to be made Result of Check Possible Cause Remedy

Using conditions
such as installation
etc.

1. Check whether the Not leveled Defect of Level the washer

washer is leveled installation
(Check clearance
without tub and out
case the left gap is the
same as the right and
the rear gap is 1.5~2
time bigger than the
front gap between the
cabinet and the wash
bowl, when it is
leveled)

2. Check whether
laundry in the wash
bowl is out of balance Laundry is Explain that it is
that can cause severe unbalance not out of order and
vibration and noise it may happen when
big and long
3. Check whether the laundry is washed
pulsator doesn’t rotate
during spin (to check Change the clutch
that, remove the front Defect of the clutch spring-B or the
lid and then run the The pulsator clutch assembly
spin only cycle) rotates initially
then the inner
tub rotates
Damper

1. Check whether the Hit Defect of the Change damper

outer tub cover hit the damper simultaneously (in
top cover without load assembling, check
during spin the position to
damper assembly)

 Possible faults and corresponding remedies

TROUBLESHOOTING GUIDE (ELECTRONICALLY CONTROLLED)
SYSTEM
SYMPTOM/
DEFECTS/ POSSIBLE CAUSE REMEDY
PROBLEM
FAULTS
WATER  Water level does  Water faucet is closed?  Open water faucet
SUPPLY & not rise to the set  Water supply is  Wait until water
INLET V/V level in 40 interrupted supply is resumed.
minutes.  Clean or replace
Page68
  Wash and rinse  Inlet V/V is clogged filter.
LED blink with dirts.  Correct the connector
 Connector has bad contact
contact to the inlet
valve.  Same as above
 Yellow (YL) 2 pin
connector has bad
contact to the
P.W.B.ASM.
DRAINAGE  Water is not  Is the drain hose  Hung up drain hose
completely drained located properly? at 0.9~1.3m high.
in ten minutes (For pump)
 Drain hose is not  Put the hose lower.
lowered (For: Non-pump)
 Rinse and spin  Unclog the drain
LED blink  Drain hose is folded or hose
clogged due to freeze or
dirt’s.  Replace drain motor
 Bad Drain Motor part or or correct the
GRAY(GY) 2 pin connector contact.
connector to the P.W.B
ASM has bad
connection
UNBALANCE  Laundry  Laundry in the INNER  Try to fill laundry
unbalance during TUB is filled unevenly. uniformly in the
spin  Water is tilted inner tub
 Wash, Rinse and  Is the CONNECTOR or  Adjust the leg
Spin LED blink Ball pressure sensor  Check B.P SENSOR
disconnected or badly CONNECTOR or
touched? replace B.P sensor
OVER  In the second QC  Check INLET valve
FLOODING Mode the following
ERROR message is
displayed
 All of process LED
blinks
DOOR OPEN  LID is opened in  Lid is opened during  Close the Lid
the course of intermittent spin or
intermittent spin, normal spin?
normal spin or  Lid is opened while
processing processing reservation?  Close the Lid
reservation  Is placed magnetic in
 Wash and spin Lid-B
LED blink  Charge the Lid-B
 SIGNAL
continuously
ringing
BALL  BALL PRESSURE  Connect the BALL  Correct the connector
PRESSURE SENSOR is off. PRESSURE SENSOR or contact
SENSOR  All water level LED BLUE (BL) 3 pin
blinks connector to P.W.B
ASM has bad
connection
 PRESSURE S/W is bad.
(In the initial state of  Replace BALL
QC TEST MODE, the PRESSURE SENSOR
number of the DISPLAY
is less than 63 or more
than 70)
Page69
 AUTO OFF AUTO OFF relay S/W BLUE(BL) 1pin connector Correct the connector
is out of order to P.W.B ASM has bad contact
connection  Change AUTO OFF
switch ASM

TROUBLESHOOTING GUIDE (MECHANICALLY CONTROLLED)

PROBLEM POSSIBLE CAUSE REMEDY

Power failure or plug dropped off Insert plug well

Pulsator
V-belt dropped off Put on V-belt properly
Ceased
Pulley loosened Tighten pulley screw
Running
Foreign matter jammed pulsator Get it away
Friction between pulsator and
Abnormal Adjust the gap between them
wash tub
Pulsator is jammed by foreign
Noise and Get it away
matter
Vibration Over tightened V-belt Adjust properly
Adjust properly or replace with new
Pulsator Stackened V-belt
one
Runs at
Low speed Motor fixing screws loosened Tighten V-belt and screws

PERFORMANCE TEST 2.1

Direction: Given a set of hand tools, multi-tester and defective washing machine with manufacturer’s
service manual perform the procedure and techniques in pre-testing and
troubleshooting a washing machine. Provide a work report/write-up after completing
the task. Write your answer on a separate sheet of paper.

STUDENT WRITE-UP A
Common Symptoms / Defects of a Washing Machine

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

1. PROBLEM/S & SYMPTOM/S :

____________________________________________________________________________________________________

____________________________________________________________________________________________________

__________

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 STUDENT WRITE UP B
Diagnosing Faults in ECEF

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

2. POSSIBLE CAUSE:

____________________________________________________________________________________________________

________________________________________________________

Teacher’s Initial: ___________

JOB SHEET 3.1

LEARNING OUTCOME 3: Maintain and repair a washing machine.

ASSESSMENT CRITERIA:

1. Personal Protective Equipment is used in accordance with Occupational Health and Safety
Practices
2. Electro-Static Discharge (ESD) protection procedures are followed
3. Defective parts/components are replaced with identical or recommended appropriate
equivalent ratings.
4. Repaired or replaced parts/components are soldered/mounted at the specific location
5. Control settings/adjustments are performed in conformity with the service manual
specifications
6. The unit is cleaned after maintenance and repair activity.
 COMPONENT REPLACEMENT
6. Determine the description of the values and ratings of the individual defective parts from the
manufacturer’s service manual
7. Identify the sources of replacement components/parts
 Original replacement components from the original factory sources
 Universal replacement components from independent factory sources
 Always consider the physical size of the replacement part
8. Consider the factors in the selection of specific part
 Quality – the ability to provide exact value or specification to replacement part
 Tolerance – the ability to provide exact value or acceptable parameters to replacement parts
 Availability – local access to parts and whether the parts are available
 Price – it refers to the affordability of the replacement parts at a reasonable price
9. Disconnect or remove properly the electrical/mechanical parts of an washing machine
10. Install correctly replacement part/components in existing washing machine

MAINTENANCE OF WASHING MACHINE

8. Turn off the washing machine and remove the cord from the source of voltage
9. Apply lubricant to mechanical parts of the washing machine that requires lubrication through a
drop of oil or grease to assure smooth operation without grinding or squeaks.
10. Replace the bushings or end bells for squeaks with the use of appropriate tools if squeaks cannot
be corrected by applying lubricants.
11. Apply or spray anti-rust lubricants to all mechanical parts of the washing machine to drive out
moisture, protect corrosion, loosen rusted metal parts and even frees sticky mechanism.
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12. Clean and check cooling louvers for any obstructions to avoid cutting off the air flow.
13. Clean or wipe dust and foreign particles at the PC Board and metal parts of the motor.
14. Replace worn or frayed AC cord and electrical wires

 SOLVENTS FOR CLEANING

3. Use mild soap and damp cloth or rug when cleaning plastic front panel and cover. They are
susceptible to immediate and long term damage from solvents.
4. Apply denatured alcohol as the safest solvent to use for plastic front panel and cover with heavy
stain. It should be used only as a last resort and applied to areas with heavy stain.

 PROCEDURE IN REPAIRING AN WASHING MACHINE

2. Once the specific electrical/mechanical problem is located:
 Consider the techniques for the proper removal of the defective component or parts
 Anticipate what to do if the replacement part does not correct the problem
 Check the installation of the replacement or original part for any improper mounting in
the mechanical assembly or circuit board
4. Examine carefully the mounting of the replacement of original parts of the system
 Check the placement of the wires or leads of the replacement component
 Consider significant factors used in the original installation such as insulating washer,
silicon grease and locating mark for pin connections
 Observe proper placement of the component leads for electrical parts
5. Perform the techniques for the proper soldering of electrical parts
 Be careful not to damage adjacent components
 Be careful not to lift the copper conductive path from circuit board base material
 Avoid any solder bridges between board path
 Do not destroy the component being removed in case it is still functional and be careful
not to damage the component being installed
5. Verify all connections and harness
 Be sure that all components pre-positioned in a manner that will avoid the possibility of
adjacent component short circuit conditions
 Be sure to check or inspect all insulators and barriers between sections after working
on any model/brand of washing machine
 Check for frayed or broken insulation on all wiring including the AC line cord
 Be sure to replace fuses, resistors and capacitors with special designation such as
flame proof to components equal to the original value for both safety and liability
purposes
6. Once the repair is completed, perform an AC leakage test on all exposed metal parts of an washing
machine to eliminate the possibility of electric shock
 Perform complete retesting of the washing machine to ensure the correctness of the
actual repair
 Connect the washing machine into the 60Hz power to allow the time period required to
let the new parts settle in and operate as they are designed to work with each other.
 Recheck or inspect if the repair was done correctly and the unit functions properly to
ensure successful completion of the repair
7. Clean the washing machine before it would be returned to the customer
 Be sure that the blade, front and rear guards of the washing machine are properly
cleaned
 Be sure that proper cleaning is given to the control panel or switch box of the washing
machine

PERFORMANCE TEST 3.1

Direction: Given a set of hand tools, multi-tester and defective washing machine with identified faults
or defect, perform preventive maintenance and repair procedure. Provide a work report/write-up after
completing the task. Write your answer on a separate sheet of paper.

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 STUDENT WRITE-UP A
Common Symptoms / Defects of a Washing machine

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

SYMPTOMS DEFECTIVE REMEDY

COMPONENT/PARTS

STUDENT WRITE UP B
Diagnosing Faults in ECEF

Student : _________________________________ Date: ________________________

Year & Section: _________________________ Teacher: _______________________

UNIT BRAND : _________________________ Unit Model: ______________________

Owner: ______________________ Address: _________________________________

SYMPTOMS DEFECTIVE REMEDY

COMPONENT/PARTS

Teacher’s Initial: __________

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