CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS KD-10 1998 DISHWASHERS Servicing and Troubleshooting MODELS DU800DWG DU801DWG DU805DWG DU810DWG DP840DWG DU840DWG DU850DWG DU890DWG DU910PFG DP920PFG DU920PFG GU940SCG GU960SCG GU980SCG JOB AID Part No.
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.
TABLE OF CONTENTS 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 . . . . . . . . . . .
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Section One DURAWASH MODELS WITH SOIL SETTLER AND TELESCOPING TOWER 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.
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.
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 fitting. 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.
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 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.
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.
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) Fig. 1-15 5. Disconnect the water lines from the water inlet valve. 6.
Removing the Check Valve 1. Remove the toe panel and access panel from the bottom of the dishwasher. RETAINING SCREW 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.
Wiring Harness Connector 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 the timer terminals. (Fig. 1-23) Screw Screw 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. Fig.
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.
Fig. 1-28 Fig. 1-29 Fig. 1-31 Fig.
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.
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 Motor Start Relay TESTING PROCEDURE 1.
COMPONENT SCHEMATIC Timer Motor TESTING PROCEDURE 1. 2. 3. Timer 1. 2. 3. 4. 5. 6. Dispenser Mechanism 1. 2. 3. 4. RESULTS Disconnect the Wiring harness connector from the timer assembly. Set VOM meter on the Rx1 scale. Measure resistance between timer motor terminals. 1. Meter should read 1800 - 3000Ω. Disconnect the wiring harness connector from the timer assembly. Set VOM meter on the Rx1 scale. Connect one probe to contact 31. (Tan) Connect the other probe to the timer contact to be tested.
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.
TECHNICAL INFORMATION Wiring Diagram Models DU800DWG, DU801DWG, DU805DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED, ALL CONTACTS OPEN 16
Cycle Timing Chart 17
Wiring Diagram Model DU810DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED, ALL CONTACTS OPEN 18
Cycle Timing Chart 19
Wiring Diagram Models DU840DWG, DP840DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED, ALL CONTACTS OPEN 20
Cycle Timing Chart 21
Wiring Diagram Model DU850DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED, ALL CONTACTS OPEN 22
Cycle Timing Chart 23
Wiring Diagram Model DU890DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED, ALL CONTACTS OPEN 24
Cycle Timing Chart 25
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Section Two POWER CLEAN FILTER MODELS WITH TOWER WATER FEED Models: DU910PFG, DP920PFG, DU920PFG THEORY OF OPERATION Console Configuration Model DU910PFG Models DP920PFG, DU920PFG Fig. 2-1 POWER CLEAN FILTER 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.
COMPONENT ACCESS INDICATOR LIGHTS TIMER DETERGENT AND RINSE AID DISPENSER ASSEMBLY PROGRAM SWITCHES HEATER LATCH ASSEMBLY FILL VALVE PUMP AND MOTOR ASSEMBLY MOTOR RELAY OPERATING THERMOSTAT (Attached to bottom of pump housing) FLOAT SWITCH 28 HI LIMIT THERMOSTAT
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. (Fig. 2-5) From inside the tub: 4. Remove the lower dish rack. Fig. 2-5 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.
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. 2-7) 4. Remove the drain hose and clamp from the check valve and unscrew the check valve from the pump. (Fig. 2-8) 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.
ACCESSING COMPONENT INSIDE THE DISHWASHER DOOR 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. 2-11) 2. Remove the access panel assembly by sliding it upward to clear the loosened screws. (Fig. 2-11) 3. Remove the two (2) screws from the bottom of the outer door panel. (Fig. 2-11) 4.
Replacing the Spring Loaded Locking Tab The inner door panel is held in place by a spring loaded locking tab located on the door frame rail, just below the console. (Fig. 2-14) To remove this assembly, remove the spring and slide the locking tab back until the locating tab is in the key hole. (Fig. 2-15) Then lift the locking tab up. To replace the assembly, reverse this procedure. Locking Tab Assembly Fig. 2-15 Fig.
TROUBLESHOOTING GUIDE Model DU910PFG 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.
TECHNICAL INFORMATION Model DU910PFG Wiring Diagram SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED, ALL CONTACTS OPEN 34
WASH (Steps 2 - 7, 10 - 12, 15 - 20, 24 - 28, 49) Strip Circuits HEAT DRY (Steps 30 - 44) NO HEAT DRY (Switch H OPEN) WATER HEATING (Steps 6 - 7, 18 - 19, 23 - 24) DRAIN (Steps 8, 13, 21 - 22, 29, 50) FILL (Steps 1, 9, 14, 23, 48) Harness Terminal Block (Wire End) Black White 35
Cycle Timing Charts 36
TROUBLESHOOTING GUIDE Models DP920PFG & DU920PFG 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.
TECHNICAL INFORMATION Models DP920PFG & DU920PFG WIRING DIAGRAM CONNECTOR PIN OUT Pin No. P1 P2-1 P2-2 P2-3 P2-4 P2-5 P3 P4 P5 P6 P7 P8 P9 P10 38 DESCRIPTION Ribbon Cable to User Interface Pressure Switch (Soil Sense) Thermistor/Thermostat Detergent Dispenser Rinse Agent Dispenser Fill Valve Motor Main Winding Motor Auxiliary Winding - Wash Motor Auxiliary Winding - Drain Switch L1 to Heater AC Neutral L1 Switched L1 to Vent, Fill Valve, Dual Dispenser & Pressure Sw.
STRIP CIRCUITS 39
STRIP CIRCUITS CYCLE TIMING CHART 40
CYCLE TIMING CHART NOTES Note 1: Pre-Wash Sense Interval Pressure switch contact closure at any time during this interval causes the cycle to jump to interval 37. Immediately. For the normal cycle, the heater is “off” during this interval. For the heavy and pots-n-pans cycles the heater is “on” during this interval. The power scour option changes this interval to a 16 minute heated wash interval for all 3 cycles (normal, heavy and pots-n-pans).
DIAGNOSTICS AND SALES DEMO TIMING CHART INTERVAL 11 10 9 8 7 6 5 4 3 1 S T A N D B Y POTS & PANS HEAVY NORMAL LOW ENERGY CHINA QUICK WASH RINSE ONLY POWER SCOUR HIGH TEMP WASH SANI RINSE AIR DRY CANCEL DELAY 2 HR DELAY 4 HR DELAY 6 HR WASHING LED ADD-A-DISH LED WATER HEATING LED NOTE 4 SENSING LED NOTE 3 RINSING LED DRYING LED CLEAN LED NOTE 5 CONTROL LOCKED LED SANI COMPLETE LED 2 S T A N D B Y (17) (17) (17) (17) (17) (17) (17) (17) 6 MINUTES SECONDS 0 2 6 2 TH 2 5 3 1 55 6 6 VE
Section Three POWER CLEAN FILTER MODELS WITH INTERNAL WATER FEED Models: GU940SCG, GU960SCG, GU980SCG THEORY OF OPERATION Console Configurations Model GU940SCG Model GU960SCG Model GU980SCG POWER CLEAN FILTER 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.
COMPONENT ACCESS 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. (Fig. 3-4) If the pump and motor assembly must be removed for servicing, the vertical water tube must be disconnected from the pump cover as follows: 1. Remove the upper dish rack. Securing Tab 2.
Servicing the Soil Sensing System The Soil Sensing System consists of a pressure sensitive switch connected to the dishwasher pump base. (Fig. 3-8) The system detects excessive amounts of food soils during the sensing portion of the wash cycle and signals the electronic control board to either terminate the wash cycle and initiate drain to flush soils from the system or skip certain parts of the heavy soil cycle. The pressure switch is connected to the pump base through a plastic hose.
Dishwasher Dispenser Disassembly 1. Remove the drawbar spring. (Fig. 3-10) 2. Grasp the lower edge of the drawbar and pull it away from the panel stop. Slide the drawbar down until the drawbar holes align with the locking tabs, then remove the drawbar. Note how the locating tabs behind the drawbar align with their respective locating holes in the drawbar. (Fig. 311) 3. Turn the wet agent cap and seal assembly counterclockwise and remove it. (Fig. 3-12) 4. Remove the seal from the cap. 5.
Fig. 3-12 Fig. 3-13 Fig.
Dishwasher Dispenser Assembly 1. Assembly the slide and slide spring to the detergent door actuator. (Fig. 3-15) 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. 3-14) 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.
DIAGNOSTICS AND SALES DEMO TIMING CHART INTERVAL 11 10 9 8 7 6 5 4 3 1 S T A N D B Y POTS & PANS HEAVY NORMAL LOW ENERGY CHINA QUICK WASH RINSE ONLY POWER SCOUR HIGH TEMP WASH SANI RINSE AIR DRY CANCEL DELAY 2 HR DELAY 4 HR DELAY 6 HR WASHING LED ADD-A-DISH LED WATER HEATING LED NOTE 4 SENSING LED NOTE 3 RINSING LED DRYING LED CLEAN LED NOTE 5 CONTROL LOCKED LED SANI COMPLETE LED 2 S T A N D B Y (17) (17) (17) (17) (17) (17) (17) (17) 6 MINUTES SECONDS 0 2 6 2 TH 2 5 3 1 55 6 6 VE
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.
TECHNICAL INFORMATION Model DU940SCG, DU960SCG, DU980SCG WIRING DIAGRAM CONNECTOR PIN OUT Pin No. P1 P2-1 P2-2 P2-3 P2-4 P2-5 P3 P4 P5 P6 P7 P8 P9 P10 51 DESCRIPTION Ribbon Cable to User Interface Pressure Switch (Soil Sense) Thermistor/Thermostat Detergent Dispenser Rinse Agent Dispenser Fill Valve Motor Main Winding Motor Auxiliary Winding - Wash Motor Auxiliary Winding - Drain Switch L1 to Heater AC Neutral L1 Switched L1 to Vent, Fill Valve, Dual Dispenser & Pressure Sw.
STRIP CIRCUITS 52
STRIP CIRCUITS CYCLE TIMING CHART 53
CYCLE TIMING CHART NOTES Note 1: Pre-Wash Sense Interval Pressure switch contact closure at any time during this interval causes the cycle to jump to interval 37. Immediately. For the normal cycle, the heater is “off” during this interval. For the heavy and pots-n-pans cycles the heater is “on” during this interval. The power scour option changes this interval to a 16 minute heated wash interval for all 3 cycles (normal, heavy and pots-n-pans).
Section Four INSTALLATION CONSIDERATIONS INSTALLING CUSTOM PANEL ACCESSORY KIT Custom Color Panels: Black White Almond P/N 675775 P/N 675776 P/N 675777 Installation Instructions In many instances, customers want to integrate the undercounter dishwasher appearance with overall kitchen design by installing panels of wood matching that used in the cabinets.
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. 4-1, inset) Set the door panel aside; it will be replaced with a new custom panel. 5. Remove the existing door insulation and discard. Installing Custom Panels 1. Slip the top edge of the mounting strip up under the tabs at the bottom of the door frame so that the strip rests on the lower frame flange. Make sure the strip seats as shown in Figure 4-2.
11. Reinstall the two (2) access panel screws removed earlier to secure the access panel to the dishwasher. Tighten the right screw first, then the left. IMPORTANT Be sure the door panel is inserted into the rear channel. (Fig. 4-5) Access Panel Extension (Fig. 4-5) Access Panel (Fig. 4-7) Insulation (Fig. 4-6) Retainer Trim Strip (Fig. 4-8) 6. Place the access panel front side down.
Installing Heavy Duty Door Springs Standard door springs may need to be replaced by heavy duty springs designed to compensate for the increased weight of the door resulting from the installation of custom panels. Perform the following tests to determine whether the heavy duty springs need to be installed. Heavy Duty Door Spring Kit: Kit contains two (2) heavy duty door springs and instruction sheet.
INSTALLING THE FLOOR MOUNTING KIT Fig. 4-12 KIT CONTENTS (P/N 4378968): 2 1 P/N 9743463 Brackets (Fig. 4-12) P/N 4378974 Instruction Sheet INSTALLATION INSTRUCTIONS 1. Loosen the two (2) screws below the access panel and remove the two (2) screws above the access panel. (Fig. 4-13) Fig. 4-13 2. Carefully slide the access panel upward and off the two (2) screws below the access panel. 3. Remove the two (2) lower screws securing the toe panel to remove the toe panel from the dish washer. 4.
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