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WHIRLPOOL CONSUMER SERVICES
Model 6ADP905/3 IX
June 2002
WHIRLPOOL AUSTRALASIA CONSUMER SERVICES
SERVICE MANUAL
DISHWASHER Model 6ADP905/3 IX Version 8542 905 53640
Copyright © 2000 Whirlpool (Australia) Pty. Limited All rights strictly reserved. Reproduction or issue to third parties in any form whatsoever is not permitted without written authority of Whirlpool (Australia) Pty. Limited Whirlpool is a registered trademark of Whirlpool U.S.A. This documentation is intended only for qualified technicians who possess the required qualifications and are aware of the regulatory requirements applicable to servicing electrical appliances.
Whirlpool (Australia) Pty Limited A. B. N. 28 003 578 023 Part No. SM4018
WHIRLPOOL CONSUMER SERVICES
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Models 6ADP905/3 IX
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WHIRLPOOL CONSUMER SERVICES
Models 6ADP905/3 IX
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CONTENTS
Page TECHNICAL DATA EXPLODED VIEW - CABINET EXPLODED VIEW - DOOR AND CONTROL PANEL SPARE PARTS LIST PROGRAM CHART CIRCUIT DIAGRAM PROGRAM SEQUENCE AND INDICATION PROCEDURE FOR DIAGNOSTIC SERVICE TEST PROGRAM PASSIVE TEST PROGRAM FAULT CODES DISPLAY FAULT DIAGNOSIS ACTIVE TEST PROGRAM CONTROL BOARD TEST POINTS 4-5 6 7 8 - 10 11 12 13 13
14 15 16 - 17 18 19
WHIRLPOOL CONSUMER SERVICES
TECHNICAL DATA Dimensions
Height Width Depth Mass 850 597 596 61 mm mm mm kg Detergent max. Pre-wash Main-wash Rinse aid 6 Dosage steps
Models 6ADP905/3 IX
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10 45 125 1-6
cm 3 cm ml ml
3
Decor Plate
Thickness (Max) Width Height Weight (max) 4 583 595 1.8 mm mm mm kg
Operating Speeds Spray pump motor Drain pump motor Spray arm, lower Spray arm, upper 2800 3000 20 - 40 25 - 35 rpm rpm rpm rpm
Electronic Circuit Boards
Service Boards See Spare Parts Serial Boards UB 4619 720 86171 DB 4619 720 80381 CB 4 23411 Dataset 0 97632
Water Pressure/Temperature
Inlet pressure, min. max. Spray pump pressure Hot Connection 30 1400 40 60 kPa kPa kPa °C max
Programs
Programs Succession See Program Chart 1a-4b-6b-6d-7a
Flow rates / Inlet volume
Flow meter calibration 208 Impulses/Iitre (at 30 kPa pressure and 1.1 Iitres per min) Spray pump ~70 I/min Drain pump 16 I/min Pump height, max. 1.1 m Inlet valve 4.5 I/min Spray arm lower ~33 I/min Spray arm upper ~27 I/min Ceiling rotor ~10 l/min
Program Indication
Start indicator Prewash Main wash Drying End
Electrical Data
Base Data Voltage Frequency Maximum input Fuse 230 - 240 50 2.4 10 V Hz kW A
Water Volume (Normal Program)
Operation Volume Level Back rinse (x3) 1.0 litre 68mm Prewash 4.8 litres 122mm Main Wash 4.5 litres 121mm Intermediate rinse 1 4.0 litre 120mm Intermediate rinse 2 4.0 litre 120mm Clear rinse 4.0 litres 120mm Safety/Overflow 8.5 litre 141mm Note: To measure the water level, remove the coarse sieve and using a ruler, measure the water depth from the bottom of the sump.
WHIRLPOOL CONSUMER SERVICES
Motors
Spray Pump Motor Voltage Power consumption. HI (in series with cap) HA Capacitor Drain Pump Motor Voltage Input Resistance 230 - 240 160 81 44 4 230 - 240 30 146 V W · · µF V W ·
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Aquasafe System Drip tray Reed Contact Flow meter NTC 15 ºC 20 ºC 25 °C 30 ºC 40 ºC 50 ºC 60 ºC 70 ºC 80 ºC 85 ºC 75 58.1 47.1 30.2 25.4 17.2 11.8 8.3 6 4 · k· k· k· k· k· k· k· k· k·
Heating
Voltage Power consumption Resistance Heating rate Temperature on surface Double safety element cut-out, self resetting Thermal Fuse 230 - 240 V 2.22 kW 25 · 2 ºC/min ~115 ºC 85 206 ºC ºC
Potentiometer
Between 1 (Black) and 2 (Middle) Position 0 0.0 Position 1 0.5 Position 2 1.0 Position 3 1.4 Position 4 1.8 Position 5 2.3 Position 6 2.6 k k k k k k k
Water Valves
Single Valve at Inlet Hose Voltage 230 - 240 Frequency 50 - 60 Resistance 3.8 Dispenser Coil Voltage Frequency Resistance 230 - 240 50 - 60 146 V Hz k· V Hz ·
WHIRLPOOL CONSUMER SERVICES
EXPLODED VIEW - CABINET
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WHIRLPOOL CONSUMER SERVICES
Models 6ADP905/3 IX
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EXPLODED VIEW - DOOR AND CONTROL PANEL
WHIRLPOOL CONSUMER SERVICES
SPARE PARTS LIST
Item 003 0 004 0 004 1 011 0 022 0 022 1 024 0 030 0 034 0 034 1 040 1 040 2 044 0 044 1 047 0 047 1 047 2 053 0 061 0 103 0 120 0 120 1 130 0 131 0 175 0 175 1 175 2 176 0 191 0 192 0 241 0 241 1 241 3 241 6 241 8 241 9 242 0 242 1 242 4 243 0 261 0 261 1 261 2 263 0 263 1 301 0 303 1 305 0 322 0 331 0 Part No 4812 440 19594 4812 440 18952 4812 401 18402 4812 505 18357 4812 440 19579 4812 440 19578 4812 440 10417 4819 310 18598 4812 404 78237 4812 404 78297 4812 417 18774 4812 417 18773 4812 492 38358 4812 492 38364 4812 404 48746 4812 401 18397 4812 404 68023 4812 440 88889 4812 466 88552 4812 440 19453 4812 440 19456 4812 440 18969 4812 417 58361 4812 401 18416 4812 310 18309 4812 310 18308 4812 310 18311 4812 310 18736 4812 466 68564 4812 466 68467 4812 458 19027 4812 458 18324 4812 528 88068 4812 458 18333 4812 466 68553 4812 528 88075 4812 458 18919 4812 528 88069 4812 466 48059 4812 458 18272 4819 462 38271 4812 462 79768 4812 462 78995 4819 520 18013 4812 520 48001 4812 453 70528 4812 460 38056 4812 440 18973 4812 453 71509 4812 413 58889 Description Traverse Drip tray assy Holder, drip tray Foot short Side panel, left, black Side panel, right, black Panel, rear Table top kit, black Spacer Fastener Hinge left Hinge right Spring, door Spring, cap Brake, door Band, brake Hook Plinth, black Counter weight Door outer, black Door, inner Batten Door lock, complete Hook lock Trim, ornamental left, black Trim, ornamental right, black Trim, ornamental lower, black Décor plate door Gasket door 21.05.2001 Gasket, door lower Basket upper straight Holder cups right wh Wheel, basket upper (set) Holder glasses wh Spacer cap set Wheel, basket upper Basket lower complete Wheel, basket lower wh Fixation wh Basket cutlery Rail telescope, inner Cap rail 19.03.2001 Cap, rail, front Ball cage complete Ball Niro 8 D Control panel, black Plate, handle, black Batten, black Insert panel Knob, program, complete
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WHIRLPOOL CONSUMER SERVICES
SPARE PARTS LIST (Cont.)
Item 332 0 350 0 350 1 400 0 405 0 405 1 420 0 421 0 430 0 430 1 450 0 480 0 480 1 480 2 480 3 490 0 490 1 521 0 571 0 583 0 620 0 633 0 680 0 680 1 681 1 681 2 682 0 691 0 701 0 701 0 701 0 701 1 701 2 710 2 710 3 714 0 714 2 716 0 716 1 716 2 721 1 721 2 721 3 721 4 722 0 Part No 4812 410 28569 4819 310 39834 4812 381 28024 4812 361 58126 4812 360 18371 4819 515 28158 4812 121 18132 4812 121 18158 4812 360 18357 4812 466 68506 4812 259 28684 4812 321 28386 4812 321 28371 4812 321 28383 4812 401 18418 4812 321 18051 4812 321 28367 4812 214 78238 4812 281 28379 4812 271 28407 4812 218 38081 4812 271 38355 4812 418 68155 4812 466 68495 4812 466 68497 4812 440 18975 4812 466 68496 4812 282 68012 4812 530 28081 4812 530 28082 4812 530 28928 4812 310 18302 4822 480 50159 4819 310 38536 4819 466 69562 4812 462 78012 4812 440 18963 4812 418 68142 4812 466 68475 4812 462 78994 4812 360 68061 4812 466 68491 4812 466 68558 4812 440 19455 4812 360 68044 Description Push button cap, black Display board (DB) KIT Lens, green Motor and spray pump complete Spray pump Gasket Capacitor Interference filter Pump, draining Shaft seal Heating element Cable harness set Cable Cable 6 poles Protector, wiring Cable, mains Strain relief Control board (CB) Valve inlet Switch diaphragm User board (UB) Microswitch, door Combidosage Gasket Gasket Flap Gasket Feeler NTC Hose, inlet 3/8Z complete 5m Hose, inlet 3/8Z complete 3m Hose Yoke Sieve inlet Threaded ring Gasket set Threaded cap Cabinet non-return flap Reg. dosage Gasket Cover Spray arm, lower, complete Gasket 25x2,3B Gasket 30x3,0 Flange Spray arm upper
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WHIRLPOOL CONSUMER SERVICES
SPARE PARTS LIST (Cont.)
Item 722 2 723 1 726 0 726 1 726 2 726 3 726 4 743 1 751 0 751 1 755 0 755 2 761 0 761 2 762 0 763 0 781 0 781 1 781 2 781 3 783 4 783 5 783 6 791 0 791 4 791 5 794 1 901 0 901 1 901 2 901 7 904 0 904 2 904 3 904 4 910 1 910 2 910 3 910 4 910 5 910 7 910 9 911 0 911 0 964 0 964 1 993 0 Part No 4812 310 28088 4819 310 39831 4812 530 28786 4812 530 28787 4812 505 18358 4812 466 68512 4812 462 79633 4812 530 28102 4812 418 18205 4819 310 39826 4812 530 28849 4812 530 48148 4812 480 58082 4812 418 18204 4812 480 58084 4812 480 58083 4812 530 28737 4819 530 28286 4819 492 68405 4812 281 28364 4812 530 28904 4812 530 78028 4812 530 28824 4812 532 68067 4812 466 68503 4812 466 68504 4819 530 58032 4822 401 10492 4812 401 18424 4812 401 18157 4812 401 18427 4812 462 78998 4812 462 79657 4812 462 79637 4812 462 79659 4812 502 38152 4812 502 18363 4812 502 18389 4812 502 18385 4812 502 18393 4812 502 18397 4812 401 18425 4812 502 38148 4812 502 38149 4812 466 68536 4812 466 68469 4819 530 29028 Description Docking station, upper basket Upper spray rose cage Tube to fixed docking station Tube to upper spray rose Nut, docking station Gasket Docking station in cavity Hose, inlet Water collector Water guide service kit Bend Tray, leak Sieve fine Cover sieve Microfilter Sieve, coarse Hose, draining Sleeve hose Clip, non-return valve Flap non-return Hose 10x3x265+10 Distributor Hose 10,3X3X245 Gasket Gasket Gasket Gasket 20x2,5 Clamp, hose 14-24 mm Strap 050,0 Strap 32-50/9 C61 Strap 031,6 Threaded cap Cover BK 3,5x5 Cover, black 3,5x4 Threaded cap Screw 4,8x19 Screw 4,0x12-H Screw 5x20 T20 Screw M3,5x8-T15M Screw 3,5x9-1 Tx15 Screw, stainless steel A2 M 5X12 Screw 2,5x18-H Screw ST3,5x9,5-C-H Screw ST3,5x9,5-C-H Gasket housing right/left Gasket housing upper Bow
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WHIRLPOOL CONSUMER SERVICES
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WHIRLPOOL CONSUMER SERVICES
PROGRAM CHART
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CIRCUIT DIAGRAM
WHIRLPOOL CONSUMER SERVICES
C1 Capacitor CB Control board DB Display board DUB Display and User board DLB Timer switch Delay DPM Drain pump Motor DO Cleaning agent dosage DR Final rinse dosage DS Door switch FM Flow meter HEWI Heating IF Interference filter L.S6 Water leakage switdl L Line MS Main switch NTC Thermostat temp. sensor N Neutral RE2 Heating relay RR RA Reed relay rinse aid SPM Spray pump motor THS1Safety thermostat THS 2 Fuse TBL Power supply terminal TL Winding protective contact UB User board VvV1 Water inlet valve WI Water indicator
00 black 66 blue 88 grey 99 white
Connector Rast 2.5 on CB: Red mark : left hand side Black mark: right hand side
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WHIRLPOOL CONSUMER SERVICES
PROGRAM SEQUENCE AND INDICATION
LED No. 1 (PS1) Rinse LED No.2 (PS2) Wash LED No. 3 (PS3) Dry LED No. 4 (PS4) End
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Flushing Pre-wash Main wash Intermediate rinse Final rinse Drying (Passive) Extinguishes after 30 minutes or if switch is turned to `O'
PROCEDURE FOR DIAGNOSTIC SERVICE TEST PROGRAM
1. Start the passive test program. (See Page 14). If there is a defective component indicated, open the plinth and take out the control board (CB). 2. Check the component. Unplug the indicated component from the control board and check with a multi-meter. If resistance is comparable with the data sheet check cabling and connections and examine component. 3. Check control board. Dishwasher components are controlled via electronic devices. As a result, when checking control board component output voltages, the component connector must be connected to the control board to load the electronic device. 4. If the dishwasher appears totally dead, perform test point tests. (See Page 19). 5. After completion of any repair, run the test program again to confirm repairs have been effective. NOTE 1 : The first step of test the program of the new service control boards is without backrinsing. If the machine contained any water at the start of the test there would be a risk of overflow. NOTE 2 : Indicated failures F1 : NTC failure F2 : Water leakage F9 : Continuous water inlet will cause the diagnostic program to terminate, so these failures must be repaired before it is possible to continue with the test.
Once a wash program has been started it cannot be altered but must be cancelled by holding the start button for more than 3 seconds. As the components are controlled by electronic devices, meaningful output voltage measurements from the control board can only be made with the component connected. Do not attempt to measure open circuit voltage output from the control board.
WHIRLPOOL CONSUMER SERVICES
Rinse
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Wash Program Indicators
PS1 PS2 PS3 PS4
Program Selector
Start
Failure NTC failure Water leakage Heating system Drain system Spray arm Blocked Water inlet closed Flow meter Water level Continuous water fill Rinse aid low
Failure No. F1 F2 F3 F4 F5 F6 F7 F8 F9
Indication Start LED flashes Start LED flashes Start LED flashes Start LED flashes Start LED flashes Start LED flashes Start LED flashes Start LED flashes Start LED flashes Red LED on
Test Program Indication PS1 LED Flashes PS2 LED Flashes PS3 LED Flashes PS4 LED Flashes PS1 & PS4 Flash PS2 & PS4 LED's Flash PS3 & PS4 LED's Flash PS2 & PS3 LED's Flash PS1 & PS3 LED's Flash Red LED on
NOTE: The machine will not store Fault Code F6 located during normal operation, only during the active test. Therefore the active test MUST be run for the diagnostics to locate this fault. All Other Fault codes located during normal operation are stored by the machine and will be displayed by the passive test.
PASSIVE TEST PROGRAM
Start Passive test program will indicate the mode of failure. If there is no failure, the test program will result in PS1 to PS4 flashing sequentially. Starting the Passive Test Program 1. Turn the program selector to the off ("O") position 2. Chosen program LED lights 3. 4. Finish passive test program by starting active test program Push and hold the start button while turning the program selector to first cycle (rinse) until the START LED begins to flash. Release the start button. The LED's, PS1 to PS4, will either flash in sequence or light to indicate the mode of failure of the dishwasher. Repair failure Reset program by pressing start button for more than 3 seconds Start passive test again and progress to active test by pressing the start button for less than 3 seconds
PS1 - PS4 Flash sequentially
5. 6. 7.
WHIRLPOOL CONSUMER SERVICES
FAULT CODES DISPLAY
Failure Indication to Customer
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Passive/Active Test Program Indication
START START
F1 NTC Fault F2 Water Leakage F3 Heating System Failure F4 Draining Failure F5 Spray Arm Blocked F6 Water Control Cock Closed
PS1 PS2 PS3 PS4
PS1 PS2 PS3 PS4
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
Note: This fault is not stored during normal operation. It is only displayed after the Active Test Program is run.
PS1 PS2 PS3 PS4
START
F7 Flow Meter Failure F8 Water Level Failure F9 Water Inlet Valve Open Continuously
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
PS1 PS2 PS3 PS4
START
LED Flashing LED Off
WHIRLPOOL CONSUMER SERVICES
FAULT DIAGNOSIS
F1
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NTC (Negative Temperature Co-efficient of Resistance) Device - Temperature is outside normal range -3°C to +85°C - Temperature inside the wash chamber is over +85°C - The device is either open circuit or short circuit.
F2
Water Leakage Water is in drip tray - Float switch (LS6) operates, closes the water inlet valve and turns on the drain pump until the water Indicator (WI) reports empty.
F3
Heating System Defective Indicated after approximately 11 minutes of heating operation. - Element (HEW) defective - Relay (RE2) on control board is defective - NTC resistance fluctuation - Water indicator (WI) defective (open-circuit) - Spray pump is not working
F4
Draining Failure Drain pump energised and after four minutes Water Indicator (WI) still detects water. - Drain pump (DPM) defective - Drain hose blocked - Control board defective - Water Indicator defective (Pressure switch contacts remain closed)
F5
Spray Arm Blocked. (Fault does not cause dishwasher to stop) SAB sensor sends less than 10 pulses/minute. - SAB sensor defective - Spray arm blocked or not located correctly - Spray pump motor inefficient (insufficient water flow through pump.
F6
Water Control Cock Closed Water valve (WV1) is energised but flow meter (FM) sends no impulses to CPU (less than 10 impulses in 10 seconds) and the water indicator is at low level. - Water inlet control cock closed - Water inlet hose blocked or kinked - Water inlet valve (WV1) blocked or defective - Flow Meter (FM) or connecting leads defective
WHIRLPOOL CONSUMER SERVICES
F7 Water Flow Meter Failure
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Water inlet valve is energised and the water indicator is switched to high level. - Flow meter (FM) sends no impulses to CPU (less than 10 impulses in 10 seconds). - Water inlet control cock closed - Water inlet hose blocked or kinked - Water inlet valve (WV1) blocked or defective - Flow Meter (FM) defective - Water indicator defective F8 Water Level Failure Spray pump motor is energised and water indicator switches to low level more than 20 times in two minutes. - Water indicator defective (switch should operate when machine contains approximately one litre of water) - Sieve blocked - Severe foaming - Item in wash load has turned over and filled with wash water - Spray pump pressure unstable F9 Continuous Water Inlet Water Inlet valve is switched off but water indicator is switched to high level and flow meter sends more than ten impulses to CPU in ten seconds. - Water inlet valve defective - Electronic control device for inlet valve failed
WHIRLPOOL CONSUMER SERVICES
ACTIVE TEST PROGRAM
Models 6ADP905/3 IX
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Start the active test procedure by first running the passive test then press the start button for less than three seconds. Operation Start Backrinsing (only after second run of test program Fill and pump at the same time (flushing) three times, 15 seconds each time Function Notes : When the machine detects a fault during normal operation the start light will begin to flash and the cycle may or may not stop. When the control knob is turned to zero the fault is stored (except Fault Code F6) and the fault code will be displayed when the passive test is run. For the diagnostics to locate fault code F6, the active test procedure MUST be followed. The active test programs runs for approximately 21 minutes or, if the heat cycle is bypassed the test runs for approximately 3 minutes and 45 seconds. The active test program runs to the point of failure then stops. If there is no failure the test programs runs to the end.
Filling
Fills, spray pump starts & continues to fill. Fill stops, pump stops for 3 sec.
Washing
Detergent dispenser operates, pump restarts, 5 sec delay then heating starts
The failure position is indicated by the flashing START LED extinguishing. To exit the test program, press the START button for more than three seconds.
Water heated to 65°C Pumpout 30 sec delay Pumpout
An empty rinse aid container will not cause the test program to stop, only illuminate the red LED.
End
PS4 LED on
WHIRLPOOL CONSUMER SERVICES
CONTROL BOARD TEST POINTS
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A pair of long, wire claw type probes are required to access the test points. Checking voltages at the test points will determine the correct operation of the function push buttons and the rotary switch. Before attaching test probes to the control board test points which are accessed via the control board service window, disconnect the dishwasher from the supply. Short circuiting of any of the electronic components will cause the control board to fail. Test Points : T0 = Common T1 = Analogue voltage T2 = Analogue voltage T3 = Digital signal
Service Window T0 T3 T2 T1
Control Board A voltmeter with a high input impedance is required to measure the control board voltages. The degree of agreement between the measured voltage and the nominated voltage will be dependent on the accuracy of the voltmeter. Test Point T0 to T1 Communication between control board and display board Push Button All off Voltage (V dc) -5.24
Test Point T0 to T2 Communication between control board and user board Rotary Switch O Program 1 Program 2 Program 3 Program 4 Program 5 Voltage (V dc) 0.00 Cold -1.32 50°C -2.90 65°C -3.36 65°C -3.80 70°C -4.27
Test Point T0 to T3 Communication between control board and display board Before Start (LED off) After Start (LED on) -5.24 V dc -3.87 V dc