Bosch SHEM63W55N Operating instructions

Concerning this document................................................................5
1.1 Important information.......................................................................................5
1.1.1 Purpose..............................................................................................5
1.1.2 Target group.......................................................................................5
1.1.3 Other applicable documents ................................................................5
1.2 Explanation of symbols ....................................................................................5
1.2.1 Danger levels......................................................................................5
1.2.2 Hazard symbols..................................................................................5
1.2.3 Structure of the warnings.....................................................................6
1.2.4 General symbols.................................................................................6
Safety.........................................................................................................7
2.1 Qualification ....................................................................................................7
2.2 General safety instructions...............................................................................7
2.2.1 All domestic appliances .......................................................................7
2.3 Measures after each repair ..............................................................................8
Design and function.............................................................................9
3.1 Operating and power modules..........................................................................9
3.1.1 Operating modules..............................................................................9
3.1.2 Power modules...................................................................................9
3.1.3 Adding PTC to power module pc boards...............................................9
3.2 Dispensers....................................................................................................10
3.2.1 Dispenser operation ..........................................................................10
3.2.2 Rinse aid sensor ...............................................................................11
3.3 Heat pump ....................................................................................................12
3.3.1 Heat pump basics .............................................................................12
3.3.2 Heat pump operation.........................................................................13
3.3.3 Heat pump heater terminal cover .......................................................13
3.4 Drain pump ...................................................................................................14
3.4.1 Drain pump basics ............................................................................14
3.4.2 Drain pump operation........................................................................14
3.4.3 Solving installation issues..................................................................14
3.5 Door latches..................................................................................................16
3.5.1 General information...........................................................................16
3.5.2 Hall effect door sensor.......................................................................16
3.5.3 Unintentional operation......................................................................16
3.6 Door springs...................................................................................................17
3.6.1 Door spring operation .........................................................................17
3.6.2 Door spring changes for Push to Open / Auto Door Open .....................17
3.6.3 Using wrong toe panel screws.............................................................18
3.7 Water inlet - condensation system....................................................................19
3.7.1 Water inlet system ..............................................................................19
3.7.2 Water valve........................................................................................19
3.7.3 Valve holder.......................................................................................20
3.7.4 Water valve installation issues.............................................................20
3.8 Sump .............................................................................................................22
3.8.1 Sump basics ......................................................................................22
3.8.2 Suction cap ........................................................................................22
3.8.3 Drain pump cover ...............................................................................22
3.8.4 Drain check valve ...............................................................................22
3.8.5 Sump filters........................................................................................23
3.9 Water switch...................................................................................................24
3.10 Safety systems ...............................................................................................25
3.10.1 Float ..................................................................................................25
3.10.2 Overflow channel................................................................................25
3.10.3 Water inlet valve.................................................................................25
3.11 Aqua sensor ...................................................................................................26
3.12 Drain hose......................................................................................................27
3.13 Toe panels .....................................................................................................28
3.13.1 1-piece slotted toe panels ...................................................................28
3.13.2 1-piece toe panels with brackets..........................................................28
3.13.3 Using wrong toe panel screws.............................................................29
3.14 Base ..............................................................................................................30
3.15 Tub ................................................................................................................31
3.16 Water spray system ........................................................................................32
3.17 Serial label location and information.................................................................33
3.17.1 Locating and using serial labels...........................................................33
3.17.2 Understanding the 18-digit factory serial # ...........................................33
3.17.3 Using rear labels when door labels are missing ....................................33
Fault Diagnosis ....................................................................................35
Error code / fault display / signal ......................................................................35
E:01 error code...............................................................................................35
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E:02 error code .............................................................................................35
E:03 error code .............................................................................................35
E:04 error code .............................................................................................35
E:05 error code .............................................................................................35
E:06 error code .............................................................................................35
E:07 error code .............................................................................................36
E:08 error code .............................................................................................36
E:09 error code .............................................................................................36
E:10 error code .............................................................................................36
E:11 error code .............................................................................................36
E:12 error code .............................................................................................36
E:13 error code .............................................................................................36
E:14 error code .............................................................................................36
E:15 error code .............................................................................................37
E:16 error code .............................................................................................37
E:17 error code .............................................................................................37
E:18 error code .............................................................................................37
E:19 error code .............................................................................................37
E:20 error code .............................................................................................37
E:21 error code .............................................................................................38
E:22 error code .............................................................................................38
E:23 error code .............................................................................................38
E:24 error code .............................................................................................38
E:25 error code .............................................................................................38
E:26 error code .............................................................................................38
E:27 error code .............................................................................................39
E:28 error code .............................................................................................39
E:29 error code .............................................................................................39
E:30 error code .............................................................................................39
E:31 error code .............................................................................................39
E:32 error code .............................................................................................39
Condensation / Humidity / Leakage ................................................................40
Suds.............................................................................................................40
Water leaks from top or sides of door..............................................................40
Excess pressure forces water past door..........................................................40
Leakage on dispenser when using liquid dishwasher detergent........................40
Malfunction ...................................................................................................40
Dishwasher won't run.....................................................................................40
Dishwasher won't restart after door has been opened......................................43
Wash cycle abruptly stops..............................................................................43
Wash cycle completed prematurely..................................................................44
Dishwasher doesn’t rinse or dry properly ..........................................................47
Dishwasher shuts off.......................................................................................48
Can't select wash cycle ...................................................................................48
Dishwasher won't drain ...................................................................................48
Dishwasher drains intermittently.......................................................................50
Dishwasher drains continually..........................................................................50
Dishwasher won't fill with water........................................................................51
Dishwasher runs without heating......................................................................51
Water switch runs continually...........................................................................52
Aqua sensor doesn't run during wash cycle ......................................................53
Dispenser not operating ..................................................................................53
Rinse aid LED is lit..........................................................................................54
Supply voltage issues......................................................................................54
Mechanical damage........................................................................................55
Fascia panel is discolored or scratched ............................................................55
Rust spots on stainless steel (ss) .....................................................................55
Noise .............................................................................................................55
Dishes rattling.................................................................................................55
Dishwasher “beeps” during wash cycle.............................................................55
Odour.............................................................................................................55
Food debris ....................................................................................................55
Standing water in bottom of dishwasher ...........................................................56
Other..............................................................................................................56
Door doesn't open or close properly.................................................................56
Result problem ...............................................................................................56
Wash cycle runs a long time ............................................................................56
Dishes still dirty...............................................................................................57
Dishes aren’t dry.............................................................................................57
Plastic items aren't dry or have water stains .....................................................58
Water stains on glassware...............................................................................58
Cloudy glasses ...............................................................................................59
Rust spots on stainless steel (ss) items ............................................................59
Detergent residue ...........................................................................................59
Residue on tub ...............................................................................................59
Test ...........................................................................................................61
5.1 Testing components........................................................................................61
5.2 Identifying flashing LED error codes.................................................................62
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5.2.1 Clarifying LED positions ....................................................................62
5.2.2 Flashing Add Rinse Aid (far right) LED ...............................................62
5.2.3 Flashing Clean (middle) LED .............................................................62
5.2.4 Flashing Clean & Add Rinse Aid LED's...............................................62
5.2.5 Flashing Sanitized (far left) LED.........................................................62
5.2.6 Flashing Sanitized & Add Rinse Aid LED's..........................................62
5.2.7 Flashing Sanitized & Clean LED's ......................................................63
5.2.8 All three LED's flashing .....................................................................63
5.2.9 Other flashing LED's .........................................................................63
5.2.10 Flashing Rinse Aid and Add Salt displays...........................................63
5.3 Customer diagnosing information ...................................................................64
5.3.1 Reasons for end of cycle tone (“beep”)...............................................64
5.3.2 Error codes seen by customers..........................................................64
5.3.3 Customer displays ............................................................................64
5.4 Dishwasher won’t run or stops with far right (Sanitized) light on........................65
5.4.1 E:01 error code.................................................................................65
5.4.2 E:02 error code.................................................................................65
5.4.3 Door didn't close properly ..................................................................65
5.4.4 Drain installation / maintenance issues...............................................66
5.5 Clearing error code E24 drain obstructions......................................................67
5.5.1 Resetting power modules ..................................................................67
5.5.2 Correcting overly high drain connections ............................................67
5.5.3 Clearing drain obstructions ................................................................67
5.5.4 Loosening tight heat pump impellers ..................................................68
5.6 Error code E25 for loose drain pump covers....................................................69
5.7 Heat pump terminal measurements ................................................................70
5.7.1 Protection of heater if there’s no water ...............................................71
5.8 Drain pump terminal measurements ...............................................................72
5.9 Water switch terminal measurements .............................................................73
Repair ......................................................................................................74
6.1 Repair access chart.......................................................................................74
6.1.1 Front access.....................................................................................74
6.1.2 Left side access ................................................................................74
6.1.3 Bottom front access ..........................................................................75
6.2 Disconnecting and pulling out dishwashers .....................................................76
6.2.1 Disconnecting and pulling out dishwashers.........................................76
6.3 Flipping dishwashers.......................................................................................77
6.4 Replacing outer doors .....................................................................................79
6.5 Replacing fascia panels...................................................................................80
6.6 Replacing operating modules...........................................................................81
6.6.1 Removing front button modules...........................................................81
6.7 Replacing door latches and sensors.................................................................82
6.7.1 Removing door latch Hall Effect sensors..............................................82
6.7.2 Removing door latches .......................................................................82
6.8 Replacing dispensers......................................................................................84
6.8.1 Removing dispensers .........................................................................84
6.8.2 Installing dispensers ...........................................................................85
6.9 Replacing toe panels.......................................................................................87
6.9.1 Removing 1-piece steel toe panels ......................................................87
6.9.2 Removing 1-piece steel toe panels with brackets..................................87
6.10 Replacing base covers ....................................................................................88
6.10.1 Removing base covers .......................................................................88
6.10.2 Installing base covers .........................................................................88
6.11 Replacing door springs....................................................................................89
6.11.1 Removing door springs .......................................................................89
6.11.2 Door spring chart................................................................................90
6.11.3 Installing door springs.........................................................................90
6.12 Replacing inner doors .....................................................................................92
6.12.1 Removing inner doors.........................................................................92
6.12.2 Replacing serial label onto replacement inner door...............................93
6.13 Replacing overflow troughs (channels) .............................................................94
6.14 Replacing lower door seals..............................................................................95
6.15 Replacing door hinge levers ............................................................................97
6.16 Replacing power modules ...............................................................................98
6.17 Replacing heat pumps...................................................................................100
6.18 Replacing drain pumps..................................................................................102
6.19 Replacing water switches ..............................................................................103
6.20 Replacing drain check valves.........................................................................104
6.20.1 Removing drain check valves............................................................104
6.20.2 Installing drain check valves..............................................................104
6.21 Replacing aqua sensors ................................................................................105
6.21.1 Removing aqua sensors ...................................................................105
6.21.2 Installing aqua sensors .....................................................................105
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6.22 Replacing water inlet valves.........................................................................106
6.22.1 Removing water inlet valves ............................................................106
6.22.2 Installing water inlet valves ..............................................................107
6.22.3 Water valve connection issues.........................................................107
6.23 Replacing water inlet controls.......................................................................109
6.24 Replacing floats (safety systems) .................................................................111
6.25 Replacing sump parts (inside tub).................................................................112
6.26 Replacing sumps.........................................................................................114
6.26.1 Removing sumps ............................................................................114
6.26.2 Installing sumps ..............................................................................115
6.27 Replacing drain hoses .................................................................................117
6.27.1 Removing drain hoses.....................................................................117
6.27.2 Removing sump hoses....................................................................118
6.28 Repairing cutlery (top) drawers.....................................................................119
6.28.1 Removing and disassembling cutlery (top) drawers...........................119
6.28.2 Installing cutlery (top) drawers .........................................................119
6.28.3 Removing rack slides (rails).............................................................119
6.28.4 Assembling rack slides (rails)...........................................................120
6.29 Replacing trim strips ....................................................................................121
6.29.1 Removing side trim strips ................................................................121
6.29.2 Installing side trim strips ..................................................................121
6.29.3 Removing top trim strips..................................................................122
6.30 Leveling dishwashers ..................................................................................123
6.31 Electrical connections ..................................................................................124
6.31.1 Making electrical connections ..........................................................124
6.32 Stowing supply lines ....................................................................................125
6.33 Changing customer settings (codings) ..........................................................126
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Concerning this document
1.1 Important information
Read and observe chapter 2 "Safety" before performing any work!
1.1.1 Purpose
These repair instructions form the basis for a systematic and safety conscious proced-
ure for the repair of domestic appliances.
These repair instructions include information about troubleshooting and repair.
1.1.2 Target group
These repair instructions are intended for persons who are familiar with equipment
technology and were instructed by BSH or an authorised body:
¡Service technicians for the repair of domestic appliances
¡Pre-assemblers in the spare part stockroom when determining required spare
parts
¡Call centre employees during order acceptance
1.1.3 Other applicable documents
The following documents include additional relevant repair information:
¡General repair instructions
¡Error codes and service programs
¡Circuit diagrams
¡Exploded drawings
¡Parts lists
¡Repair videos
1.2 Explanation of symbols
1.2.1 Danger levels
The warning levels consist of a symbol and a signal word. The signal word indicates
the severity of the danger.
Warning level Meaning
Danger Non-observance of the warning message
will result in death or serious injuries.
Warning Non-observance of the warning message
could result in death or serious injuries.
Caution Non-observance of the warning message
could result in minor injuries.
Notice Non-observance of the warning message
could result in damage to property.
Table1: Danger levels
1.2.2 Hazard symbols
Hazard symbols are symbolic representations which give an indication of the kind of
danger.
The following hazard symbols are used in this document:
Hazard symbol Meaning
General warning message
Danger from electrical voltage
Risk of explosion
Danger of cuts
Concerning this document
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Hazard symbol Meaning
Danger of crushing
Danger from hot surfaces
Danger from strong magnetic field
Danger from non-ionizing radiation
Table2: Hazard symbols
1.2.3 Structure of the warnings
Warnings in this document have a standardised appearance and a standardised struc-
ture.
Danger
Type and source of danger!
Possible consequences of ignoring the danger / warning.
▶Measures and prohibitions for preventing the danger.
The following example shows a warning that warns against electric shock due to live
parts. The measure for avoiding the danger is mentioned.
Danger
Risk of electric shock due to live parts!
Death by electrocution
▶Disconnect appliances from electrical supply at least 60 seconds
before starting repairs.
1.2.4 General symbols
The following general symbols are used in this document:
Gen. symbol Meaning
Identification of a special tip (text and/or
graphic)
Identification of a simple tip (only text)
Identification of a link to a video tutorial
Identification of required tools
Identification of required preconditions
Identification of a condition (if ..., then ...)
Identification of a result
Start Identification of a key or button
[00123456] Identification of a material number
Status Identification of displayed text / window
(in the appliance's display)
Table3: General symbols
Concerning this document
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Safety
2.1 Qualification
In Germany, only qualified electricians trained by BSH or an authorised body may per-
form any repair work.
In other countries, only similarly trained qualified personnel is permitted to perform the
repair work.
Appliances must only be repaired by persons that are qualified, approved and trained
by BSH or an authorised body as instructed.
2.2 General safety instructions
2.2.1 All domestic appliances
Risk of electric shock due to live parts!
¡Disconnect the appliance from the mains for at least 60 seconds before starting
work.
¡Do not touch the housing, components and cables.
¡For tests on an energised system, use a residual current circuit breaker.
¡Discharge high-voltage capacitors.
Risk of injury from sharp edges!
¡Wear protective gloves.
Risk of crushing during repair, maintenance, troubleshooting and service due to
heavy and moving components
¡Wear protective shoes.
¡Secure heavy components from falling down.
¡Do not stick body parts into moving components.
Risk of injury when dealing with harmful substances!
¡Observe the associated safety data sheet!
Risk to the appliance's safety / function!
¡Only use original spare parts.
Risk of damage to electrostatically sensitive components (ESDs)!
¡Before touching ESDs, use an electrostatic protection system (wristband with earth
safe plug).
¡Do not touch connections and conductor paths of the modules.
¡Only transport ESDs in conductive materials or original packaging.
¡Keep ESDs clear of electrostatically chargeable materials (i.e. plastic).
Safety
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2.3 Measures after each repair
If the appliance is functional:
¡Check according to VDE 0701 or country-specific regulations.
¡Check external appearance, function and tightness.
¡Document repair work, measured values and functional reliability.
If the appliance is not functional:
¡Identify the appliance as “not functionally reliable”.
¡Warn customers of commissioning and notify them in writing .
Safety
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Design and function
3.1 Operating and power modules
Dishwashers have two control modules, an operating module in the fascia (control)
panel and a power module in the base on the right side.
3.1.1 Operating modules
Operating modules provide a user interface with displays, lights and buttons / touch
pads. They control info lights and process rinse aid sensor signals.
Fig.1: Operating module (in fascia panel)
The wire harness connected to the operating module (1) is a separate harness.
3.1.2 Power modules
Power modules control and power dishwashers, containing all operating software, self
diagnostics, error codes and power relays.
Fig.2: Power module (in base)
Power modules (1) control BLDC (Brushless DC) heat and drain pumps, all parts (other
than info lights) and read all sensors (other than rinse aid sensors).
Although they don't read rinse aid sensors, they process the signals and direct wash
programs to default to longest times when there's no rinse aid.
3.1.3 Adding PTC to power module pc boards
Fig.3: On-board power module PTC
Starting FD9903, power modules have an on-board PTC to measure the temperature
where power cords plug into them, as required by UL. If temperatures exceed a preset
level, the power module software ends the wash cycle and generates an E:03 error
code.
Design and function
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3.2 Dispensers
The dispenser, located in the middle of the inner door, reliably dispenses detergent and
rinse aid.
¡Detergent covers (lids) are closed by pressing down on them until they "click".
¡Dispensers allow rinse aid dosages to be controlled by dishwasher control cod-
ings / settings.
Fig.4: Dispenser detail
1 Rinse aid cover with seal
2 Rinse aid outlet
3 Rinse aid filler opening
4 Detergent cover lock
5 Detergent cover
6 Detergent dispenser
7 Plastic ribs (keeping tabs from sticking)
¡A vent equalizes internal pressure to dispense rinse aid accurately.
¡The actuator is reset when the detergent door is opened so the detergent cover
opens first the next time the coil is activated.
¡Detergent tablets dissolve more slowly if there’s moisture left in the detergent dis-
penser. Two plastic ribs in the detergent cup prevent detergent tablets from “stick-
ing” to the cup.
3.2.1 Dispenser operation
During each wash cycle, the dispenser operates twice, once to dispense detergent and
again to dispense rinse aid.
Fig.5: Dispenser internal operating parts (front view)
1 Coil
2 Cover release lever
3 Actuator
4 Rinse aid pump
Coil operation:
¡The coil (1), powered by 165 VDC pulses from the control, moves the detergent
cover actuator (3) to the left. A plastic link turns, rotating the detergent cover re-
lease lever (2), which opens the detergent cover.
¡A mechanical link between the coil actuator and rinse aid valve prevents rinse aid
from being dispensed when the coil is first actuated. After the detergent cover has
opened, the link moves and locks in place, allowing the rinse aid pump to dispense
rinse aid.
Rinse aid dosage:
¡Rinse aid is dispensed at 1 ml per dose, with the # of doses equal to the rinse aid
setting (e.g. setting 5 provides five 1 ml doses and setting 1 provides one 1 ml
dose).
¡Each 165 VDC control pulse dispenses 1 ml of rinse aid.
Design and function
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¡The rinse aid chamber holds around 90 ml of rinse aid, depending on how it's
filled, and triggers the "Add rinse aid" LED when 45 ml is left.
¡Without rinse aid, whether rinse aid has run out or the setting had been set to
"0" (r:00), wash cycles default to the longest time with most washes and rinses to
make sure dishes are clean.
Fig.6: Dispenser cutaway showing internal parts (rear view)
1 Coil
2 Actuator
3 Rinse aid pump
4 Optical rinse aid sensor
If customers complain of long wash times, check rinse aid settings and
levels.
3.2.2 Rinse aid sensor
Dispensers have an optical rinse aid sensor to alert customers they need to refill their
dispensers with rinse aid.
¡A transmitter diode (3) sends a beam of light through a prism (2) in the rinse aid
reservoir to a receiver diode (1), which sends a signal showing rinse aid is present
or absent.
¡With rinse aid present (left), the receiver diode (1) senses a weak, diffused light
beam through the prism (2) from the transmitter diode (3).
¡When rinse aid has run out (right), the receiver diode (1) senses a strong light
beam through the prism (2) from the transmitter diode (3).
Fig.7: Dispenser rinse aid sensor detail (with rinse aid (left) and without rinse aid
(right))
1 Receiver diode
2 Prism
3 Transmitter diode
Design and function
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3.3 Heat pump
3.3.1 Heat pump basics
The heat pump contains the heating element, motor speed sensor, two temperature
sensors (NTC’s), motor and pump (head). The component parts aren’t available separ-
ately.
Fig.8: Heat pump
The heat pump uses a 1200 W flow-through heated cylinder, which provides plenty of
heating surface area and heats water quickly (about 2ºF / minute).
The pump impeller is driven by a 3-pole BLDC motor controlled by the power module.
Fig.9: Heat pump construction
1 Pump
2 Heating element
3 O-ring
4 Motor
The heat pump (7), attached to the sump to the right of the drain pump (1), is access-
ible from the right side of the dishwasher.
Fig.10: Heat pump location
1 Drain pump
2 Outlet to lower spray arm
3 Outlet to top sprinkler
4 Outlet to upper spray arm
5 Water switch
6 Water switch motor
7 Heat pump
¡The dishwasher won’t run if the heat pump is disconnected or disabled.
¡The heat pump is best accessed by pulling out the dishwasher and placing it on its
back or by blocking up the right side of the tub.
¡The motor and pump are isolated from each other to eliminate leaking or binding
and the need for a shaft seal.
¡Depending on the model and wash cycle, heat pumps speed up to provide more
water pressure (for intensive cycles) or slow down to provide less water pressure
(for delicate cycles). This is determined by the wash cycle software, not the aqua
sensor, so it doesn’t matter how clean or dirty the water is.
There are two terminal connectors:
¡6-pin heater terminal on the side of the pump.
Design and function
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¡3-pin motor terminal at the end of the motor.
Fig.11: Heat pump terminals
1 6-pin heater terminal
2 3-pin motor terminal
Ratings: 3-pole BLDC, 110 - 120 VAC, 150 Hz, 1200 W thick film heater, < 80 W mo-
tor, class F insulation, 5-blade impeller with guide wheel.
3.3.2 Heat pump operation
The impeller draws water into the pump and circulates it inside the cylindrical heating
element. The guide wheel directs the water through the pump outlet to the water switch
to be directed to the spray arms.
Fig.12: Heat pump detail
1 Outlet to water switch
2 Heating cylinder w/ NTC's
3 BLDC motor
4 Impeller
5 Guide wheel
6 Inlet from sump
7 Pump housing
While water is being circulated, the BLDC (Brushless DC) motor senses the pump
status based on the current (amp) draw of the motor windings:
¡No water
¡Too little water (cavitating)
¡Proper water level
¡Pump blockage
Safety-related issues, such as “heating without water” or “water too hot”, are detected
and evaluated.
If the pump is blocked, the pump tries several times to loosen the blockage. If unsuc-
cessful, the wash cycle ends and an error code is stored in memory.
3.3.3 Heat pump heater terminal cover
Starting FD 0004 (April, 2020), all dishwashers include heat pump heater terminal cov-
ers to meet new UL requirements. If lost, they are available separately and are easily
snapped onto heat pump heater terminals.
Fig.13: Heater terminal cover (top view)
Fig.14: Heater terminal cover (bottom view)
Being due to a new requirement, heater terminal covers don't need to be added to
older units.
Design and function
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3.4 Drain pump
3.4.1 Drain pump basics
The BLDC (Brushless DC) 9-vane drain pump has variable speed and direction. The
power control module controls pump speed and direction, detects end of draining and
blocked rotor and corrects locked rotor conditions.
Fig.15: Drain pump detail
1 Cable guide
2 Lock (latch)
3 Impeller
4 Seal
¡The dishwasher won’t run if the drain pump is disconnected or disabled.
¡The drain pump is best accessed from the front, but can be accessed by pulling
out the dishwasher and placing it on its back (except for zeolite dishwashers).
Resistances as follows:
¡1 – 2: 130 Ω (@ 68 ºF)
¡2 – 3: 130 Ω (@ 68 ºF)
¡3 – 1: 130 Ω (@ 68 ºF)
Ratings: 3-pole BLDC, 54 VAC, 55 Hz, 2500 – 3500 RPM, 0.15 - 0.25 A, 10 – 25 W,
class F insulation, 9-vane impeller.
3.4.2 Drain pump operation
The impeller draws water from the sump and pumps it through the drain check valve
into the drain hose.
While water is being pumped, the BLDC (Brushless DC) motor senses the pump status
based on the current (amp) draw of the motor windings:
¡No water (idle – not pumping)
¡No pressure build-up (missing pump cover)
¡Pump blockage
¡Blocked or kinked drain hose
Drain pump diagnostics:
¡If there is too little water in the sump, pumping is stopped.
¡If there is no drain pump cover in the sump, water pressure cannot build up and
the pump cannot pump. An error code is stored in memory.
¡The motor senses if the pump is blocked. Using brief, intermittent bursts, the pump
tries several times to loosen the blockage.
¡If draining is disrupted by a blockage or kink in the drain hose, draining is stopped
and an error code is stored in memory.
3.4.3 Solving installation issues
Often improper installations, not drain pump issues, cause dishwashers to not drain
properly:
¡Must have drain hoses with high loops (min. 33” high) or drains with air gaps.
¡To avoid damaging drain hoses, place high loops inside cabinets near customer
drain connections, not next to dishwasher tubs.
¡Drain hoses are 92” long and can be up to 150” long (with [SGZ1010UC] / service
# [00663105]) extension.
¡Make sure drain hoses aren't too long.
¡Make sure drain hoses aren’t kinked.
¡Make sure drain hoses are pointed toward customer drains and are supported by
dishwasher base straps.
3.4.3.1 Cavitating
Cavitating can occur in pumps of all types when impellers spin faster from low inlet /
outlet pressure, creating air pockets around impellers.
Fig.16: Cavitating
Cavitating pumps can be noisy. Air gaps / high loops keep water contacting pump out-
lets, preventing air pockets from forming.
Design and function
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3.4.3.2 Siphoning
Siphoning may occur in any type of drain pump when low water flow allows a siphon
(suction) to develop, pulling waste water back into the pump.
Fig.17: Siphoning
Drain check valves along with air gaps / high loops prevent siphons from being created.
3.4.3.3 Johnson Tee applications
For installations with a Johnson Tee, the Johnson Tee must be installed in the wall
behind the dishwasher, no more than 50” (at its maximum height) above the floor.
¡The connection must be ¾” minimum – ½” must not be used.
¡Dishwasher drain hose extensions must not be used.
Fig.18: Johnson Tee
Johnson Tee's are primarily used in Washington State, although some are used in Cali-
fornia.
Design and function
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3.5 Door latches
Door latches consist of two parts - a door latch and a Hall Effect sensor. The latch se-
curely holds doors closed and the sensor senses when doors are open or closed.
3.5.1 General information
The door latch on top of the tub has a magnet sensed by a Hall Effect sensor in the
door to determine if the door is open or closed. The Hall Effect sensor is held by two
T10 Torx screws and the door latch is held by two crimped tub tabs.
Fig.19: Door latch and sensor location
1 Door latch
2 Hall Effect sensor
Fig.20: Hall effect sensor location
2 Hall Effect sensor
3.5.2 Hall effect door sensor
The Hall Effect sensor is a proximity sensor. When the door is about to latch, it moves
into the door latch magnetic field, causing positive (“+”) and negative (“-“) charges to
move to opposite sides of it, creating a small voltage. This voltage increases until it
reaches a preset value when the sensor gets close enough to the door latch magnet,
signifying the door is closed.
Fig.21: Hall Effect
3.5.3 Unintentional operation
The dishwasher is protected from "unintentional operation" (i.e. accidently resuming a
wash cycle after the door has been opened). After the door has been opened for more
than 4 s, the dishwasher will be paused, requiring customers to deliberately resume the
wash cycle by pressing Start (Resume) before closing the door.
If customers complain their dishwashers won't restart once the door has
been opened, advise them to open the door and press Start (Resume)
before closing the door.
Design and function
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3.6 Door springs
3.6.1 Door spring operation
Fig.22: Door spring system
The door spring mechanism uses a “sliding” pulley and cord to provide proper tension
and enable self-closing.
¡The fixed sliding pulley slides onto the base and is held in position in tension by a
spring. The cord slides on the pulley, using the friction between it and the cord to
provide better control.
¡The back of the spring slides into a slotted pocket in the side of the base and the
front of it connects to the cord. Springs are color coded for specific tensions.
¡Bases and cords are new and aren't backward compatible (i.e. with older dish-
washers).
Service calls have occurred from customers with dishwasher doors
without wooden panels installed. Door springs are chosen to support the
weight of most wooden panels – doors without panels are too light and
close on their own.
3.6.2 Door spring changes for Push to Open / Auto Door Open
To add Push to Open and Auto Door Open (to some models), changes were made to
the door spring system for all dishwashers.
¡Hinge cords (4) and door springs (2) are longer.
¡The base (6) is new to allow for the longer hinge cords and door springs.
¡New hinge cords, door springs and bases aren't backward compatible (i.e. with
older dishwashers).
¡There is a new spring guide (3).
¡Hinge levers were changed where hinge cords are attached.
Fig.23: Changes to door springs for Push to Open
1 Spring clip
2 Longer door spring
3 New spring guide
4 Longer hinge cord
5 Spring-loaded hinge pulley
6 New base
A new spring-loaded pulley and hinge lever improve door spring operation for Push to
Open / Auto Door Open models. Other models get new hinge levers, but use existing
pulleys.
Fig.24: Spring-loaded hinge pulley
Design and function
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Fig.25: New hinge lever
3.6.3 Using wrong toe panel screws
Some installers have used long wood or drywall screws instead of the supplied toe
panel screws.
¡Long, sharp screws cut hinge cords (see below).
¡Use the supplied toe panel screws.
Fig.26: Consequences of not using supplied toe panel screws
¡All toe panel screws are included in the installation parts bag included with dish-
washers and are available for service.
¡Starting FD 9906, toe panels with brackets were used to prevent improper installa-
tions.
Design and function
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3.7 Water inlet - condensation system
3.7.1 Water inlet system
The water inlet system lies next to the left side of the tub, filling water into the bottom
left side of the tub. A vent above the water inlet aids water flow and allows condensa-
tion to exit during drying.
Fig.27: Water inlet system (without softener)
1 Water inlet (to tub)
2 Vent (to tub)
There are two hoses connected to it, the water inlet hose (from the water inlet valve)
and drain hose. The total drain hose length is 92” (~ 7.67’), including the portion inside
the dishwasher.
3.7.2 Water valve
Inlet valves have a flow limiter to keep the incoming water pressure to specified levels,
regardless of the water supply pressure.
Fig.28: Water valve detail (640A US valve, with dual filter)
1 Terminals
2 Terminal housing
3 Plunger
4 Diaphragm
5 Plunger seal
6 Water outlet
7 Flow limiter support
8 Flow limiter
9 2nd (inner) inlet filter
10 1st (outer) inlet filter
11 Mounting flange
12 Coil (solenoid)
Design and function
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13 Spring
Water inlet valves use a double inlet filter to help prevent clogging.
Fig.29: Water valve double filter
Ratings:
¡110 - 127 VAC, 60 Hz, 4.7 W, 990 Ω
¡0.2 - 10 bar, 2.5 l/min. (0.66 gal/min.), 70 ºC (158 ºF) max.
3.7.3 Valve holder
A plastic holder secures hot water inlet valves onto the rear of bases.
Fig.30: Water inlet valve and valve holder
Water inlet valves have grooved plastic flanges which slide into the right side of holders
until they lock. Three springs molded into holders securely hold valves into place - no
screws are needed.
Fig.31: Valve holder spring detail
3.7.4 Water valve installation issues
Some installation issues have occurred with water inlet valves.
3.7.4.1 Cross-threaded or stripped threads
Fig.32: NPT threads (wrong, left) compared with hose threads (correct, right)
Some installers / customers have cross-threaded / stripped valve threads or used
wrong connectors (e.g. ¾" NPT instead of ¾" hose fittings), resulting in E:15 error
codes from leaking.
¡When customers complain of water leaking from tubs, check water inlet valves for
cross-threaded / stripped threads - don't assume leaks are due to leaky tubs.
¡Replace water inlet valves with cross-threaded or stripped threads.
¡Instruct installers / customers to use ¾” garden hose connectors / fittings, not ¾”
NPT, as NPT threads can cross-thread / strip plastic water valve threads. NPT fit-
tings have fine, tapered threads designed to wedge / grind together to prevent
leaking without gaskets and are often used in automotive / hydraulic applications.
3.7.4.2 Plastic filters removed
Fig.33: Water valve with missing filter and loose flow restrictor
Some installers / customers have removed water valve filters, thinking they were
removable plugs / caps, dislodging or losing water flow restrictors, generating E:17
error codes from excessive inlet water pressure.
¡Plastic filters hold flow restrictors in place - when filters are removed, flow restrict-
ors come loose.
¡There are no covers or parts to be removed from water inlet valves.
¡Replace water inlet valves with missing plastic filters.
Fig.34: Intact water valve with filter
Design and function
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