Whirlpool KD-11 User Manual

CONSUMER SERVICES TECHNICAL

EDUCATION GROUP PRESENTS

1998 WHIRLPOOL

POWER CLEAN

FILTER

KD-11

DISHWASHERS

JOB AID

Part No. 4322451L

INTRODUCTION

This Job Aid, provides specific information for the installation, service and repair of 1998 Whirlpool Dishwashers equipped with Power Clean Filter pump and motor modules.

“1998 WHIRLPOOL POWER CLEAN FILTER DISHWASHERS

most recent information on design, features, troubleshooting, service and repair procedures.

“1998 WHIRLPOOL POWER CLEAN FILTER DISHWASHERS

,” has been compiled to provide the

,” (Part No. 4322451)

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.

ADDITIONAL INFORMATION

Complete instructions on the disassembly and servicing of the Power Clean Filter Module are available in the Job Aid, “POWER CLEAN FILTER PUMP MOTOR ASSEMBLY SERVICE,” Part No.

4322455. This Job Aid, and the accompanying video tape, Part No. 4322456V, have been revised to include specific details on the most recent version of this dishwasher pump and motor assembly.

CORPORATION

WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY

FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE

OTHER THAN AUTHORIZED SERVICE TECHNICIANS.

TABLE OF CONTENTS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

SECTION ONE

THEORY OF OPERATION

Console Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump and Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION TWO

COMPONENT ACCESS

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removing Access and Outer Door Panels . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removing the Heater Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Replacing the Heater Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Servicing the Vertical Water Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removing the Pump and Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7

Servicing the Operating Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Servicing the Soil Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Removing the Inside Door Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Dishwasher Dispenser Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION THREE

DIAGNOSIS AND TROUBLESHOOTING

Troubleshooting Guide (Model DU910PFG) . . . . . . . . . . . . . . . . . . . . . . . 11

Troubleshooting Guide (Models DP920PFG, DU920PFG

GU940SCG, GU960SCG, GU980SCG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Component Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION FOUR

TECH TIPS

Wiring Diagram and Cycle Timing Chart (Model DU910PFG). . . . . . . . . . 15

Strip Circuits (Model DU910PFG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring Diagram (Model DP920PFG, DU920PFG, GU940SCG,

GU960SCG, GU980SCG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 18

Cycle Timing Chart (Model DP920PFG, DU920PFG,

GU940SCG, GU960SCG, GU980SCG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cycle Timing Chart Notes (Model DP920PFG, DU920PFG,

GU940SCG, GU960SCG, GU980SCG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Diagnostic and Sales Demo Timing Chart (Model DP920PFG,

DU920PFG, GU940SCG, GU960SCG, GU980SCG) . . . . . . . . . . . . . . . . 21

Strip Circuits (Model DP920PFG, DU920PFG, GU940SCG,

GU960SCG, GU980SCG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Custom Door Panel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Floor Mount Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Model and Serial Number Designators . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Service Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

III

Section One

THEORY OF OPERATION

1998 POWER CLEAN FILTER MODELS

Console Configuration

Model DU910PFG

Models DP920PFG, DU920PFG

Model GU940SCG

Model GU960SCG

Model GU980SCG

PUMP AND MOTOR OPERATION

1. Once the tub has filled with hot water the motor begins to rotate forcing the water up through the pump chamber and out through the spray arms. Two spray jets on the underside of the lower spray arm direct water down onto the fine mesh screen of the pump housing to clear soils that may collect there during the wash cycle.

2. As water and soils return to the lower pump area, the chopper blade grinds the particles into smaller sizes that then pass through the perforated plate into the upper chamber of the pump. The pump impeller causes the soil ladened water to be lifted and moved to the outer edges of the pump chamber where they are forced into the separator. Clean water is then forced up through the spray arms and fine mesh screen.

3. When the drain cycle begins, the drive motor changes direction. This relieves the pressure on the two check balls, opening the drain system.

4. Water is pumped from the tub carrying soils from the separator into the drain sump of the pump.

5. Soiled water is pumped out of the dishwasher through the check valve and drain hose.

PROGRAM SWITCHES

Section Two

COMPONENT ACCESS

COMPONENT LOCATION

INDICATOR

LIGHTS

TIMER

DETERGENT

AND RINSE AID

DISPENSER

ASSEMBLY

LATCH

ASSEMBLY

FILL

VALVE

MOTOR

RELAY

FLOAT

SWITCH

OPERATING

THERMOSTAT

(Attached to bottom

of pump housing)

HEATER

PUMP AND

MOTOR

ASSEMBLY

HI LIMIT

THERMOSTAT

Removing Access and Outer Door Panels

1. Loosen but do not remove the two (2) toe panel screws below the access panel. Remove and set aside the two (2) screws above the access panel.

(Fig. 2-1)

2. Remove the access panel assembly by sliding it upward to clear the loosened screws.

3. Remove the two (2) screws from the bottom of the outer door panel.

4. Pull the bottom of the outer door panel outward and slide it down approximately ¼” to ½”. The panel will then be free for removal. (Fig. 2-1, inset)

5. Remove the existing door insulation. Access to the detergent and rinse aid dispensers is now possible.

(Fig. 2-1)

Fig. 2-1

Removing the Heater Element

From beneath the cabinet:

1. Remove the front access panel. (See Removing the Outer Door Panel)

2. Pull the spade connectors off the heater element terminals.

3. Unscrew the two (2) nuts securing the heater element to the bottom of the tub.

From inside the tub:

4. Remove the lower dish rack.

5. Remove the lower spray arm.

6. Slide the metal disks from the metal clips securing the left and right sides of the heater element.

7. Carefully lift the heater element from the unit.

Element Retaining Nuts (2)

Fig. 2-2

(Fig. 2-2)

Replacing the Heater Element

From inside the tub:

1. Carefully place the terminal ends of the heater element through the two (2) holes at the

bottom rear of the cabinet.

2. Slide the metal disks into the clips to secure the left and right sides of the heater element.

3. Replace the lower spray arm.

4. Replace the lower dish rack.

From underneath the cabinet:

5. Secure the heater element in place with two (2) nuts. Be sure the element is seated firmly

against the tub.

6. Slide the spade connectors onto the heater element terminals.

7. Replace the front access panel.

Servicing the Vertical Water Tube

The vertical water tube in these models delivers water to the spray arm mounted underneath the upper dish rack and a smaller spray arm mounted at the top of the dishwasher tub.

If the pump and motor assembly must be removed for servicing, the vertical water tube must be disconnected from the pump cover as follows:

(Fig. 2-3)

1. Remove the upper dish rack.

2. Dislodge the upper portion of the vertical water tube from the plastic knob on the back of the tub by pressing down on the nozzle.

3. Pull the securing tabs of the clamp holding the internal water feed tube to the pump outlet nozzle and remove the clamp.

4. Rotate the lower end of the tube either left or right off the pump nozzle.

Securing

Clamp

(Fig. 2-4)

(Fig. 2-5)

(Fig. 2-6)

Securing

Tab

Fig. 2-6-3

PUSH

DOWN ON

NOZZLE

Fig. 2-4

PULL

Securing

Tab

Internal

Water

Securing

Tab

O-Ring

Tube

Fig. 2-5

Fig. 2-6

-- NOTE --

Do not pull the vertical water tube forward or up in an attempt to remove it from the pump nozzle.

The smaller spray arm at the top of the tub does not need to be removed

to service the pump and motor assembly.

Removing the Pump Motor Assembly

1. Unscrew and remove the nozzle cap and remove

the nozzle bearing and spray arm.

2. Disconnect the wiring harness from the motor

harness plug.

3. Rubber clamps secure the pump and motor

assembly to the tub. Rotate these inward 90°.

(Fig. 2-8)

(Fig. 2-7)

SPRAY ARM

Fig. 2-7

NOZZLE

CAP

4. Remove the drain hose and clamp from the

NOZZLE BEARING

check valve and unscrew the check valve from the pump.

(Fig. 2-9)

5. Remove the tuned sound absorber. Use an open-end wrench to loosen the shaft from the

motor. Do not loosen the sound absorber by torquing on the large tuned resonator.

-- NOTE --

A small container will be required to catch water from the drain hose after removal.

Check Valve

Drain Hose

Clamp

Tuned Sound

Absorber

Clamp

Shown Rotated

Inward 90°

Drain Hose

Fig. 2-8

Fig. 2-9

6. Remove the pump and motor assembly by pulling up through the inside of the tub.

Fig. 2-10

(Fig. 2-10)

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