Bosch SHV, SHX, SHU Schematic

DISHWASHER SERVICE TRAINING

MANUAL

Table of Contents

I. Safety Concerns………………………..……….…..…………...2

II. Product Line Related…………………………………..……….. 2

III. Product Specific………………………………………………… 3

IV. Installation Issues…………………….………………..…….…. 6

V. Theory of Operation…………………………………..………. 22

VI. Component Access/Replacement………………..………… 31

VII. Component Testing/Test Procedures……………..………. 59

VIII. Troubleshooting…………………………………….………… 64

IX. Wiring Diagrams/Tech Sheet…………………….………….104

I. Safety Concerns

IA. Safety Symbol Explanation

m = Warning symbol included in Installation Instructions and on this page. It includes serious warnings

such as injury or death, electric shock & dishwasher damage.

IB. Identify Potential Hazards

There are few hazards associated with dishwashers. Two possible hazards are:

m Electrical shock hazard (as with any electrical appliance).

m Sharp edges – only on tank when sump is removed and on inner door when dispenser is removed.

IC. Warning Personal Injury

m Danger of electric shock. Disconnect power before disassembling or working on dishwashers. Make

sure dishwashers are electrically grounded. Use only copper conductors for all wiring or rewiring.

ID. Warning Property Damage

Only warning on property damage comes from improper water connections – overly tightened water connections could cause water to leak from water inlet valves. This only applies to older models with water inlet valves with vertical solenoids (coils). Newer models with water inlet valves with horizontal solenoids (coils) have water connections integrated with mounting brackets to eliminate possibility of damaging valves from overtightening water fittings.

IE. Electrostatic Sensitive Devices

None since all control modules have pc boards mounted in plastic housings – no pc boards are handled in repairing dishwashers.

II. Product Line Related

IIA. CFC Information

There are no CFC’s or any other refrigerant used in dishwashers.

IIB. Emissions Related

There are no emissions related to dishwashers. Occasionally smells come from customer drains into dishwashers if dishwashers weren’t properly connected to drains.

IIC. CO

No carbon monoxide is emitted by dishwashers.

IID. Government Compliance Issues

None.

IIE. Certification Requirements

All dishwashers are designed, tested and certified by UL for use in the U.S. and Canada. In addition, all dishwashers are Energy Star certified as energy savers. Many dishwashers have NSF sanitized wash cycles.

III. Product Specific

IIIA. Product Specification Chart

 Rated 120V, 60 Hz, 15A, 1450W (max.). Maximum amp draw when heaters running ~ 11A.

 Water connection 3/8” NPT female.

 Inlet water pressure range 5 - 120 psi (0.3 – 8.27 bars).

 Circulation pump motor rated 120V, 60 Hz, 160W, insulation class A. Motor has an auto-reset thermal

protector and uses a 10µF capacitor.

 Drain pump rated 120V, 60 Hz, 35W, 0.85A.

IIIB. Model Number Listing and Explanation

Model numbers were changed with the dishwashers introduced during the 4thquarter of 2002.

 Current model # listing – see below

 Older model # listing – see below

Current Mode l # Legend

SH V 9 9 A 03

Tall

Di shw a she r

1 2 3 4 5 6 789

S =

Dishwasher

Tub Type

U =

Tal l

H =

Tub

Undercounter, standard

Fully

V =

integrated

Integra I

X =

Integra II

Y =

Semi

I =

Integrated

# Wash

Programs

Automatic

9 =

Six

6 =

Five

5 =

Four

4 =

Three

3 =

Control Sold Through

Mechanical

0 =

Electronic

3 =

Electronic +

6 =

Options

Automatic

9 =

Distribution

A =

Sears

B =

Common

C =

Builder

D =

Other

E =

Dummy

Color UC/#

White

2 = 5 =

Stainless

Black

6 =

Biscuit

7 =

N/A,

3 =

Fully Integrated

CSI

Old Model # Legend

SH V 6 8 0 3

Dishwasher Tall Tub Type

12 3 4 5 6 78

S =

Dishwasher

H =

Tub

Tal l

Undercounter,

U =

standard

Fully integrated

V =

U88x x

Integra I

U995x = I =

U99xx =

Integra II

Semi Integrated3 &

# W ash Programs Control Level

Integra I (four)

9 =

or II (five)

Six

6 =

Five

5 =

Four

4 =

8 =

Three

Mechanic al

0 =

3, 8

9 =

Electronic

0 =

Standard

1, 2

Deluxe

= 5 =

Integra II

Color UC/ #

White

2 =

N/A, Fully

3 =

Integrated

Almond

4 =

Stainless

5 =

Black

6 =

Biscuit

7 =

CSI

III. Product Specific

IIIC. Model Number Location

Located on right edge of inner door. See below.

The serial label is fastened to the right edge of the inner door.

FD8303 00011

Understanding FD Serial #

(used for warranty)

The FD # shows the Fabrication Date

• The first 2 #s represent the year: 83 = 2003 (add 20 to #; e.g. 20 + 83 = 103 → 2003)

• The next 2 #s represent the month: 03 = March

• The next 5 #s represent the unit made that month: 00011 = 11th SHY99A05UC made that month

10 3 03 0081344 00011 5

Please hold all warranty parts for (60) days for possible return for analysis.

• The first 2 #’s represent a factory code: 10 = New Bern dishwasher, 82 = New Bern cooking

•The 3

• The next 2 #’s represent the month: 03 = March

• The next 7 #’s represent the model: 0081344 = SHY99S05UC

• The next 5 #’s represent the unit made that month: 00011 = 11th SHY99A05UC made that

• The last # represents a check digit = 5 in this case (is dependent on all preceding #’s)

# represents the last digit of the year: 3 = 2003

month

This helps the

factory

investigate

product

problems.

Understanding Factory Serial #

III. Product Specific

IIID. Tech Sheet Location

Wiring and circuit diagram folded up and located in slot in front of dishwasher bases.

IIIE. Warranty Information

See below.

Bosch Dishwashers Limited Lifetime Warranty Statement of Limited Warranty

The warranties provided by BSH Home Appliances ("Bosch") in this Statement of Warranties apply only to Bosch dishwashers sold to the first using purchaser by Bosch or its authorized dealers, retailers or service centers in the United States or Canada. The Warranties provided herein are not transferable, and take place from date of installation or ten business days after delivery date, whichever comes first.

1 Year Full Limited Warranty

Bosch will repair or replace, free of charge, any component part that proves defective under conditions of normal home use, labor and shipping costs included. Warranty repair service must be performed by an authorized Bosch Service Center. All cosmetic defects must be reported within 30 days of installation.

2 Year Limited Warranty

Bosch will provide replacement parts, free of charge, for any component part that proves defective under conditions of normal home use, shipping costs included, labor charges excluded.

5 Year Limited Warranty On Electronics

Bosch will repair or replace, free of charge, any microprocessor or printed circuit board that proves defective under conditions of normal home use during the second through fifth year from the date of original installation, labor charges excluded.

5 Year Limited Warranty On Racks

Bosch will repair or replace, free of charge, the upper or lower dish rack (excluding rack components) if the rack proves defective under conditions of nor mal home use during the second through fifth year from the date of original installation, labor charges excluded.

Lifetime Limited Warranty Against Stainless Steel Rust-Through

Bosch will replace your dishwasher, free of charge, with the same model or a current model that is equivalent or better in functionality if the inner liner should rust through under conditions of normal home use, labor charges excluded. Bosch will replace the stainless steel door of any dishwasher if the door should rust through under conditions of normal home use, labor charges excluded.

For location of nearest repair depot call 1--

For location of nearest repair depot call 1

800--

800

944--

2904 from 5:00 AM --

944

2904 from 5:00 AM

5:00 PM M--

5:00 PM M

F (Pacific time)

IV. Installation Issues

IVA. Location Requirements

See attached installation instructions.

IVB. Electrical Requirements

See attached installation instructions.

IVC. Water/Drain Requirements

See attached installation instructions.

IVD. Shipping/Packaging Removal

See attached installation instructions.

IVE. Installation Related Process

1. Leveling cabinet –

2. Leveling doors – not required for steel doors. For wooden panels added to steel doors,

see installation instructions.

3. Installing handles – See attached installation instructions.

4. Door reversal – not possible or necessary.

5. Quick test procedure

Top Ten Cosmetic/Customer Use/Installation Issues::

Top Ten Cosmetic/Customer Use/Installation Issues

See attached installation instructions.

 Not cleaning sump filters.…Customers often don’t know they exist.  Smelly dishwashers….Often occurs from filters not being cleaned, drain hose high loops

missing or drain gases being present. If all else is OK, then problem can be preservative not purged from tank door gasket.

 Doors leaking or not latching….Usually an installation issue (dishwasher brackets

installed before dishwashers are leveled front to back, tanks & doors out of square, wooden doors not drilled accurately). Can be blockage in condensation tubes or having condensation tubes connected to drain hose air gaps.

 Inner door damage.…From upper rack during improper shipping and handling

(dishwashers clamped on wrong sides or dropped).

 Doors hit toe kicks.…Toe kick installation issue.  Junction boxes.…Comes from wires not being connected correctly during installation.  Dispensers.…Customers using too much detergent, not using rinse-aid & not knowing how to

close the door.

 Drain hoses not installed properly.…Often no air gap or high loop + pinched hoses --

causes poor draining & smelly dishwashers. Most drain pumps are mistakenly replaced for drain hose installation issues.

 Outer doors….Most are dinged during shipment.  Damaged water valves….Primarily from fittings being overtightened. A damaged valve

can allow some water onto kitchen floors.

IV. Installation Issues: Installation Instructions

V. Theory of Operation

VA. Description of Operation/Cycle

 Bosch dishwashers use separate circulation and drain pumps to reduce overall size, noise, vibration

and energy consumption. This allows the use of tall tanks, increasing overall space inside dishwashers where full-sized plates can be placed in both upper and lower racks. Circulation pumps are suspended by rubber straps to further reduce noise and vibration.

 Bosch dishwashers use flow-through heaters instead of exposed elements used on most other

dishwashers. Water from spray arms drops to the sump and flows through the circulation pump into the flow-through heater. Flow-through heaters prevent dishware damage from exposed elements and allow water to be continuously filtered and heated. Bosch flow-through heaters heat water by two degrees (ºF) per minute. All heaters are protected by a 185ºF Hi-limit (high temperature cutout) and by a flow switch which prevents heaters from operating when no water is flowing.

 Bosch dishwashers regulate water temperatures using NTC (Negative Temperature Coefficient)

sensors and electronic controls. As water temperatures increase, NTC resistances decrease. Electronic control modules measure these resistance changes and hold wash and rinse cycles to tight preset temperatures. Older Bosch mechanical dishwashers use thermostats to regulate water temperatures.

 Bosch dishwashers use condensation drying instead of exposed heating elements. Tanks and inner

doors are coated with bitumen (asphalt compound) which absorbs and retains heat from the heated wash and rinse water. A condensation tube is connected to a cold zone in the tank which isn’t covered by bitumen (on right side tank wall for UC/12 & later models and at detergent dispenser on older UC/06 – UC/11 models). Since the cold zone doesn’t retain heat and is cooler than the areas coated with bitumen, moisture condenses around it and exits the dishwasher through the condensation tube. For best results, doors should remain closed until dishwashers have completely finished drying.

V. Theory of Operation

VA. Description of Operation/Cycle (continued)

 Bosch dishwashers continuously filter all water using a triple filter method. A filter screen above the

sump filters out larger particles. A two-stage microfilter in the sump filters out finer particles. This microfilter can easily be removed by customers for cleaning and should be cleaned regularly.

 All currently sold Bosch dishwashers use aqua sensors to save water and energy – many older

models used them as well. These aqua sensors, located in the sump next to the flow-through heater, measure water cleanliness (using a light beam and sensor) and add a pre-wash and/or pre-rinse cycle only if water is dirty. Aqua sensors can save up to 20% of water and energy usage.

 Bosch dishwashers use a four-level water spray as shown below. Water sprays up from the lower

spray arm, down from the overhead sprayer and both up and down from the upper spray arm.

V. Theory of Operation

VA. Description of Operation/Cycle (continued)

 Bosch dishwashers fill with water as shown below.

Normal fill: Water rises to proper level, pushing air in pressure chamber which operates diaphragm.

Overfill: Water rises too high & operates float switch, causing drain pump to remove water from sump.

V. Theory of Operation

VB.

Description of Components

 Circulation pump -- Unlike many dishwashers, Bosch dishwashers use separate circulation and

drain pumps to reduce noise, vibration, space and energy usage. The circulation pump circulates water from the sump into the spray arms.

 Drain pump – The drain pump drains water from the dishwasher. Being a separate pump, it is much

smaller and uses much less energy than a single circulation/drain pump used on other dishwashers.

 Impeller – This part of the circulation pump is what drives water throughout the dishwasher. It uses a

precisely manufactured ceramic disk to reduce friction, yet prevent water leaking. This is the part to replace in rarely used dishwashers if pumps don’t turn.

 Flow-through water heater – Unlike most dishwashers, that rely on exposed heating elements in the

bottom of tanks, Bosch dishwashers use flow-through water heaters (that heat ~ 2ºF/minute). This saves space and allows Tall Tubs (see below), where full-sized plates can be placed in both upper and lower racks.

 NTC – Stands for “Negative Temperature Coefficient”. This temperature sensor in the water heater

provides accurate water temperatures. Its called a “NTC” since its resistance goes down as the water temperature goes up.

 Thermostat – Temperature sensor (and switch) used on older mechanical dishwashers. They open

when temperatures are reached.

 Control module – The brain of electronic dishwashers, it receives water temperature values and

controls the entire wash process. It also contains the test program to help diagnose dishwasher issues.

 Display module – A separate electronic module with a digital display used on some models.  Water inlet valve – Water valve which turns on and off to allow water into the dishwasher.  Water inlet system (with fill switch and diaphragm) -- It insures dishwashers fill properly at various

incoming pressures. It uses a air pressure diaphragm and fill (micro) switch to alert the dishwasher control module when the proper amount of water has filled the dishwasher.

 Float switch – This safety feature shuts down the dishwasher and starts the drain pump if the

dishwasher has gotten excessive water in the base or has overfilled. The drain pump empties out the sump and hoses, not the base (I.e. the drain pump isn’t a base bilge pump).

 Condensation drying – This feature saves energy and enables Bosch dishwashers to have Tall Tubs

– the tallest tubs in the industry, allowing full-sized plate to be placed in both upper and lower racks. Bitumen insulation around doors and tanks holds heat inside tanks, which forces water vapor out of tanks before it can condense onto dishes. The area around the condensation tube exit isn’t coated with bitumen, providing a cold zone for water vapor to condense (instead of on dishes).

 Condensation tube – This is part of the genius of condensation drying. It carries moisture out of the

tank while condensation drying is occuring.

 Detergent & rinse-aid dispenser – This dispenses detergent and rinse-aid at just the right times. In

older dishwashers (service indexes UC/06 & UC/11), it attached to the condensation tube (in the door).

 Aqua sensor (Sensotronic) – This sends a beam of light through water in the heater and measures

how clean the water is. Depending on water cleanliness, rinses are omitted, saving time & energy.

 Microfilter and filter screen – Unlike other dishwashers, the water in Bosch dishwashers is

continuously filtered (100% of the time). The filter screen traps large food chunks while the two or three stage microfilter (depending on model) filters out small food particles.

 Softer bearing – Used to describe circulation pump mounting system using rubber straps to further

reduce noise and vibration (on UC/11 & later models). Sumps and heaters were changed as well as circulation pumps. Older models (UC/06, UC/07 & UC/09) had pumps mounted on rubber bushings.

 Tall tubs – This distinctive feature allows full-sized plates (~ 10”) to be placed in upper racks. The

tallest tanks in the industry is made possible by separate pumps, condensation drying and good use of space in the dishwasher base.

V. Theory of Operation

Dispensers

During each wash program, the wax motor opens twice -once to dispense detergent and again to dispense rinse-aid. The wax motor opens the same way -- the linkages make the separate compartments open.

NOTE: The white plastic linkage 1st opens the detergent dispenser door, then cocks in place to dispense rinse-aid when the wax motor operates the 2nd time. After the 2nd operation, the linkage resets itself so it will open the dispenser detergent door for the next wash program.

Condensation

tube (for vented

dispenser)

V. Theory of Operation

Top Rack Only

Models with the Top Rack Only feature have separate

actuators mounted underneath heater assemblies. The actuator moves a magnetic plunger in the lower rack heater port, diverting water to the top rack.

Heater with top rack actuator

Plunger

Both racks Top rack only

UC/11 heater

UC/06 heater

HINT: Models with water switches and Top Rack Only have the Top Rack Only parts integrated with the water switches. No separate actuators are needed.

Where plunger engages sump

HINT: Do not use softer bearing heater assemblies (UC/11 & later) on older UC/06 models since the sump, circulation pump, base and heater clamps/gaskets have to be replaced as well for the heaters to fit.

HINT: Models with water switches and Top Rack Only have the Top Rack Only parts integrated with the water switches. No separate actuators are needed.

V. Theory of Operation

Door Latches

SHU & SHI dishwashers have door latches linked mechanically to door switches. All other dishwashers (SHV, SHX & SHY) use electronic door switches (microswitches activated by door latches).

187184 ball bearing door latch

with microswitch

419827 door latch for SHI/SHU

(for mechanical linking)

419828 door latch with

microswitch

V. Theory of Operation

Aqua Sensors

The aqua sensor only affects energy usage, eliminating a pre-wash and/or pre-rinse cycle if water is clean. Most customers won’t notice the difference if an aqua sensor fails.

NOTE: Aqua sensors provide ~ 20% energy savings.

HINT: Dishwashers still operate adequately when aqua sensors fail.

HINT: Customers will only notice aqua sensors failing if they see their dishwashers running slightly longer or their electric and water usage getting slightly higher.

NOTE: If water is clean enough, it will be kept for the wash cycle. If not, the aqua sensor directs the dishwasher to add an additional pre-rinse or prewash cycle.

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