Kenmore DU890DWG, DP840DWG, DU805DWG, DU840DWG, DU810DWG User Manual

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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

Kenmore DU890DWG, DP840DWG, DU805DWG, DU840DWG, DU810DWG User Manual

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

 

to the tub. (Fig. 1-17)

FLOAT

3.

Lift the float from the housing inside the tub.

SWITCH

HOUSING

 

 

4.

Unsnap the float switch housing cover and disconnect

RETAINING

 

the two (2) wires from the terminals of the switch.

 

(Fig. 1-18)

SCREW

 

 

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

Harness

 

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

 

Screw

the switch assembly to the door frame. (Fig. 1-24)

 

 

 

The switch assembly can now be removed.

Screw

Fig. 1-24

 

Removing the Door Latch Switches

 

 

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

 

TESTING PROCEDURE

 

RESULTS

 

 

 

 

 

Motor Start Relay

1.

Disconnect the wire connectors and

1.

Relay upright - meter should read

 

 

remove relay from unit.

 

º (infinity.)

 

2.

Set VOM meter on the Rx1 scale.

2.

Relay upside-down - meter should

 

3.

Set the relay upright.

 

read less than two (2)Ω.

 

4.

Measure resistance between blue and

 

 

 

 

violet contacts.

 

 

 

5.

Turn relay upside-down.

 

 

 

6.

Measure resistance between blue and

 

 

 

 

violet contacts.

 

 

 

 

 

 

 

Drive Motor

1.

Disconnect the motor wiring harness

1.

White/violet to blue/white - meter

 

 

plug from the motor connector.

 

should read 5 - 7Ω.

 

2.

Set VOM meter on the Rx1 scale.

2.

White/violet to yellow - meter

 

3.

Connect one probe to the white/violet

 

should read 5 - 7Ω.

 

 

connector.

3.

White/violet to gray - meter

 

4.

Connect the other probe to the blue/

 

should read 5 - 7Ω.

 

 

white connector.

 

 

 

5.

Connect the meter probe to the yellow

 

 

 

 

connector.

 

 

 

6.

Connect the probe to the grey

 

 

 

 

connector.

 

 

 

 

 

 

 

Thermal Fuse

1.

Disconnect wires connectors from the

1.

Meter should read 0Ω.

 

 

thermal fuse terminals.

 

 

 

2.

Set VOM meter to read Rx1 scale.

 

 

 

3.

Measure resistance between thermal

 

 

 

 

fuse terminals.

 

 

 

 

 

 

 

Heater Element

1.

Disconnect the wire connectors from

1.

Meter should read 25 - 35Ω.

 

 

the heater element terminals.

 

 

 

2.

Set VOM meter to read Rx1 scale.

 

 

 

3.

Measure resistance between heater

 

 

 

 

element terminals.

 

 

 

 

 

 

 

Fill Valve

1.

Disconnect the wiring harness plug

1.

Meter should read approximately

 

 

from the fill valve connector.

 

700Ω.

 

2.

Set VOM meter to read Rx1 scale.

 

 

 

3.

Measure resistance between the

 

 

 

 

terminals of the fill valve.

 

 

 

 

 

 

 

Overfill Switch

1.

Disconnect the wires connectors from

1.

Float DOWN - meter should read

 

 

the overfill switch terminals.

 

0Ω.

 

2.

Set VOM meter to read Rx1 scale.

2.

Float UP - meter should read

 

3.

Measure resistance between switch

 

º (infinity).

 

 

terminals.

 

 

 

4.

Block the float in the UP (full) position

 

 

 

 

and measure resistance again.

 

 

13

COMPONENT SCHEMATIC

 

TESTING PROCEDURE

 

RESULTS

 

 

 

 

 

Timer Motor

1.

Disconnect the Wiring harness

1.

Meter should read 1800 - 3000Ω.

 

 

connector from the timer assembly.

 

 

 

2.

Set VOM meter on the Rx1 scale.

 

 

 

3.

Measure resistance between timer

 

 

 

 

motor terminals.

 

 

 

 

 

 

 

Timer

1.

Disconnect the wiring harness

1.

Contact CLOSED - meter should

 

 

connector from the timer assembly.

 

read 0Ω.

 

2.

Set VOM meter on the Rx1 scale.

2.

Contact OPEN - meter should

 

3.

Connect one probe to contact 31.

 

read º (infinity).

 

 

(Tan)

 

 

 

4.

Connect the other probe to the timer

 

 

 

 

contact to be tested.

 

 

 

5.

Manually advance the timer until the

 

 

 

 

contact closes.

 

 

 

6.

Manually advance the timer until the

 

 

 

 

contact opens.

 

 

 

 

 

 

 

Dispenser Mechanism

1.

Remove the front door panel.

1.

At 12 o’clock position - Draw bars

 

2.

Remove the drip cover.

 

 

will move upward causing the

 

3.

Latch the detergent door closed.

 

 

 

detergent actuator assembly to

 

4.

Manually advance the timer through a

 

 

 

release the latch and detergent

 

 

complete cycle slowly.

 

 

 

 

cup should open.

 

 

 

 

 

 

 

2. At 4 o’clock position - Draw bars

 

 

 

 

will again move upward causing

 

 

 

 

the wetting agent actuator to

 

 

 

 

release wetting agent.

 

 

 

3. From the 6 o’clock position to the

 

 

 

 

8 o’clock position the draw bars

 

 

 

 

are driven down to reset the

 

 

 

 

mechanism.

 

 

 

 

 

 

 

 

 

 

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

 

POSSIBLE CAUSES

 

CORRECTION/TEST

 

 

 

 

 

Dishwasher does not run or

1.

Door is not latching properly.

1.

Check to make sure handle link

stops during a cycle

 

 

 

is properly seated in door latch

 

 

 

 

assembly. Check that the door

 

 

 

 

switch is opening and closing

 

 

 

 

properly.

 

2.

Child lock is "ON".

2.

Turn child lock "OFF"

 

3.

Wash Cycle not set properly.

3.

Review setting Wash Cycles in

 

 

 

 

the Use and Care Guide.

 

4.

Household fuse blown or circuit

4.

Have a qualified electrician check

 

 

breaker tripped.

 

the circuit breaker or fuse.

 

5.

Washer is not wired into a circuit with

5.

Have customer call a qualified

 

 

proper voltage.

 

electrician.

 

 

 

 

 

Dishwasher will not fill

1.

Overflow protection float is stuck in

1.

Check that the overflow

 

 

"up" position.

 

protection float is free to move

 

 

 

 

"up" and "down". Check that the

 

 

 

 

overfill switch in opening and

 

 

 

 

closing properly.

 

2.

Fill valve is inoperable.

2.

Check for continuity between

 

 

 

 

contacts on fill valve.

 

3.

Open timer contacts.

3.

Test timer contacts.

 

 

 

 

 

Dishwasher will not drain

1.

Air gap (if installed) is clogged.

1.

Follow air gap manufacturer's

 

 

 

 

direction for cleaning.

 

2.

Pump motor is inoperable.

2.

Disconnect pump motor from

 

 

 

 

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

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