CONSUMER SERVICES TECHNICAL |
KD-10 |
EDUCATION GROUP PRESENTS |
1998 DISHWASHERS
Servicing and Troubleshooting
MODELS
DU800DWG DU801DWG DU805DWG DU810DWG DP840DWG DU840DWG DU850DWG DU890DWG DU910PFG DP920PFG DU920PFG GU940SCG GU960SCG GU980SCG
JOB AID
Part No. 4322430
INTRODUCTION
This Job Aid, “1998 DISHWASHERS, Servicing and Troubleshooting,” (Part No. 4322430) provides specific information for the installation, service and repair of 1998 Whirlpool Dishwashers.
“1998 DISHWASHERS, Servicing and Troubleshooting,” has been compiled to provide the most recent information on design, features, troubleshooting, service and repair procedures.
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair the 1998 lineup of Dishwashers.
The objectives of the Job Aid are:
The service technician will -
•Understand proper safety precautions.
•Successfully troubleshoot and diagnose malfunction.
•Successfully perform necessary repairs.
•Successfully return the dishwasher to proper operational status.
CORPORATION
WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY
FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE
OTHER THAN AUTHORIZED SERVICE TECHNICIANS.
© 1998 Whirlpool Corporation, Benton Harbor, MI 49022
II
TABLEOFCONTENTS
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV SECTION ONE
DURAWASH MODELS W/ SOIL SETTLER AND TELESCOPING TOWER Model: DU800DWG, DU801DWG, DU805DWG, DU810DWG, DP840DWG, DU840DWG, DU850DWG, DU890DWG
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Solutions to Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION TWO
POWER CLEAN FILTER MODELS W/ TOWER WATER FEED
Models: DU910PFG, DP920PFG, DU920PFG
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION THREE
POWER CLEAN FILTER MODELS W/ INTERNAL WATER FEED
Models: GU940SCG, GU960SCG, GU980SCG
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SECTION FOUR
Installation Considerations
Custom Door Panel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Floor Mount Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
This Service Manual is accompanied by a companion video presentation,
SERVICING AND TROUBLESHOOTING
1998 DISHWSHERS
Part No. 4322329
III
-- NOTES --
IV
Section One
DURAWASH MODELS WITH
SOILSETTLERANDTELESCOPINGTOWER
THEORY OF OPERATION
Console Configuration
DU800DWG, DU801DWG, DU805
DU810DWG
DU840DWG, DP840DWG
DU850DWG
DU890DWG
1
Special Feature
Soil Settler
This model is equipped with a soil settler system. The inlet to the soil settler funnel is located to the right and just behind the lower spray arm assembly. (Fig. 1-1)
Fig. 1-1
Since this inlet is located in an area that is relatively free of water turbulence, food particles washed from the dishes can collect in this area and fall through the funnel and accumulate in the collector. (Fig. 1-2) Food particles continue to collect as long as the dishwasher is in the Wash mode.
COLLECTOR
PUMP INLET
HOSE
Fig. 1-2
When the Wash cycle is finished, the dishwasher will reverse the direction of the motor and enter the Drain mode. Water is pumped into the port at the bottom of the soil collector during the Drain cycle causing the ball in the collector to rise against the opening in the bottom of the funnel. Water flows through and out of the collector through the top port and into the drain line. (Fig. 1-3) Food particles collected during the Wash cycle are carried out with the drain water. When the Drain cycle ends and the pump stops running, the ball settles to the bottom of the collector.
Fig. 1-3
2
COMPONENT ACCESS
! WARNING
ELECTRICAL SHOCK HAZARD
Disconnect electric supply from the dishwasher before servicing. Replace all panels before operating.
Failure to do so could result in death or electrical shock.
Component Location
(Bottom Right-side
Rear of Tub)
3
Removing the Spray Arm Assembly
1.Disconnect the dishwasher from the household electrical system.
2.Open the dishwasher door and remove the lower rack.
3.Use an adjustable slip-nut wrench and loosen the pump outlet nut. (Fig. 1-4)
4. Lift the spray arm assembly out of the pump |
Fig. 1-4 |
|
5.The spray arm can be disassembled by removing
the retaining screw from the spray arm and removing the split-ring seal, the pump outlet nut and the support and bearing assembly. (Fig. 1-5)
SPRAY ARM ASSEMBLY
SPLIT RING SEAL
PUMP OUTLET NUT
SUPPORT & BEARING
RETAINING SCREW
Fig. 1-5
Removing the Pump and Motor Assembly
1.Disconnect the dishwasher from the household electrical system.
2.Lay the dishwasher on its back and disconnect the wiring harness connector from the motor.
3.Remove the motor support slip nut and remove the motor support. (Fig. 1-6)
MOTOR SUPPORT
SUPPORT
SPLIT NUT
Fig. 1-6
4
4.Disconnect the drain hose from the drain valve by loosening the Hex-head screw on the hose clamp. (Fig. 1-7)
5.Disconnect the pump inlet hose from the pump and motor assembly. (Fig. 1-7)
6.Remove the pump and motor assembly from the bottom of the dishwasher.
PUMP INLET
HOSE
DRAIN
HOSE
Fig. 1-7
NOTE: Once the pump and motor assembly has been removed from the tub, the pump outlet grommet can be removed from the inside of the tub. Check the pump outlet grommet for wear or damage and replace it if necessary.
The motor can be removed from the pump assembly by removing the three T-20 Torx screws securing the motor to the pump assembly. (Fig. 1-8)
TORX
SCREWS
NOTE: When reinstalling the motor make sure the keyed motor shaft lines up with the pump impeller.
Fig. 1-8
Servicing the Pump Assembly
The pump impeller can be accessed by using an adjustable slip-nut wrench to turn the
disk mount assembly counterclockwise. Once the disk mount assembly is removed, the impeller can be removed. (Fig. 1-9)
SLIP-NUT WRENCH
TORX
SCREWS
Fig. 1-9
The drain valve can be accessed by removing the four (4) T-20 Torx screws securing the drain outlet cover to the pump assembly. The drain cover seal, diaphragm and diaphragm ring can
be removed and replaced. (Fig. 1-10)
Fig. 1-10
5
Removing the Soil Settler Assembly
1.Disconnect the dishwasher from the household electrical system and lay the unit on its back.
2.Remove the four (4) Hex-head screws securing the soil settler assembly to the tub.
3.Disconnect the two (2) hoses from the soil settler collector.
4.Remove the funnel and funnel grate, check valve ball and seal from the soil settler collector.
(Fig. 1-11)
FUNNEL GRATE
FUNNEL
CHECK VALVE BALL
SEAL
CLAMPS
HOSE
Fig. 1-11
Removing the Heater Element
1.Disconnect the dishwasher from the household electrical system.
2.Disconnect the wiring harness connectors from the heater element terminals with a pair of needlenose pliers.
3.Remove the two long Hex-head nuts securing the heater element to the tub. (Fig. 1-12)
4.Remove the heater element from the three (3) metal clips that hold it suspended inside the tub.
(Fig. 1-13)
HEATER
ELEMENT
HEATER
ELEMENT
RETAINING
NUTS
Fig. 1-12 |
Fig. 1-13 |
6
Removing the Water Inlet Valve
1.Turn off the water supply to the dishwasher.
2.Turn the timer knob clockwise to the NORMAL WASH position to energize the water inlet valve and relieve water pressure in the line.
3.Turn the electrical supply to the dishwasher off and remove the toe panel and access panel.
(Fig. 1-14)
Fig. 1-14
4.Disconnect the wiring harness connector from the water inlet valve terminals. (Fig. 1-15)
5.Disconnect the water lines from the water inlet valve.
6.Remove the Hex-head screw securing the water inlet valve to the tub support assembly.
Removing the Thermal Fuse
1.Turn the electrical supply to the dishwasher off and remove the toe panel and access panel.
2.Disconnect the orange and white wires from the thermal
fuse terminals. (Fig. 1-16) |
THERMAL |
|
FUSE |
3.Remove the Hex-head screw securing the thermal fuse
to the tub and remove the thermal fuse from the dishwasher.
Removing the Float Switch
1.Turn the electrical supply to the dishwasher off and remove the toe panel and access panel.
2.Remove the Hex-head screw securing the float switch
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to the tub. (Fig. 1-17) |
FLOAT |
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3. |
Lift the float from the housing inside the tub. |
SWITCH |
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HOUSING |
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4. |
Unsnap the float switch housing cover and disconnect |
RETAINING |
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the two (2) wires from the terminals of the switch. |
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(Fig. 1-18) |
SCREW |
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TERMINALS
WIRES
Fig. 1-18
Fig. 1-15
WHITE
WIRE
RETAINING
SCREW
ORANGE
WIRE
Fig. 1-17
SWITCH COVER
7
Removing the Check Valve
RETAINING
1. Remove the toe panel and access panel from the SCREW bottom of the dishwasher.
2. Remove the hoses from the check valve. |
Fig. 1-19 |
3.Remove the Hex-head screw securing the check valve to the tub support. (Fig. 1-19)
Removing the Motor Relay
1.Disconnect the dishwasher from the electrical supply and remove the toe panel and access panel from the bottom of the dishwasher.
2.Disconnect the three (3) wiring harness connectors from the motor relay terminals.
3.Remove the Hex-head screw securing the motor relay to the tub support. (Fig. 1-20)
RETAINING
SCREW
Fig. 1-20
Accessing Components Inside the Door
1.Disconnect the dishwasher from the electrical supply and remove the toe panel and access panel from the bottom of the dishwasher.
2.Disconnect the end of the door springs from the door spring tension adjustment holes in the frame runner. Note which holes were used and reattach the door springs in the same holes when the repairs are complete. (Fig. 1-21)
3.Open the dishwasher door and remove the eight (8) T-15 Torx screws securing the inner door panel from the door frame. (Fig. 1-22)
4.Remove the timer cover by releasing the two (2) retaining tabs at each end from the door frame.
Fig. 1-21
T-15
TORX
Fig. 1-22
8
Removing the Timer
1.Disconnect the dishwasher from the electrical supply and remove the toe panel and access panel from the bottom of the dishwasher and the inner door panel.
|
Screw |
2. Disconnect the wiring harness connectors from |
Screw |
the timer terminals. (Fig. 1-23) |
3.Remove the three (3) Hex-head screws securing the timer to the door frame. (Fig. 1-23) The timer, cam and cam follower can now be removed.
Wiring Harness
Connector
Screw |
Wiring |
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Harness |
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Fig. 1-23 Connector |
NOTE: When reinstalling the cam, be sure it is aligned with the keyed shaft of the timer. When reinstalling the timer, be sure the cam follower post is positioned inside the cam’s groove.
Removing the Switch Assembly
1. Disconnect the dishwasher from the electrical supply and remove the toe panel and access panel from the bottom of the dishwasher and the inner door panel.
2. Disconnect the harness wires from the spade connectors on the switch assembly. (Fig. 1-24)
3. Remove the two (2) Hex-head screws securing |
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Screw |
the switch assembly to the door frame. (Fig. 1-24) |
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The switch assembly can now be removed. |
Screw |
Fig. 1-24 |
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Removing the Door Latch Switches |
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1.Disconnect the dishwasher from the electrical supply and remove the toe panel and access panel from the bottom of the dishwasher and the inner door panel. (Fig. 1-25)
2.Disconnect the wiring harness connectors from the door latch switch terminals.
3.Unclip the handle and latch assembly from the door frame.
4.To remove the switches from the handle and latch assembly, push the two (2) retaining pins out of the holes and remove the switches.
SWITCHES
HANDLE &
LATCH
ASSEMBLY
RETAINING
PINS
Fig. 1-25
9
Dishwasher Dispenser Disassembly
1.Remove the drawbar spring. (Fig. 1-26)
2.Align the lower drawbar holes with the locking tabs and remove the upper and lower drawbars. As you do, note the locating tabs behind them and how they align with their respective locating holes. (Fig. 1-27)
3.Slide the drawbars apart. (Fig. 1-28)
4.Turn the wet agent cap and seal assembly counterclockwise and remove it. (Fig. 1-29)
5.Remove the seal from the cap.
6.Use Special Tool - Part No. 303918 or a ¾” socket to press over the attaching tabs in the wet agent cap opening. Remove wet agent dispenser assembly.
7.Remove wet agent dispenser actuator by spreading the two (2) locking tabs. (Fig. 1-30)
8.Remove the upper and lower slides from the wet agent dispenser actuator.
9.Remove the diaphragm spring and diaphragm.
10.Use a screwdriver to gently release the lower tab and remove the detergent door
actuator assembly. As you do, note the position of the door latch level through the hole in the lower slide. (Fig. 1-31)
11.Remove the upper slide, the slide spring and the lower slide. (Fig. 1-32)
Fig. 1-26 |
Fig. 1-27 |
10
Fig. 1-28
Fig. 1-29
Fig. 1-30 |
Fig. 1-31 |
11
Dishwasher Dispenser Assembly
1.Assembly the upper slide, slide spring and lower slide to the detergent
door actuator. (Fig. 1-32)
2.Pass the detergent door latch lever through the panel making sure to turn the hook of the latch toward the detergent door. Snap the detergent door latch snap onto the door latch lever. (Fig. 1-31)
3.The door latch lever must pass through the opening in the lower slide. Press the actuator assembly into position until the upper and lower tabs engage.
4.Insert the diaphragm and diaphragm spring into the wet agent dispenser. Seat the diaphragm flush with the surface of the dispenser. (Fig. 1-30)
5.Install the upper and lower slides into the wet agent dispenser actuator.
6.Press the wet agent dispenser actuator into position on the dispenser so the lock-
ing tabs engage. |
Fig. 1-32 |
7.Press the wet agent dispenser assembly into position so the locking tabs engage the wet agent cap opening. No tool is needed for assembly. (Fig. 1-29)
8.Install the seal on the wet agent cap.
9.Insert the wet agent cap. Turn it clockwise and close it.
10.Slide the upper and lower drawbars together. (Fig. 1-28)
11.Move all slides in both assemblies fully down. Keep the drawbars slid fully together and align the drawbar holes over the locking tabs. Look behind the draw bars and make sure to engage the locating tabs with their respective locating holes. Press the drawbars into position and slide them upward behind the locking tab ears. (Fig. 1-27)
12.Install the drawbar spring. (Fig. 1-26)
13.Install the drip cover by snapping it into place.
12
SOLUTIONS TO COMMON PROBLEMS
DIAGNOSING PROBLEM COMPONENTS
PRECAUTIONS TO BE OBSERVED WHILE DIAGNOSING
PROBLEM COMPONENTS
Disconnect electric power from the dishwasher.
Voltage checks should be made by inserting meter probes beside the wires in the connector blocks with the electric power source on and the connector block plugged in.
Resistance checks should be made on components with the electric power off and the connector blocks disconnected.
COMPONENT SCHEMATIC |
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TESTING PROCEDURE |
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RESULTS |
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Motor Start Relay |
1. |
Disconnect the wire connectors and |
1. |
Relay upright - meter should read |
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remove relay from unit. |
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º (infinity.) |
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2. |
Set VOM meter on the Rx1 scale. |
2. |
Relay upside-down - meter should |
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3. |
Set the relay upright. |
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read less than two (2)Ω. |
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4. |
Measure resistance between blue and |
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violet contacts. |
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5. |
Turn relay upside-down. |
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6. |
Measure resistance between blue and |
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violet contacts. |
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Drive Motor |
1. |
Disconnect the motor wiring harness |
1. |
White/violet to blue/white - meter |
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plug from the motor connector. |
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should read 5 - 7Ω. |
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2. |
Set VOM meter on the Rx1 scale. |
2. |
White/violet to yellow - meter |
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3. |
Connect one probe to the white/violet |
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should read 5 - 7Ω. |
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connector. |
3. |
White/violet to gray - meter |
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4. |
Connect the other probe to the blue/ |
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should read 5 - 7Ω. |
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white connector. |
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5. |
Connect the meter probe to the yellow |
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connector. |
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6. |
Connect the probe to the grey |
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connector. |
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Thermal Fuse |
1. |
Disconnect wires connectors from the |
1. |
Meter should read 0Ω. |
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thermal fuse terminals. |
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2. |
Set VOM meter to read Rx1 scale. |
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3. |
Measure resistance between thermal |
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fuse terminals. |
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Heater Element |
1. |
Disconnect the wire connectors from |
1. |
Meter should read 25 - 35Ω. |
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the heater element terminals. |
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2. |
Set VOM meter to read Rx1 scale. |
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3. |
Measure resistance between heater |
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element terminals. |
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Fill Valve |
1. |
Disconnect the wiring harness plug |
1. |
Meter should read approximately |
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from the fill valve connector. |
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700Ω. |
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2. |
Set VOM meter to read Rx1 scale. |
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3. |
Measure resistance between the |
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terminals of the fill valve. |
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Overfill Switch |
1. |
Disconnect the wires connectors from |
1. |
Float DOWN - meter should read |
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the overfill switch terminals. |
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0Ω. |
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2. |
Set VOM meter to read Rx1 scale. |
2. |
Float UP - meter should read |
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3. |
Measure resistance between switch |
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º (infinity). |
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terminals. |
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4. |
Block the float in the UP (full) position |
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and measure resistance again. |
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13
COMPONENT SCHEMATIC |
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TESTING PROCEDURE |
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RESULTS |
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Timer Motor |
1. |
Disconnect the Wiring harness |
1. |
Meter should read 1800 - 3000Ω. |
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connector from the timer assembly. |
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2. |
Set VOM meter on the Rx1 scale. |
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3. |
Measure resistance between timer |
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motor terminals. |
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Timer |
1. |
Disconnect the wiring harness |
1. |
Contact CLOSED - meter should |
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connector from the timer assembly. |
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read 0Ω. |
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2. |
Set VOM meter on the Rx1 scale. |
2. |
Contact OPEN - meter should |
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3. |
Connect one probe to contact 31. |
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read º (infinity). |
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(Tan) |
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4. |
Connect the other probe to the timer |
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contact to be tested. |
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5. |
Manually advance the timer until the |
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contact closes. |
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6. |
Manually advance the timer until the |
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contact opens. |
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Dispenser Mechanism |
1. |
Remove the front door panel. |
1. |
At 12 o’clock position - Draw bars |
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2. |
Remove the drip cover. |
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will move upward causing the |
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3. |
Latch the detergent door closed. |
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detergent actuator assembly to |
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4. |
Manually advance the timer through a |
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release the latch and detergent |
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complete cycle slowly. |
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cup should open. |
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2. At 4 o’clock position - Draw bars |
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will again move upward causing |
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the wetting agent actuator to |
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release wetting agent. |
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3. From the 6 o’clock position to the |
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8 o’clock position the draw bars |
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are driven down to reset the |
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mechanism. |
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14
TROUBLESHOOTING GUIDE
PRECAUTIONS TO BE OBSERVED WHILE TROUBLESHOOTING
AND DIAGNOSING PROBLEMS
Always check wiring harness and connectors before initiating any test procedures.
Disconnect electric power from the dishwasher before touching the printed circuit boards or re-seating wire connectors.
Voltage checks should be made by inserting meter probes beside the wires in the connector blocks with the electric power source on and the connector block plugged in.
Resistance checks should be made on components with the electric power off and the connector blocks disconnected.
PROBLEM |
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POSSIBLE CAUSES |
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CORRECTION/TEST |
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Dishwasher does not run or |
1. |
Door is not latching properly. |
1. |
Check to make sure handle link |
stops during a cycle |
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is properly seated in door latch |
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assembly. Check that the door |
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switch is opening and closing |
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properly. |
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2. |
Child lock is "ON". |
2. |
Turn child lock "OFF" |
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3. |
Wash Cycle not set properly. |
3. |
Review setting Wash Cycles in |
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the Use and Care Guide. |
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4. |
Household fuse blown or circuit |
4. |
Have a qualified electrician check |
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breaker tripped. |
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the circuit breaker or fuse. |
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5. |
Washer is not wired into a circuit with |
5. |
Have customer call a qualified |
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proper voltage. |
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electrician. |
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Dishwasher will not fill |
1. |
Overflow protection float is stuck in |
1. |
Check that the overflow |
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"up" position. |
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protection float is free to move |
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"up" and "down". Check that the |
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overfill switch in opening and |
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closing properly. |
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2. |
Fill valve is inoperable. |
2. |
Check for continuity between |
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contacts on fill valve. |
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3. |
Open timer contacts. |
3. |
Test timer contacts. |
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Dishwasher will not drain |
1. |
Air gap (if installed) is clogged. |
1. |
Follow air gap manufacturer's |
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direction for cleaning. |
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2. |
Pump motor is inoperable. |
2. |
Disconnect pump motor from |
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|
wiring harness and check for |
|
3. |
Open timer contacts. |
|
continuity. |
|
|
|
3. |
Test timer contacts. |
|
|
|
|
|
Dishwasher will not |
1. |
Heater element burned out. |
1. |
Check for continuity between the |
dry dishes |
2. |
Hi-limit thermostat inoperable. |
|
terminals of the heater element. |
|
2. |
Check for continuity between |
||
|
|
|
|
terminals of the hi-limit |
|
3. |
Open circuit between timer and |
|
thermostat. |
|
3. |
Check for continuity between |
||
|
|
heater. |
|
timer switch contacts and heater. |
|
|
|
|
|
15
TECHNICAL INFORMATION
Wiring Diagram
Models DU800DWG, DU801DWG, DU805DWG
SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED,
ALL CONTACTS OPEN
16