Dishwasher Repair Manual - Uncleharrywizard

While pushing (and holding) any two wash cycle buttons, turn thedishwasher on with the on/off switch. The current coding (e.g.“C1”) will show in the display or LED's until you release thebuttons. After releasing the buttons, LED “B” will be lit and LED“C” will flash, confirming you’re in the special programs menu.Push button “B” repeatedly until you’ve selected your desiredprogram (see P(X) Program codes, “P1” or “P4” -- programs “P0”and “P3” are factory tests that aren’t to be used).displays. Whenever you get call about a “strange” display, checkif the customer put the dishwasher into the test program or someother program.The following typical codes cover most dishwashers. Consult thetest program for your model to confirm the codes to use.Enter the special program mode – see section 3.5. Beforereleasing the two buttons held while you turned the dishwasheron, note the coding on the digital display (e.g. “C1”, “C2”, etc) -the dishwasher must be returned to this code for resale.3.4.1Typical P(X) Program codesP0 Functional test - used for assembly (do not use)P1 Customer service test program (see E(X) error codes)P3 Endurance / Life test (do not use)P4 Control coding (see C(X) control codes)3.4.2Typical E(X) Error codesE0 No errorsE1 Heating errorE2 NTC errorE3 Filling errorE4 Water switch cannot be positionedE5 Safety float water level reached or motor speed error (errorcode dependent on model – check test program)E6 Aqua sensor error3.4.3Typical C(X) Control codesC9 Sales demo mode3.4.4Sales demo (showroom) program3.4.4.1Entering sales demo programPush button “B” repeatedly until the display shows sales demoprogram mode “P4”. Push button “C” to confirm it.Push button “B” repeatedly until the display shows sales democode “C9”. Push button “C” to confirm it.Turn power off and then back on. The dishwasher is now indemo mode -- all button lights will light up.3.4.4.2Preparing a dishwasher for showroom use1. Turn off the power to the dishwasher or disconnect thedishwasher from the electrical power.m WARNING:Danger of electrical shock!2. Remove the toe kick and locate the drain pump terminalshown below. Disconnect the terminal from the drainpump by squeezing and pulling it out. Cover the terminalwith electrical tape to prevent electrical shock.Codes C1 through C9 are possible, depending on the model.HINT: Customers pushing and holding Cancel-Drain or CancelReset buttons while turning dishwashers on can see strange702 58300000148618 ara en aPage 8 of 42

Push button “B” repeatedly until the display shows the originaldishwasher code (e.g. “C1”, “C2”, etc). Push button “C” toconfirm it.Turn power off and then back on. The dishwasher now has it’soriginal coding. Reconnect the pump and heater that waspreviously disconnected.3. Disconnect both ends of the short heater red wire – seesection 5.2.3 to remove right side panel for access. Tapethe wire with electrical tape to the plastic base so it can bereconnected for resale.3.5Dispenser3.5.1Adjusting rinse-aid dosageThe amount of rinse-aid can be adjusted at the dispenser.4. Do NOT connect dishwasher to a water line, but slowlypour about 4.5 liters of distilled water into the tank. Thewater level should be near the bottom of the fine filterscreen in the sump.5. Add a small amount of rinse aid and a 1/2 capful ofantibacterial agent (bacteriastat) onto the inner door. DoNOT add bleach.6. Reconnect the dishwasher and turn it on by pushing theon/off button. Close the door and run dishwasher for oneminute. If necessary, add more water until level reachesthe fine filter screen.3.4.4.3Preparing a showroom dishwasher for resaleRinse-aid can be added by pouring it onto the arrow.3.5.2Closing dispenser doors1. Slide cover fully left.2. Push back end of the cover(onto the arrow) downfirmly until you hear a click.To return the dishwasher back to it’s original condition for resale,enter the special program mode – see section 3.4. Push button“B” repeatedly until the display shows sales demo program mode“P4”. Push button “C” to confirm it.702 58300000148618 ara en aPage 9 of 42

4COMPONENTS4.1.34.1Dishwasher components4.1.3.14.1.1TankThe tank, made of 304 stainless steel, isn’t available as a servicepart.HeaterOperationBosch dishwashers use flow-through heaters instead of exposedelements, saving space and allowing taller tanks holding largerdinner plates. Flow-through heaters prevent dishware damagefrom exposed elements and allow water to be continuouslyfiltered and heated.SealHeating elementNTC/Hi-limitFlowswitch4.1.2Leveling feet (front and rear)To upperspray armThe base is supported by three leveling feet, two front and onerear. The rear leveling foot is adjusted from the front. Front feethave provisions for set screws (in installation parts bag).To lowerspray armFrom circulation pumpFiltered water from the sump flows through the circulation pumpinto the flow-through heater. All heaters are protected by a 185ºFHi-limit (high temperature cutout) and by a flow switch whichprevents heaters from operating when no water is flowing.4.1.3.2 702 58300000148618 ara en aHeater ratings120 VAC, 60 Hz, 1200 WHeats water about 2ºF / minutePage 10 of 42

4.1.3.3Softer bearing (UC/11 and later)Softer bearing (UC/11 and later) & non-softer bearing (UC/06)heater assemblies, circulation pumps and sumps cannot bemixed and matched. Softer bearing heaters don’t fit in oldermodels and older heaters don’t fit in softer bearing models.Softer bearing & non-softer bearing heater assemblies areconnected to circulation pumps differently: Softer bearing models (UC/11 & above) have gasketassembled to heater and have a separate hose clamp(order # 172272). Older models (UC/06) have a separate gasket and donot have a hose clamp.4.1.3.4Top Rack OnlyModels with Top Rack Only have separate actuators mountedunderneath heater assemblies. The actuator moves a magneticfloat to block the lower rack port, diverting water to the top rack.Lowerspray armLower spray armMagneticfloatMagnetic floatMagnetMagnetActuator (hotwax motor)Actuator (hotwax motor)The actuator moves a magnet under the magnetic float so thenorth poles align, repelling the magnetic float upward until itblocks the water flow to the lower spray arm.Heater with top rack housing702 58300000148618 ara en aBoth racksTop rack onlyPage 11 of 42

Models with water switches & Top Rack Only use water switchesto divert water. Separate actuators aren’t needed.Top viewMicroswitchPlungerCamEuropean disk shown,which is different thanU.S. diskBottom viewWhere plunger engages heater4.1.3.5Where plunger engages sumpHalf LoadStarting with UC/33 dishwashers, Half Load replaced Top RackOnly. Like Top Rack Only, it uses 30% less water, saving waterand energy. Unlike Top Rack Only with mechanical actuators,Half Load is done by control software (through shortening cycles)and doesn’t limit water flow to the top rack.4.1.3.6Water switchMotor operated water switches are mounted underneath heaterassemblies. They consist of a motor-controlled disk with 3 holeswhich rotates and lines up over two sump ports (upper / lowerspray arms) to provide precise water control to upper, lower orboth spray arms.DiskModels with water switches need stronger circulation pumps (#437345) with separate motor starters (# 182318). Circulationpumps, heaters & sumps for water switch / non-water switchmodels can’t be interchanged.4.1.4Circulation pumpsBosch dishwashers use separate circulation and drain pumps toreduce overall size, noise, vibration and energy consumption.This allows the use of tall tanks, increasing overall space insidedishwashers where full-sized plates can be placed in both upperand lower racks. Circulation pumps are suspended by rubberstraps to further reduce noise and vibration.Depending on features, dishwashers have one of four types ofcirculation pumps. Pumps use different controls, wire harnesses,heaters & sump filters, so replace with identical replacementpumps.702 58300000148618 ara en aPage 12 of 42

4.1.4.1“Sisme” (UC/06 through UC/23)It has a capacitor start motor with a centrifugal switch cutting outthe starting capacitor once the motor comes up to speed. Thispump can be replaced as # 239144 pump assembly, # 266511motor only or # 167085 impeller kit.It has a ceramic seal keeping water from entering the motor andan 8mm nut on the impeller to free it if it should ever stick.4.1.4.2“Sisme” pump with PTC motor starterPump # 437345 pump is more powerful for use with heaters withwater switches and sumps with extra filter cylinder. It uses aseparate motor starter (# 182318) attached to the motorterminals. It can use # 167085 impeller kit.The (PTC) circulation pump motor starter cuts out the startwinding after the motor starts.4.1.4.3“Sicasym” (UC/21 through present)8mm nutdriverMost common pump (used starting with UC/21 index). Smallerthan 239144 “Sisme” pump. Used with controls & single wireharnesses designed for Sicasym pumps. Motor controls havemotor starter software, so there are no mechanical starters.SumpSumpaccess toimpellerImpellerThere is no impeller kit.702 58300000148618 ara en aPage 13 of 42

4.1.4.4BLDC (UC/46 through present)4.1.6Drain pumpPump, motor and control come as one unit (# 665510). Speedchanges as needed for wash cycle and washability (Vario wash).Pump is isolated from motor, so there’s no seal needed and noneed to loosen or replace impellers.Drain pumps are mounted to sumps in the front of dishwashers -they’re easily accessible from the front of dishwashers byremoving toe kicks.4.1.54.1.6.1FloatThe float is a safety device which starts the drain pump if there’stoo much water in the tank. It doesn’t act like a bilge pump (i.e. itwon’t drain water from the base).Pump specificationsDrain pump is rated 120V, 60 Hz, 35W, 0.85A.4.1.6.2Solving installation issuesOften improper installations, not drain pump issues, causedishwashers to not drain properly. Must have drain hoses with high loops (min. 20” high) ordrains with air gaps.Drain hoses are 6’ long and can be up to 10’ long. Drainhose extension kit SGZ1010UC/01 (76.75”) is available.Secure drain hoses to rear of dishwashers with non-metalbands.Make sure drain hoses aren’t kinked.If there’s water in the base or the float switch isn’t working, errorcode E5 is possible (except for models where E5 motor speederror).702 58300000148618 ara en aPage 14 of 42

4.1.6.3CavitatingCavitating may occur in any type of pump when impellers spinfaster (from low inlet or outlet pressure), creating air pocketsaround impellers. Cavitating pumps can be noisy. Air gaps/highloops keep water contacting pump outlets, preventing air pocketsfrom forming.4.1.6.5.1 Spade terminals (UC/42 and before)Wire harnesses to drain pumps have locking spade terminals,which must be released using a small blade screwdriver.or4.1.6.4SiphoningSiphoning may occur in any type of drain pump when low waterflow allows a siphon (suction) to develop, pulling waste waterback into the pump. Sump check valves along with air gaps/highloops prevent siphons from being created.4.1.6.54.1.6.5.2 Rast 5 connectors (UC/43 and later)Rast 5 terminal connectors provide more positive connectionsthan spade terminals.Terminal connectionsDrain pump terminals were changed from spade type to (Rast 5)connectors during November, 2006 and can’t be interchanged.702 58300000148618 ara en aPage 15 of 42

4.1.6.6Johnson Tee installations (Washington State)Drain pumps in installations with Johnson Tees (in WashingtonState) must use stronger 4-vane pumps (# 184178 spade /607468 Rast 5).During normal fill, rising water compresses air in a chamber untilthe diaphragm operates when the proper water level is reached.If water overfills, the float (shown in red below) stops the water filland operates the drain pump. This float is connected to the floatin the base – either float operates the drain pump.Standard 9-vane drain pumps (#167082 spade / 642239 Rast 5) arequieter and smoother than 4-vanepumps. Older spade terminal pumpshad 6-vanes.4.1.7Water fill assemblyThe water fill assembly is easily accessed from the left side byjust removing the left side panel. It can be a pressure-fill (withdiaphragm) or time-fill, depending on model.4.1.7.1Pressure fillPressure-fill assemblies use a diaphragm to accurately measurewater levels.702 58300000148618 ara en aPage 16 of 42

4.1.7.2Time fillThe time-fill water inlet system is similar to the pressure-fillsystem, except it doesn’t have a diaphragm or water level switch.Dishwasher controls allow water to fill for a specific time, relyingon consistent water flow through the water inlet valve to providethe correct water level.4.1.8Condensation tubeThe condensation tube is crucial for condensation drying, whichdries dishes without a heating element in the bottom of the tank.Starting with UC/12, condensation tubes were moved from thedispenser to the right side of the tank.Time-fill water valves look like pressure-fill valves, but have tightpart tolerances to insure consistent water levels. Time-fill valvescan replace pressure-fill valves, but pressure-fill valves can’treplace time-fill valves.Condensation tubes exit in the rear of dishwasher bases, allowingwater vapor to evaporate, and aren’t connected to customerdrains.702 58300000148618 ara en aPage 17 of 42

4.1.94.1.9.1Door springUsing hinge pulleyThe door spring mechanism allows dishwasher doors to open /close with little effort and to stay open when racks are loaded orunloaded.Dishwashers with wood doors have adjusting screws to changespring tension for different wooden door panel weights. Tightenscrews (cw) to increase spring tension and loosen screws (ccw)to reduce tension.Dishwashers with heavy or light wood doors will need doorsprings changed. The following chart shows when to adjusttension screws and when to replace door springs.Door Wood Panel WeightThe door spring connects to the cord and slides into slots in therear corners of the base. Springs are color coded for specifictensions for specific door weights.702 58300000148618 ara en aExistingDoorSpringLess than 5.5lbs (2.5 kg)5.5 to 9 lbs(2.5 to 4.1kg)9 to 15lbs(4.1 to6.8 kg)15 to 18 lbs(6.8 to 8.2kg)18 to 21 lbs(8.2 to 9.5 kg)Violet(168568)Changeto173696Yellow spring- use tensionscrewifneededChangeto No action168576 Bluespring - usetension screwif neededUse tensionscrewtoincreasetensionChangeto182640Orange spring- use tensionscrewifneededOrange(182640)Changeto Changeto No action168576 Blue 168568spring - use Violet springtension screwif neededUse tensionscrewifneeded age 18 of 42

4.1.9.2Using hinge slider (sliding pulley)During FD 8910, hinge pulleys were replaced with hinge sliders(sliding hinge pulleys). Instead of rolling over rotating pulleys,door spring cords slide over pulley sliding surfaces. The slidingsurfaces provide better control than rotating pulleys (i.e. reducespossibility of doors slamming closed or falling open).4.1.10 Hinge bushingHinge bushings hold doors in place (at hinges). Older hingebushings used a separate lock. Newer hinge bushings havelatches holding doors in place.Bushings have differentdiameters and can’t be mixed. Bushings can be changed as longas matching hinge levers are used.618605 sliding hinge pulley kit replaces all prior pulleys, including426067. The kit consists of (2) sliding pulleys and (2) cordswhich are installed in the field.Side Part #Left 492033Left 488250Replacement Hinge Levers and BushingsDescriptionReplaced byDescriptionLever (14mm)494876 165296 Lever bushing (15mm)Bushing (14mm)Left 263115 Lever bushing (14mm)494876 165296 Lever bushing (15mm)Right 492034Lever (14mm)494875 165296 Lever bushing (15mm)Right 488250Bushing (14mm)494875 165296 Lever bushing (15mm)Right 263119 Lever bushing (14mm)702 58300000148618 ara en a494876 165296 Lever bushing (15mm)494875 165296 Lever bushing (15mm)Page 19 of 42

4.1.11 Water inlet valveDishwashers use standard horizontal coil water inlet valves.Dishwashers UC/43 and later have valves with (Rast 5)connectors. The valve nestles in the left side of the base and isheld into place with two screws.4.1.13 Door latchOther than occasional misalignment, theonly door latch repairs will be replacingmicroswitches. Door latches are held inplace in console (frames) by tabs. It’simportant latches are properly seated inconsoles and tabs are fully inserted intolatches.4.1.14 Terminal block When reconnecting the water supply to the water valve,don’t overtighten the elbow fitting. On valves with verticalsolenoids, the plastic can crack and cause leaking ifexcessive force is used. Using Teflon tape on water fittings can help preventleaking. The water valve can be accessed without removing outerdoor or base cover. However, removing them will provideeasier access.4.1.12 On/off switchThe on/off switch turns the dishwasher onand off and is crucial in resetting controls.Terminal blocks (UC/40 and later) clearly show line (L), neutral(N) & ground (G) connections. Dishwasher wire harnesses havespade terminals which connect to terminals on the rear of theterminal block.Terminal blocks can’t be installed in the field – the terminal boxassy with terminal block must be ordered. The terminal box assyassures the terminal block is properly grounded to the terminalbox.Contacts 5 & 6 reset the control. Whenevera control won’t reset or won’t go into washprograms, check the on/off switch andjumper.Replace switch and jumper ifthey’re faulty.702 58300000148618 ara en aPage 20 of 42

4.1.15 Terminal box4.1.17 DispenserSince 9/23/02, all dishwashers have terminal boxes (“junctionboxes” / ”J-boxes”) with covers. Boxes were upgraded to a largerstyle (with conduit exits) on 3/18/03.The dispenser is located near the top of the inner door andreliably dispenses detergent and rinse-aid.NOTE: Old terminal boxes built before 9/22/02 met UL standards– toe kicks were approved as terminal box covers. There’s noneed to change out old terminal boxes. Covers can’t be added tothese boxes since they don’t have cover screw holes.During each wash program, the wax motor opens twice, once todispense detergent and again to dispense rinse-aid. The waxmotor opens the same -- linkages open the detergent door &operate the rinse-aid dosage plunger. Dispensers can have reedswitches or optical rinse-aid sensors.4.1.16 Drain hosem CAUTION:Dishwashers UC/48 and later use a two-hose (internal / external)drain hose system. A customer (external) drain hose (duringinstallation) is connected to the internal drain hose, with the 90ºelbow pointing toward the customer drain. The external drainhose connects directly to the customer drain system without anadapter.702 58300000148618 ara en aInner door edges are sharp! Cover door edgesand remove dispenser carefully.Page 21 of 42

dishwasher electrical installation is in compliance with all national and local electrical codes and ordinances. The dishwasher is designed for an electrical supply of 120VAC, 60 Hz, connected to a dishwasher-dedicated, properly grounded electrical circuit with a fuse or breaker rated for 15 amps. Electrical supply conductorsFile Size: 2MB