Bosch Dishwasher Service Training

DISHWASHER SERVICE TRAINING MANUAL S

0

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Table of Contents

I.

Safety Concerns………………… Concerns………………………..……….….. ……..……….…..…………... …………...2 2

II.

Product Line Related……………………… Related…………………………………..…… …………..……….. ….. 2

III.

Product Specific………………………… Specific…………………………………………… ……………………… …… 3

IV.

Installation Installation Issues…………………….… Issues…………………….………………..…… ……………..…….…. .…. 6

V.

Theory of Operation……… Operation………………………… …………………………..……… ………..……….. 22

VI.

Component Component Access/Replace Access/Replacement…… ment………………..……… …………..………… … 31

VII.

Component Component Testing/T Testing/Test est Procedures Procedures……………..…… ……………..………. …. 59

VIII.

Trouble Troublesho shooti oting… ng………… ………………… …………………… ……………….… …….………… ……… 64

IX.

Wiring Diagrams/Tech Sheet…………………….………….104



























I. Safety Concerns IA. Safety Symbol Explanation m

= Warning symbol included included in Installation Installation Instructions and on this page. page. It includes serious warnings warnings such as injury or death, electric shock & dishwasher damage.

IB. Identify Potential Hazards There are few hazards associated with with dishwashers. dishwashers. Two possible hazards are: m

Electrical shock hazard (as with any electrical appliance).

m

Sharp edges – only on tank when sump is removed and on inner door when dispenser is removed.

IC. Warning Personal Injury m

Danger of electric electric shock. Disconnect power before disassembling or working working on dishwashers. Make sure dishwashers are electrically electrically grounded. Use only copper conductors for all wiring or rewiring.

ID. Warning Property Damage Only warning on property property damage comes from improper water connections connections – overly tightened tightened water connections could cause water water to leak from water inlet valves. This only applies to older models with water inlet valves with vertical vertical solenoids (coils). Newer models models with water inlet valves valves with horizontal horizontal solenoids (coils) have water connections integrated integrated with mounting mounting brackets to eliminate possibility of damaging valves from overtightening water fittings.

IE. Electrostatic Sensitive Devices None since all control modules have pc boards mounted in plastic housings – no pc boards are handled handled in repairing dishwashers.

II. Product Line Related IIA. CFC Information Information There are no CFC’s or any other refrigerant used in dishwashers. dishwashers.

IIB. Emissions Related There are no emissions related to dishwashers. dishwashers. Occasionally smells smells come from customer customer drains into dishwashers if dishwashers weren’t properly connected to drains.

IIC. CO No carbon monoxide is emitted by dishwashers.

IID. Government Compliance Issues None.

IIE. Certification Certificati on Requirements All dishwashers dishwashers are designed, designed, tested and certified certified by UL for use in the U.S. U.S. and Canada. In addition, all dishwashers are Energy Energy Star certified certified as energy savers. Many dishwashers have NSF sanitized sanitized wash



























III. Product Specific IIIA. Product Specification Chart 

Rated 120V, 60 Hz, 15A, 15A, 1450W (max.). Maximum amp draw when when heaters running ~ 11A.



Water connection connection 3/8” NPT female. female.



Inlet water water pressur pressure e range 5 - 120 psi (0.3 (0.3 – 8.27 bars). bars).



Circulation pump pump motor rated 120V, 60 Hz, 160W, insulation insulation class A. Motor has an auto-reset thermal thermal protector and uses a 10µF capacitor.



Drain pump rated 120V, 60 Hz, 35W, 0.85A.

IIIB. Model Number Number Listing and Explanation Explanation Model numbers were changed with the dishwashers introduced during the 4th quarter of 2002. 

Current model # listing – see below



Older model # listing – see below Current Model # Legend

S

V

9

9

A

0

3

Dishwasher

H Tall Tub

Type

# Wash Programs

Control

Sold Through

Dummy #

Color

UC/#

1

2

3

4

5

6

7

8

9

U= S= H = Tall Undercounter, Dishwasher Tub Tub standard 9 = Automatic 0 = Mechanical V = Fully integrated 6 = Six 3 = Electronic Electronic + 6 = Electronic Options X = Integra I 5 = Five Y = Integra II 4 = Four 9 = Automatic I = Semi Integrated

3 = Three

A = Distribution P L A C E

B = Sears C = Common D = Builder

E = Other

H O L D E R

2 = White 5= Stainless CSI

6 = Black 7 = Biscuit 3 = N/A, Fully Integrated

Old Model # Legend

S H Dishw a she r Ta ll Tub 1

2

S= H = Tall Dishwasher Tub Tub

V Type

6

8

0

# W as as h Progr am ams

Contr ol ol

3

4

5

U = Undercounter, standard

9 = Integra I (four) or II (five) 0 = Mechanical 3, 8 & 9 = Electronic V = Fully integrated 6 = Six U88xx & U99xx = Integra I 5 = Five U995x = Integra II 4 = Four

Leve l

3 Color

UC/ #

6

7

8

0= Standard 1, 2 & 3 = Deluxe 5= Integra II

2 = White 3 = N/A, Fully Integrated CSI

4 = Almond 5 = Stainless



























III. Product Specific IIIC. Model Number Location Located on right edge edge of inner door. See below.

The serial label is fastened to the right edge of the inner door.

FD8303 00011

Understanding FD Serial # (used for warranty)

The FD # shows the Fabrication Date • The The first 2 #s repres represent ent the year: year: 83 = 2003 2003 (add (add 20 20 to #; #; e.g. 20 + 83 = 103 → 2003) • The The next next 2 #s repre represe sent nt the mon month: th: 03 = Marc March h • The The next next 5 #s repres represent ent the unit unit made made that that month: month: 00011 00011 = 11th SHY99A05UC SHY99A05UC made that that month

10 3 03 0081344 00011 5 • •

This helps the factory investigate product problems.

Understanding Factory Serial #

The first 2 #’s represent represent a factory code: code: 10 = New New Bern dishwasher, dishwasher, 82 = New New Bern cooking The 3rd # represents the last digit of the year: 3 = 2003 Th ext 2 #’s re ent th onth: onth: 03 = March



























III. Product Specific IIID. Tech Sheet Location Wiring and circuit diagram folded up and located in slot in front of dishwasher bases.

IIIE. Warranty Information See below.

Bosch Dishwashers Limited Lifetime Warranty Statement of Limited Warranty The warranties provided provided by BSH Home Appliances Appliances ("Bosch") in this Statement of Warranties Warranties apply only to Bosch dishwashers sold to the first using purchaser by Bosch or its authorized dealers, retailers or service service centers in the United United States or Canada. The Warranties provided provided herein are not transferable, and take place from date of installation or ten business days after delivery date, whichever comes first. 1 Year Full Limited Warranty Bosch will repair repair or replace, replace, free of charge, any component component part that proves proves defective under conditions of normal home use, labor and shipping costs included. Warranty repair service must be performed by an authorized authorized Bosch Bosch Service Center. All cosmetic defects must be reported within within 30 days of installation. 2 Year Limited Warranty Bosch will provide replacement parts, free of charge, for any component part that proves defective under conditions of normal home use, shipping costs included, labor charges excluded. 5 Year Limited Warranty On Electronics Bosch will repair or replace, replace, free of charge, charge, any microprocessor microprocessor or printed circuit board board that proves defective under conditions of normal home use during the second through fifth year from the date of original installation, labor charges excluded. 5 Year Limited Warranty On Racks Bosch will repair or replace, replace, free of charge, the upper or lower dish rack (excluding (excluding rack components) components) if the rack proves defective under under conditions of normal home use during the second through fifth year year from the date of original installation, labor charges excluded. Lifetime Limited Warranty Against Stainless Steel Rust-Through Bosch will replace your dishwasher, free of charge, with the same model or a current model that is equivalent or better in functionality if the inner liner should rust through under conditions of normal





























IV. Installation Issues IVA. Location Requirements See attached installation instructions.

IVB. Electrical Requirements See attached installation instructions.

IVC. Water/Drain Requirements See attached installation instructions.

IVD. Shipping/Packaging Shipping/ Packaging Removal See attached installation instructions.

IVE. Installation Related Process 1.

installation instructions. Leveling cabinet – See attached installation

2.

Leveling doors – not required for steel steel doors. For wooden panels added added to steel doors, see installation instructions.

3.

Installing handles – See attached installation instructions.

4.

Door reversal – not possible or necessary.

5.

Quick test procedure

Top Ten Cosmetic/Customer Use/Installation Issues : 

Not cleaning sump filters.…Customers often don’t know they exist.



Smelly dishwashers….Often occurs from filters not being cleaned, drain hose high loops missing or drain gases being present. If all else is OK, then then problem can be preservative preservative not purged from tank door gasket.



Doors leaking or not latching….Usually

an installation issue (dishwasher brackets installed before dishwashers are leveled front to back, tanks & doors out of square, wooden doors not drilled accurately). accurately). Can be blockage in in condensation tubes tubes or having having condensation condensation tubes connected to drain hose air gaps.





























IV. Installation Issues: Installation Instructions





























































































































































































































































































































































































































































































V. Theory of Operation VA. Description of Operation/Cycle 

Bosch dishwashers use separate circulation and drain pumps to reduce overall size, noise, vibration and energy consumption. consumption. This allows the use of tall tanks, increasing increasing overall space inside dishwashers where full-sized full-sized plates can be placed in both upper and lower racks. Circulation pumps are suspended by rubber straps to further reduce noise and vibration.



































V. Theory of Operation VA. Description of Operation/Cycle Operation/Cycl e (continued) 

Bosch dishwashers continuously continuously filter all water using a triple filter method. method. A filter screen above the sump filters out larger particles. A two-stage microfilter in the sump sump filters out out finer particles. particles. This microfilter can easily be removed by customers for cleaning and should be cleaned regularly.



































V. Theory of Operation VA. Description of Operation/Cycle Operation/Cycl e (continued) 

Bosch dishwashers fill with water as shown below.



































V. Theory of Operation VB. Description of Components 

Circulation pump -- Unlike many dishwashers, Bosch dishwashers use separate circulation and drain pumps to reduce noise, vibration, space and energy usage. The circulation pump circulates water from the sump into the spray arms.



Drain pump – The drain pump drains water from from the dishwasher. Being a separate pump, it is is much















































































































































































































































































































































































































































































































































































































































































































































































































































































































VII. Component Testing/Test Procedures (continued) Fault Codes (1) DISHWASHER DISHWASHER TEST PROGRAM ERROR CODES (on 2 & 3-digit digital displays):      

0 – No faults 1 – Aqua Aqua Sens Sensor or (Se (Sens nsotr otroni onic) c) fault fault 2 – Heating system fault (heater, Hi-Limit, flow switch, switch, NTC, NTC, control control heater heater relay) relay) 4 – Wate Waterr fil filli ling ng faul fault t 8 – NTC NTC (tem (tempe perat rature ure se sens nsor) or) fault fault 16 – Water Water switch switch fault fault

DISHWASHER CUSTOMER USE ERROR CODES (on 2 & 3-digit digital displays): F – Water Water fillin filling g fault fault (underfi (underfill, ll, overfill overfill or water water in the base) base) 2H – Last wash wash cycle too long (> (> 99 minutes). minutes). Can be cold inlet water water or heating heating system fault (heater, Hi-Limit, flow switch, NTC, control module heater relay).  _h – Delay Delay Start Start featu feature re (not (not a fault fault code) code)  

DISHWASHER TEST PROGRAM ERROR CODES (on lower line of full text Apexx SH_99 displays): No faul faults ts Aqua Aqua Se Sens nsor or (red (red)) fau fault lt Aqua Aqua Se Sens nsor or (gre (green en)) fau fault lt Wate Waterr swit switch ch fau fault lt (no (no puls pulses es detected)  F – Wate Waterr fil fillling ing fa fault  G – Wate Waterr swit switch ch faul faultt (won (won’t ’t stop running)  H – Heat Heating ing syst system em faul faultt (heate (heater, r, Hi-Limit, flow switch, NTC, control module heater relay)  K – NTC NTC fault fault (short(short-cir circui cuited ted or open-circuited)  xx – Test Test progr program am step step count count (testing done when = 00) TIP: Top line shows wash cycle & bottom line shows fault code.    

S3 – A– B– E–

000

00 000

S-- 3-- -- -- -Start

Selecting test program Checking fault codes

Test program steps

00

Top

Front

In Cycle S3

0---- ---

STEP S3

00

S3

00

HINT: HINT: Apex Apexx x heate heaterr runs runs during steps 05 – 08. Press “-” button to skip to test 05 to measure heater amp draw.



























VII. Component Testing/Test Procedures (continued) Fault Codes (2)

DISHWASHER TEST PROGRAM ERROR CODES (on SHX33A/43E/46A-B, SHV46C, SL84A models): 

–

     

– – – – – –

Heat Heatin ing g syst system em fau fault lt (he (heat ater er,, Hi-L Hi-Lim imit it,, flow switch, control heater relay) NTC NTC (tem (tempe pera ratu ture re se sens nsor or)) faul fault t Water filling fault SHV46C, SHX43E/ N/A 46A-B, SL84A N/A Aqua Aqua Sen Senso sorr (Sen (Senso sotr tron onic ic)) faul fault t SHX33A N/A

Fault code LED’s

Top Rack

Power Scrub

Reg. Wash

Del./ Econo

Power Scrub

Reg. Wash

Rinse & Hold

Rinse & Hold

TIP: Fault Fault codes codes do do NOT NOT add up up for multiple multiple faults faults – shows shows highes highestt fault fault code code st nd rd th on list above (1 – heatin heating, g, 2 – NTC NTC, 3 – water water filling filling,, 4 – aqua sensor) sensor)

DISHWASHER TEST PROGRAM ERROR CODES (on SHU43E/53E/66E models): Faults

LED flashe flashe s

LED Fa ult ult Codes

LED lit 0 - No faults 1 - He ater Element 2 - W ater Filling Filling 3 - NT C 4 - Aquasensor

READY

CYCLE

CLEAN

NSF

READY

CYCLE

CLEAN

NSF

READY

CYCLE

CLEAN

NSF

READY

CYCLE

CLEAN

NSF

READY

CYCLE CLEAN

NSF

LED off



























VII. Component Testing/Test Procedures (continued) Using Test Programs to Measure Heater/NTC Resistances

HINT: Because the flow switch only closes when water is flowing, the heater resistance can only be measured at the heater terminals (not at the control module).

HINT: The NTC and High Limit are contained in the same part. When either fails, replace entire part # 165281. 165281. NOTE: Open door to run test program for fullyintegrated models.

Use dishwasher test program to turn on heater, then measure dishwasher incoming current. If ~ 1.5A, heater, Hi-Limit, flow switch or circulation circulation pump pump has failed. failed. Check voltage voltage @ module module (or (or timer) - if 0V,

NOTE: Flow through heaters heat water ~ 2ºF / minute.



























VIII. Troubleshooting Basic Dishwasher Troubleshooting Troubleshooting Problem

Possible Cause

Inappropriat e dis hw hwas he her Washability  detergent used. prob problem lems s (dis dishwasher hwasher detergent won't clean properly) Blo Blocked cked or clo clogged upper/ low lower  spray arms. Water Water does doesn' n'tt circu circula late te prop proper erly ly  due t o debris in c irculat ion motor impeller.



Suggested Action Ins truc t c ustomer to us e a powdered dishwasher detergent (e.g. Cascade powder).



Chec k s pr pray arm s – c le lean or replac e as  needed. Twist wist and and remo remov ve filter ilter,, then then remo remov ve debr debris is  from right s id ide of s um ump where water enters c irc ulation pump impeller. If debris has jammed impeller, turn off and pull out dish dishw wash asher, er, remov move tan tank, remov move circu circula lati tion on motor and unscrew and clean out imp HINT: If impeller impeller is damaged, damaged, replac replace e entire entire impeller assembly or it won't seal adequately.

Filt Filte er not locke locked d down secu securrely, ly,  Twist wist and and remo remov ve filter ilter,, then then remo remov ve debr debris is allowing debris debris t o enter sump. from s ump. Ins truc t c us tomer to twis t and lock filter (cylinder) securely into sump. 

o CAUTION CAUTION : Use caution caution when removing HINT: Due to high high tempera temperatture ure rinse rinse (161 (161 debris from from sump to avoid being cut by breaking dow down n food food debris and triple triple filterin filtering g sharp debris such such as aluminum can tab tab s syst system em trappin trapping g food food debris, debris, filte filters rs shouldn' shouldn't t or brok en glass. normally clog up. Problem often caused by filter

not not being being secur ecurel ely y customer to twist twist and l

locke locked d

dow down.

Ins Instruct uct

HINT: Wate Waterr level level will will not not  Drain hose behind ind dishw shwashe sher  Loop drain hose behind ind the the dishw shwashe sher affect affect washability washability as water doesn't have an adequate loop. (with the the top top of the the loop) at least 20" above the the fi l l is m ea ea su red by floor. pressure, pressure, not time – water  Partia Partially lly clogg clogged ed air air gap, gap, allo allow wing ing  Unclog sink air gap. level cannot be adjusted. wastewater from prior was hes to

circulate in dishwasher. NOT NOTE : Cleani Cleaning ng sink sink air gaps is is not cove covere red d under warranty. warranty.

See Wat Water doesn't drain prop roperly rly on page 65. Soa Soap doesn' sn't enter ter dish ishwashe sher  Turn off dis hw hwas he her and t es es t ac tu tuat or or –  due to dispenser actuator (A2 ) failure. replace if faulty. 

Water doesn't drain properly



HINT: Must ust pull pull out dishw dishwas asher her and and HIN HINT: T: One "wax" ax" motor motor oper operat ates es bot both h the remove left side panel to access access float float deterg detergent ent and rinse rinse aid dispense dispensers rs throug through h a switch. mechanical link age. The syst system em always always resets resets when door closes. closes. Check Check linkage by moving it manua manuall lly. y. Chec Check k "wax" ax" motor motor by runn runnin ing g a continuity check on its terminals.



























VIII. Troubleshooting (continued) Problem 

Di sh she s w on on't dry properly.

Possible Cause 

Rinse aid not used.

Suggested Action Ins truc t c ustomer on us ing rins e aid – dishes won't dry without it.



Sta Standing water ter in dishw shwashe sher  Unclog air gap. Mak e s ure top of drain Dish ishwash washer has has  sump. hose loo loop (behind ind dish ishwashe sher) is at lea least 20" an odor. above floor (add a loop in hos e if there is n' n't one). 

H I NT NT : Wa te r l e ve l in su m p sh o u ld b e at or bel ow drain motor cover.

Sta Standing water ter in dishw shwashe sher  Turn urn off off dishw dishwash asher er,, drai drain n water water manu manual ally ly base. from dishw shwashe sher base and cor correct sou source of water leakage. Minerals in c ust omer water  Recom ecomme mend nd custo custome merr to get get wate ater teste tested d  supply. and use an appropriate water softener. Food debris debr is in dishwasher filters. Clean dishwasher filters.   



Dis Dishwasher hwasher won't won't run run or indi indic cator ator ligh lightts won't come on.



W a te r doe sn't drain properly.



Dishwasher not turned on. No power to dishwasher.



Door ajar or on/off switch failed.



Door latch has broken.



Indicator Indicator light failed. failed.



Kink in drain hose. Dishwasher filt er er(s ) or sump  clogged. Drain motor impeller clogged.  

Turn on/off switch on. Check heck custo custome merr circu circuit it brea reaker ker, fuse use box  or power connections. 

Turn off dis hw hwas he her and c he hec k door or on/off switch -- adjust or replace them. Turn urn off off dishw dishwash asher er and and repl replace ace door door latch latch  – instr instru uct custo custome merr to not pull on door with ithout pulling latch. Run tes t program t o see if light failed. If  so, so, tur turn off dish ishwashe sher and replace lace ind indica icator tor light. 

 

Straighten or replace drain hose. Clean dishwasher filters filters or sump.

Turn off dish ishwashe sher, remov move drain moto motor r c over (in s ump) and clean impeller. If nec es s ary , remove drain motor to clean impeller. CAU TI ON ON : Use cau tio n  K itchen s ink or s ink air gap  Unclog sink or sink air gap. wh e n re m o vin g d eb ri ri s clogged. fro m su mp mp to avo id id b e in in g  Drain motor (m3 ) failed. N OTE : C l e an in g sin k ai r g a ps o r si n k s a re n o t 

cu t b y sh arp de b ri ri s su ch covered unde r warranty. as al um in in um ca n ta b s o r  Timer (SH Turn off dis hwas her and measure SHU U 30/40 /40 models ) or  brok en glass. glass. module (all other models ) failed. resis ta tanc e at motor terminals (≈ 16.5 Ω

Replace Replace faulty motor. Impr Improp oper er drain drain conne connection ction heigh heightt  Chec k voltage at and wiring to timer or  (< 20" or 508mm above floor). modu module le.. Turn urn off off dishw dishwash asher er and and repl replace ace faulty aulty timer or module (for S HU/I 43/53 models , ins tall exis ting module jumper onto new





























VIII. Troubleshooting (continued) Problem

Possible Cause

Dishwasher won't stop filling or won't stop draining.

Water in i n dishwasher base from leaky or loose hose.



Float switch or diaphragm (e6 ) failed. Debris Debris in dishwasher base  activated float switch (e6 ).

Turn off dishwasher, drain water manually from dishwasher base and reinstall or replace hose. Level dishwasher using front and rear  leveling leveling legs (see customer cust omer dishwasher installation instructions). Turn off dishwasher and replace float  switch switc h or diaphragm. diaphragm. Turn off dishwasher and remove debris  from dishwasher base

Low customer water supply pressure. Inadequate customer water  supply piping. Scale in customer supply piping  or dishwasher piping/parts from hard water.

Adjust customer water supply pressure (to 5-20 psi or 0.3-8.27 bars). Install appropriate appropriate piping t o dishwasher  according to local codes. Clean or replace clogged piping/parts and  have have customer cus tomer get water t ested and use appropriate water softener.



Dishwasher isn't level, level, c ausing float switch (e6 ) to operate. 





Water fills too slowly.

Suggested Action







Custo Custome merr water water suppl supply y turne turned d off off  Rec on onnec t and t ur urn on c us us to tomer wat er er or disconnected. supply. NOTE : An "F" fa u lt cod e  Water valve (s2 ) failed. Check Check resista resistance nce @ water water valv alve term termin inal als s  in the d isp la y sho ws (≈ 1000 Ω ). Turn off dish ishwashe sher and replace lace th e re 's a fi l li n g prob le le m faulty valve. 

Water won't fill.



( not

fi l l i ng, over - fi l l i ng, under fifi llll in ing or water i n the

base ).

The fa u lt co d e ca n' n't b e rese t m an an ua ual ly ly – it wil l re se t itsel f 1 5 m in u te s a fte r th e di sh wa sh e r h as b e e n turned on (aft

Water level switch (f1 ) failed.

Turn off dishwasher and replace faulty level  switch. Timer (SH SHU U 30/40 /40 models ) or  Chec k voltage at and wiring to timer or  module (all other models ) failed. modu module le.. Turn urn off off dishw dishwash asher er and and repl replace ace faulty aulty ti d l (f SHU/I 43/53 d l 





























VIII. Troubleshooting (continued) Problem

Possible Cause

Suggested Action



Wa ter doesn't doesn't circulate.



Circulation motor (m2 ) failed. Timer (SHU 30/40 models ) or  module (all other models ) failed.

Turn off dishwasher and replace motor. Check voltage at and wiring to timer or  module. Turn off dishwasher and replace faulty timer or module (for SHU/I 43/53 models, install existing module jumper onto new ). module ).



Hi-Limit (f5 ) tripped and failed to reset.

Run test program & measure current to dishwasher. dis hwasher. If current ≈ 11A, Hi-Limit Hi-Limit is OK. If not (and for all other models), turn off dishwasher and measure resistance @ Hi-Limit terminals (≈ .3 Ω ). Replace Replace faulty faulty Hi-Limit. Hi-Limit.

Water doesn’t heat up properly.





NTC (temperature sensor) failed.







Turn Turn off dishwasher dishwasher and check resistance

of NTC (≈ 55 kΩ @ 72oF). Replace faulty faulty NTC. NTC. 

Heater (r1 ) failed.

Run test program & measure current to dishwasher. dis hwasher. If current ≈ 11A, heater heater is OK. If not (and for all other models), turn off dishwasher and measure heater resis resistance tance (≈ 11 Ω ). Replace Replace faulty faulty heater.



Water flow switch (e5 ) failed.

Run test program & measure current to dishwasher. dis hwasher. If current ≈ 11A, flow switch is OK. If not, remove remove flow flow switch microswitch, microswitc h, close its contacts & measure measure its resistance (≈ .4 Ω ). Replace faulty faulty flow switch. switc h.



Timer (SHU 30/40 models ) or  module (all other models ) failed.



Dishwasher cycle runs too long, yet dishwasher washes, rinses and shuts off



Customer hot water supply isn't o

o

hot enough (< 140 F/ 60 C).



Check voltage at and wiring to timer or module. Turn off dishwasher and replace faulty timer or module (for SHU/I 43/53 models, install existing module jumper onto new ). module ). 

Adjust hot water supply according to local codes. 





























VIII. Troubleshooting (continued) NOTE: The following parts can't be serviced from the front of the dishwasher (the dishwasher must be pulled out and the tank removed or tilted/blocked up to replace them):

Heater •· Circulation motor Aqua sensor – •· – can be reached reached without without blocking blocking up tank •· NTC NTC (tem (tempe pera ratu ture re pro probe be)/ )/Hi Hi-L -Lim imit it (18 (185º 5ºF) F) ther thermo most stat at NOTE: On electronic models, run test program to identify dishwasher problems. The test can run 20 minutes or more (to get temperature up to 150ºF), but tests can be cancelled to shorten testing testing time. The test program program allows draining, draining, filling, circulating circulating and heating heating to be checked more quickly than running a standard wash cycle. To use test program for troubleshooting, measure voltages/currents as parts come on. For example, example, run heating test and measure measure current coming into dishwasher dishwasher – if current ≈ 11A, HiLimit, heater and flow switch are OK. If not, check each part to see which one failed. This test saves time since you can't get to these parts without removing the tank and can't run resistance checks from front of dishwasher because flow switch stays open. NOTE: Jumpers aren't aren't included with SHU/I SHU/I 43/53 replacement replacement modules – take jumper off old module and put it on new module. NOTE: An "F" fault fault code in the display display shows shows there's there's a filling filling problem problem (not filling, filling, overfil overfillin ling, g, underfi underfillin lling g or water water in the base base). ). The fault fault code code can't can't be be reset reset manuall manually y – it will will reset itself 15 minutes after the dishwasher has been turned on (after testing how it fills). •·





























VIII. Troubleshooting Dishwasher Parts Issues 

Water valves…. valves…. Most damaged valves occur from being cracked by fittings being overtightened -- some valves are damaged from hard water or debris from customer pipes clogging them so they can’t close securely. A damaged valve can allow allow some water onto kitchen floors.



Impellers or circulation pumps…. pumps ….They’re



Control modules…. modules….From heater relay solder joints to broken buttons to “F” or

improved and perform well, but expectations are high for dishwashers in rarely used summer homes. “2H” fault codes, codes, modules can fail occasionally. occasionally. However, many good modules modules have been replaced due to unrelated problems.



Heat Heater ers s & NTC’ NTC’s s.…Either one can cause heating problems, but there can be other parts to check as well....



installation 1st to confirm confirm if it’s the pump pump or not. Drain pumps.… pumps.…Check drain hose installation Many good pumps have been replaced because high loops were missing.



Dispensers.… Dispensers.…Repairs often due to customer abuse.



Cosmetic damage.… damage.…Dinged doors and broken buttons, often during shipment.



Door



Aqua sensors…. sensors….Not crucial to operation, but can affect energy & water usage.



Water fill assemblies.… assemblies.…Microswitches can fail.

latches.… latches.…Often

broken microswitches on integrated models, understandable understandable seeing how dishwashers dishwashers are treated. treated. Can be misaligned misaligned latches latches or miswired miswired switches. switches.

Can be affected affected when units have been flipped upside-down, allowing sump water to get into diaphragm.

Circulation Pump - Impeller Sym ptom Impe mpelle ller wo won't tur turn.

Problem

Solution

Impe mpelle ller is is fr frozen zen. Replace lace imp impelle ller with ith imp impelle ller kit kit # 167085. 167085. If not able to replace lace imp impelle ller imme immed diate iately ly place lace





























VIII. Troubleshooting Control Control Module - Modules Displaying “1”

Occasionally Occasionally dishwashers will run for hours, not finish washing & show a “1 “1” in the display. This means the module has timed out due to an unidentified heating problem -- all heating related parts must be checked until the problem is found. IMPORTANT: Whenever a “1” shows in the module display, the module must be reset (after the heating problem has been fixed) by running the dishwasher. dishwasher . The module resets after the 1 st run.

START

If no, module is working fine.

NO

Has dishwasher stopped washing and is showing a “1” in the display?

YES

If yes, control module has timed out showing there’s an unidenti unidentified fied heater heater problem.

NOTE: The heating prob proble lem m must must be fixe fixed d before the module will reset and stop showing a “1” in the display. 3-winding circulation pumps can measure ~ 7 Ω Ω or 9.4 Ω Ω , depending on motor starter.

Have these parts been































VIII. Troubleshooting Heater - Troubleshooting Troubleshooting Flowchart NOTE: Flow through heaters heat water ~ 2ºF / minute.

Can also measure heater current @ module red heater heater wire (~ 9.5A). 9.5A).

START If ~ 11A, heater is working fine.

With heater on (during test program), measure dishwasher incoming current (blac (black k wire). wire).

If ~ 1.5A, heater circuit has failed.

Measure voltage @ control module.































VIII. Troubleshooting Water Leaking Past Doors Water seldom leaks out of bottom of dishwasher doors. Usually it’s a customer or installation issue. Occasionally temporary blockages of condensation tubes by air pockets (from standing water in loops) or kinks in tubes causes leaking. Pressure builds in tanks, blowing water past lower door seals. Draining condensation tubes and straightening out kinks solves these occasional problems.

START

Water occasionally leaks past bottom of doors, usually at start of cycles.

Make sure condensation tubes aren’t connected to drains or air gaps!

Making sure bottom end of condensation tubes are in bases

Have these issues been checked??































VIII. Troubleshooting Circulation Pump - Checking PTC Pump Motor Starter (1) The (PTC) circulation pump motor starter (# 182318) 182318) is used on SHX99B / SHV9 SHV99A 9A / SHY9 SHY99A 9A (“Apexx”), SL95A & SHX5 SHX56B 6B / SHV SHV66 66A A / SHY SHY56 56AA66C (“ExactWash”) models with water switches. The matching circulation pump (# 437345) 437345) has three slightly smaller & more efficient windings compared to the traditional pump with two larger windings (# 266511 motor / # 239144 pump). The 3rd (start) winding winding is cut out when the motor motor gets running. This stronger stronger pump pump is needed due to the increased water flow resistance from the water switch.

NOTE: Install starter with terminal pointing inward.

NOTE: Pump # 437345 includes starter # 182318. 182318. HINT: (PTC) motor starter is located on top of the pump motor and faces inward over the motor.































VIII. Troubleshooting Circulation Pump - Checking PTC Pump Motor Starter (2) PTC TECH TIPS: measurements:

3 2 4

1

Apexx model shown

Resistance



Between Between termin terminals als 1 - 2 is ~ 7 Ω (one of the main run windings).



Won’t help between terminals 2 - 4 (sta (start rt windin winding, g, a run run winding & the motor starter). The motor starter can’t be measured since the windings are always connected. Must disconnect PTC 1st to measure its continuity.































VIII.

Troubleshooting Circulation Pump - Water Switch Pump Nuisance Tripping (1)

There has been some nuisance tripping of motor thermal protectors on three-winding circulation pumps for use with water switches (# 239129). 239129). To prevent nuisance tripping, these pumps have been replaced by pumps with upgraded thermal protectors (# 437345). 437345). IMPORTANT: Circulation pump # 437345 includes motor starter # 182318. 182318. When replacing any pump, always replace the motor starter as well.

































VIII.

Troubleshooting Circulation Pump - Water Switch Pump Nuisance Tripping (2)

HINTS: Identifying circulation circulation pumps & motor starters: •

Circulation pump # 437345 – look look for for # “5600 060022” stamped on housing.

•

Motor starter # 182318 – 182318 – look look for for # “036906” stamped on housing.

•

Circulation pump # 239129 – look look for for # “5600 050139” stamped on housing.

•

Motor starter # 423023 – 423023 – look look for for # “041692” stamped on housing.

Motor starter 182318

































VIII.

Troubleshooting Circulation Pump – Replacing Impellers (1)

Occasionally, a circulation pump impeller can stick if a dishwasher hasn’t been used for a long time. Impeller ceramic rings and carbon rings had been changed (during January, 2001) to reduce or eliminate impeller sticking (ceramic rings are located around shaft on rear of impeller). For temporary repairs when impeller replacement isn’t possible, impellers can be loosened by rotating them (through the sump) using an 8mm nut driver (impellers should be replaced shortly thereafter when repairs are possible). 8 mm nutdriver

HINTS:

































VIII.


Occasionally, a circulation pump will jam when debris gets caught inside (when the sump filter wasn’t tightened down) or when a dishwasher hasn’t been used for months. Often circulation pumps are replaced when merely changing the impeller (kit # 167085, 167085, item # 24 ) will solve the problem. “Softer bearing” circulation pump supported by rubber straps

8mm nutdriver Sump

impeller

































VIII.


Replacement impellers will have a green tint compared to older impellers. The impeller impeller ceramic ring should should be pink or bright white.

Carbon ring ring used 1/01 1/01 – 12/02 shown shown

HINT: To remove or temporarily break loose an impell impeller, er, plac place e a 8mm 8mm nut nut driver (or similar tool) on 8mm stud in center of impeller. Freed impellers

































VIII.

Troubleshooting Circulation Pump – Service Index UC/06, UC/11 & UC/12 Parts Changes

Pa rt de scr iption Circ Circulation ulation pump Pump suppor t bus hings

Old pa rt #

M odels use d on

263835

All models (index #’s UC/06 & UC/09)

(m otor only) only)

16 72 44

All models (index #’s UC/06 & UC/09)

Softer bearing part # 491434 (pump) or 266511 (motor only) only)

--------

M odels used used on All models models (index ( index #’s UC/07, UC/11 & UC/12)

-------All models models (index ( index #’s



































VIII.

Troubleshooting Circulation Pump – Service Index UC/14 Water Switch Parts Changes



































VIII.

Troubleshooting Circulation Pump – Pump & Motor Part # Changes

The softer bearing bearing (UC/07, UC/11 & UC/12 index) index) circulation circulation pump and motor only part #’s for all B , Thermador & G models have been



































VIII.

Troubleshooting Control Module – Heater Relays HINT: Occasionally, a heater relay

HINT:

Faulty

heater



































VIII.

Troubleshooting Control Module – Using # 264946 Front Cover to Replace Broken # 266746, # 263832 or # 264461 Control Module Buttons

# 266746, # 263832 or # 264461 control modules are often replaced when buttons



































VIII.

Troubleshooting Control Module – Using # 481055 Control Modules in Older SHU 99 and SHV 43/48 Dishwashers (1) Control module # 265401 used on older SHV older SHV 43/48 and SHU 990x/991x





































































































































































































































































































































































































































































































































































































































































































































































































































Bosch Dishwasher Service Training

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