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III

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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Summary of Contents for DP840DWG

Page 1: ...DUCATION GROUP PRESENTS KD 10 JOB AID Part No 4322430 1998 DISHWASHERS Servicing and Troubleshooting MODELS DU800DWG DU801DWG DU805DWG DU810DWG DP840DWG DU840DWG DU850DWG DU890DWG DU910PFG DP920PFG DU920PFG GU940SCG GU960SCG GU980SCG ...

Page 2: ...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...

Page 3: ...ELS 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...

Page 4: ...IV NOTES ...

Page 5: ...1 Section One DURAWASH MODELS WITH SOILSETTLERANDTELESCOPINGTOWER THEORY OF OPERATION Console Configuration DU800DWG DU801DWG DU805 DU810DWG DU840DWG DP840DWG DU850DWG DU890DWG ...

Page 6: ...he dishwasher is in the Wash mode 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 ...

Page 7: ... Location 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 Bottom Right side Rear of Tub ...

Page 8: ...etaining screw from the spray arm and removing the split ring seal the pump outlet nut and the support and bearing assembly Fig 1 5 Fig 1 4 Fig 1 5 SPRAY ARM ASSEMBLY SPLIT RING SEAL PUMP OUTLET NUT SUPPORT BEARING RETAINING SCREW 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 ...

Page 9: ... 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 impel ler 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...

Page 10: ...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 heate...

Page 11: ...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 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...

Page 12: ...sing the two 2 retaining tabs at each end from the door frame Removing the Check Valve 1 Remove the toe panel and access panel from the bottom of the dishwasher 2 Remove the hoses from the check valve 3 Remove the Hex head screw securing the check valve to the tub support Fig 1 19 RETAINING SCREW Fig 1 19 Removing the Motor Relay 1 Disconnect the dishwasher from the electrical supply and remove th...

Page 13: ... timer cam and cam follower can now be removed 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 Timer Fig 1 23 Screw Wiring Harness Connector Removing the Switch Assembly Screw 1 Disconnect the dishwasher from the electrical supply and remove the toe pa...

Page 14: ...Use Special Tool Part No 303918 or a 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 ...

Page 15: ...11 Fig 1 28 Fig 1 29 Fig 1 30 Fig 1 31 ...

Page 16: ...t agent dispenser actuator 6 Press the wet agent dispenser actuator into position on the dispenser so the lock ing tabs engage 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 clock wise and close it 10 Slide the upper and low...

Page 17: ... the blue white connector 5 Connect the meter probe to the yellow connector 6 Connect the probe to the grey connector 1 Disconnect wires connectors from the thermal fuse terminals 2 Set VOM meter to read Rx1 scale 3 Measure resistance between thermal fuse terminals 1 Disconnect the wire connectors from the heater element terminals 2 Set VOM meter to read Rx1 scale 3 Measure resistance between heat...

Page 18: ...es 6 Manually advance the timer until the contact opens 1 Remove the front door panel 2 Remove the drip cover 3 Latch the detergent door closed 4 Manually advance the timer through a complete cycle slowly 1 Meter should read 1800 3000Ω 1 Contact CLOSED meter should read 0Ω 2 Contact OPEN meter should read º infinity 1 At 12 o clock position Draw bars will move upward causing the detergent actuator...

Page 19: ...rotection float is stuck in up position 2 Fill valve is inoperable 3 Open timer contacts 1 Air gap if installed is clogged 2 Pump motor is inoperable 3 Open timer contacts 1 Heater element burned out 2 Hi limit thermostat inoperable 3 Open circuit between timer and heater 1 Check to make sure handle link is properly seated in door latch assembly Check that the door switch is opening and closing pr...

Page 20: ...16 TECHNICAL INFORMATION Wiring Diagram Models DU800DWG DU801DWG DU805DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED ALL CONTACTS OPEN ...

Page 21: ...17 Cycle Timing Chart ...

Page 22: ...18 Wiring Diagram Model DU810DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED ALL CONTACTS OPEN ...

Page 23: ...19 Cycle Timing Chart ...

Page 24: ...20 Wiring Diagram Models DU840DWG DP840DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED ALL CONTACTS OPEN ...

Page 25: ...21 Cycle Timing Chart ...

Page 26: ...22 Wiring Diagram Model DU850DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED ALL CONTACTS OPEN ...

Page 27: ...23 Cycle Timing Chart ...

Page 28: ...24 Wiring Diagram Model DU890DWG SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED ALL CONTACTS OPEN ...

Page 29: ...25 Cycle Timing Chart ...

Page 30: ...26 NOTES ...

Page 31: ...lade 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 Fig 2 3 3 When the drain cycle begins the drive mot...

Page 32: ...CH ASSEMBLY FILL VALVE MOTOR RELAY FLOAT SWITCH OPERATING THERMOSTAT Attached to bottom of pump housing HI LIMIT THERMOSTAT PUMP AND MOTOR ASSEMBLY HEATER DETERGENT AND RINSE AID DISPENSER ASSEMBLY PROGRAM SWITCHES INDICATOR LIGHTS ...

Page 33: ...ment 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...

Page 34: ...tuned resonator NOTE A small container will be required to catch water from the drain hose after removal 6 Remove the pump and motor assembly by pulling up through the inside of the tub Fig 2 9 Fig 2 9 Fig 2 7 Clamp Shown Rotated Inward 90 Check Valve Drain Hose Clamp Drain Hose Fig 2 8 Servicing the Operating Thermostat The operating thermostat is secured to the bottom of the pump housing Fig 2 1...

Page 35: ...et 5 Remove the existing door insulation Access to the detergent and rinse aid dispensers is now possible Fig 2 11 1 Disconnect the dishwasher from the electrical supply 2 Disconnect the end of the door springs from the door spring tension adjustment holes in the frame runner 3 Open the dishwasher door and remove the eight 8 T 15 Torx screws securing the inner door panel from the door frame Fig 2 ...

Page 36: ...g 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 14 Fig 2 15 ...

Page 37: ...erflow protection float is stuck in up position 2 Fill valve is inoperable 3 Open timer contacts 1 Air gap if installed is clogged 2 Pump motor is inoperable 3 Open timer contacts 1 Heater element burned out 2 HI limit thermostat inoperable 3 Open circuit between timer and heater 1 Check to make sure handle link is properly seated in door latch assembly Check that the door switch is opening and cl...

Page 38: ...34 TECHNICAL INFORMATION Model DU910PFG Wiring Diagram SCHEMATIC SHOWN WITH DOOR SWITCHES CLOSED ALL CONTACTS OPEN ...

Page 39: ...s HEAT DRY Steps 30 44 FILL Steps 1 9 14 23 48 WASH Steps 2 7 10 12 15 20 24 28 49 DRAIN Steps 8 13 21 22 29 50 WATER HEATING Steps 6 7 18 19 23 24 NO HEAT DRY Switch H OPEN Harness Terminal Block Wire End Black White ...

Page 40: ...36 Cycle Timing Charts ...

Page 41: ... free to move up and down Check that the overfill switch in opening and closing properly 2 Check for continuity between contacts on fill valve 3 Check for 110VAC between P2 5 and P12 3 1 Follow air gap manufacturer s direction for cleaning 2 Disconnect pump motor from wiring harness and check for continuity between V BU V GY and V Y 3 Check for 110VAC between P10 and P3 P10 and P5 and P10 and P4 1...

Page 42: ...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 Switched L1 to Motor Common Wire Color O GY GY O O BK LBU BR BU Y GY W R W V T R BK P9 BU BK ...

Page 43: ...39 STRIP CIRCUITS ...

Page 44: ...40 STRIP CIRCUITS CYCLE TIMING CHART ...

Page 45: ...icator is illuminated at the end of the cycle During a cycle in which sani rinse has been selected the target thermal hold temperature for the sani rinse option must be satisfied and maintained If this condition is not satisfied because the final rinse thermal hold default time elapsed or power to the dishwasher was lost at any time during the remainder of the cycle that follows due to a door open...

Page 46: ... the resistance of the thermistor is always less than 45 K OHMS and would not trigger the clean LED 7 The wash and drain auxiliary windings are only on when the motor is being started When the control has determined that the motor has been started satisfactorily the auxiliary winding will be turned off 8 Entering the key sequence high temp wash or power scour air dry high temp wash or power scour ...

Page 47: ... 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 Fig 3 1 3 When the drain cycle begins the...

Page 48: ...r tube from the plastic knob on the back of the tub by pressing down on the nozzle Fig 3 5 3 Pull the securing tabs of the clamp holding the internal water feed tube to the pump outlet nozzle and remove the clamp Fig 3 6 4 Rotate the lower end of the tube either left or right off the pump nozzle Fig 3 7 Fig 3 4 Securing Tab Fig 3 5 Fig 3 7 Fig 3 6 Securing Tab Securing Tab Internal Water Tube Secu...

Page 49: ...ystem 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 swi...

Page 50: ...ching tabs in the wet agent cap opening Remove wet agent dispenser assembly Fig 3 12 6 Remove wet agent dispenser actuator by spreading the two 2 locking tabs Fig 3 13 7 Remove the actuator slide from the wet agent dispenser actuator 8 Remove the diaphragm spring and diaphragm 9 Use a screwdriver to gently release the lower tab and remove the detergent door actuator assembly As you do note the pos...

Page 51: ...47 Fig 3 12 Fig 3 13 Fig 3 14 ...

Page 52: ...ctuator into position on the dispenser so the lock ing tabs engage 6 Install the actuator slide into the wet agent dispenser actuator 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 3 12 8 Install the seal on the wet agent cap 9 Insert the wet agent cap Turn it clock wise and close it 10 Install the draw...

Page 53: ... the resistance of the thermistor is always less than 45 K OHMS and would not trigger the clean LED 7 The wash and drain auxiliary windings are only on when the motor is being started When the control has determined that the motor has been started satisfactorily the auxiliary winding will be turned off 8 Entering the key sequence high temp wash or power scour air dry high temp wash or power scour ...

Page 54: ...tion float is free to move up and down Check that the overfill switch in opening and closing properly 2 Check for continuity between contacts on fill valve 3 Check for 110VAC between P2 5 and P12 3 1 Follow air gap manufacturer s direction for cleaning 2 Disconnect pump motor from wiring harness and check for continuity between V BU V GY and V Y 3 Check for 110VAC between P10 and P3 P10 and P5 and...

Page 55: ...ser 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 Switched L1 to Motor Common Wire Color O GY GY O O BK LBU BR BU Y GY W R W V T R BK P9 BU BK ...

Page 56: ...52 STRIP CIRCUITS ...

Page 57: ...53 STRIP CIRCUITS CYCLE TIMING CHART ...

Page 58: ...icator is illuminated at the end of the cycle During a cycle in which sani rinse has been selected the target thermal hold temperature for the sani rinse option must be satisfied and maintained If this condition is not satisfied because the final rinse thermal hold default time elapsed or power to the dishwasher was lost at any time during the remainder of the cycle that follows due to a door open...

Page 59: ... and a lower panel are cut and finished as described below use the materials in the Dishwasher Custom Panel Accessory Kit to install them by following the installation instructions Custom Panel Dimensions NOTE A thickness actual 7 32 can be used for wood panels If using thicker material edges must be routed to 7 32 as shown in box below 7 32 Max 1 Min Required on top and bottom edges 18 21 32 22 1...

Page 60: ...notches 2 Using the end of a flat bladed screwdriver push in on the three 3 tabs to lock the mounting strip into place 3 Install the J strips by removing the protective strip from the adhesive backing and carefully positioning the J strips over the left and right door frames Fig 4 3 Peel off the protective film from the outside of the J strips after in stalling 4 Tip the custom door panel as shown...

Page 61: ...f the access panel Press firmly on the forward edge of the retainer to snap it into place Fig 4 10 10 Refer to Fig 4 1 on page 71 Install the ac cess panel assembly to the dishwasher by aligning the slots in the back flange of the extension over the two 2 screw heads pro truding from the tow panel Slide the access panel downward and tighten the screws IMPORTANT Be sure the door panel is inserted i...

Page 62: ...n tests again fail the heavy duty springs supplied must be used 3 Close and lock the dishwasher door Remove a spring from one side by releasing the lower hook from the adjustment slot first then disen gaging the upper hook from the door hinge bracket Fig 4 11 4 Install a heavy duty spring Insert the smaller hook through the door hinge bracket first then engage the larger hook in the first notch of...

Page 63: ...stalled position 5 Place the floor mounting brackets so the top of the bracket hooks over the top of the dishwasher side brace towards the back of the unit Fig 4 14 6 Mark the location of the mounting holes on the floor 7 Remove the dishwasher and drill two 2 holes on each side of the dishwasher location 8 Position the dishwasher in its final installed position and install the floor mounting brack...

Page 64: ...60 NOTES ...

Page 65: ...V ...

Page 66: ...VI ...

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