4317352 KAL-4 KitchenAid Ensemble Front-Loading Automatic Washer

TECHNICAL EDUCATION

JOB AID 4317352

KAL-4

FRONT-LOADINGAUTOMATIC WASHER

MODEL KHWS01PMT / WH

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WHIRLPOOL CORPORATION assumes no responsibility for any repairs madeon our products by anyone other than Authorized Service Technicians.

FORWARDThis KitchenAid Job Aid Ensemble Front-Loading Automatic Washer (Part No. 4317352),provides the technician with information on the installation, operation, and service of the EnsembleFront-Loading Automatic Washer. It is to be used as a training Job Aid and Service Manual. Forspecific information on the model being serviced, refer to the Use and Care Guide, or TechSheet provided with the washer.

The Wiring Diagram used in this Job Aid is typical and should be used for training purposes only.Always use the Wiring Diagram supplied with the product when servicing the unit.

GOALS AND OBJECTIVESThe goal of this Job Aid is to provide detailed information that will enable the service technician toproperly diagnose malfunctions and repair the KitchenAid Ensemble Front-Loading AutomaticWasher.

The objectives of this Job Aid are to:

Understand and follow proper safety precautions.

Successfully troubleshoot and diagnose malfunctions.

Successfully perform necessary repairs.

Successfully return the washer to its proper operational status.

Copyright 2004, Whirlpool Corporation, Benton Harbor, MI 49022

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TABLE OF CONTENTSPage

GENERAL ............................................................................................................................... 1-1KitchenAid Model & Serial Number Designations.............................................................. 1-1Model & Serial Number Label And Tech Sheet Locations................................................. 1-2Specifications..................................................................................................................... 1-3Pedestal Warranty ............................................................................................................. 1-3KitchenAid Washer Warranty ............................................................................................. 1-4

INSTALLATION INFORMATION ........................................................................................... 2-1Installation Requirements .................................................................................................. 2-1Installation Instructions ...................................................................................................... 2-5Installing The Washer On The Pedestal ............................................................................ 2-7

PRODUCT OPERATION ........................................................................................................ 3-1Theory Of Operation .......................................................................................................... 3-1Customer Interface & Cycle Selection ............................................................................... 3-7Cycles ................................................................................................................................ 3-8Options ............................................................................................................................ 3-10Modifiers .......................................................................................................................... 3-11

COMPONENT ACCESS ......................................................................................................... 4-1Component Locations ........................................................................................................ 4-1Removing The Console And The Touchpad/LED Assembly ............................................. 4-2Removing The Door Lock/Switch Assembly, And The Front Panel & Bellows ............................................................................................................. 4-4Removing The Flowmeter .................................................................................................. 4-7Removing The Detergent Dispenser Motor & Assembly ................................................... 4-8Removing The Inlet Valves .............................................................................................. 4-10Removing The Central Control Unit ................................................................................. 4-11Removing The Interference Filter .................................................................................... 4-12Removing The Pressure Switch ...................................................................................... 4-13Removing The Motor Controller ....................................................................................... 4-14Removing The Temperature Sensor & The Heating Element ......................................... 4-16Removing The Heating Element Relay............................................................................ 4-17Removing The Drain Pump Assembly ............................................................................. 4-18Removing The Airtrap ...................................................................................................... 4-19Removing An Interlock Switch ......................................................................................... 4-20Removing The Drive Motor .............................................................................................. 4-22Removing The Tub And Basket Assembly ...................................................................... 4-24

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COMPONENT TESTING ........................................................................................................ 5-1Pressure Switch ................................................................................................................. 5-1Detergent Dispenser Motor & Switch................................................................................. 5-2Inlet Valve Solenoids ......................................................................................................... 5-2Door Lock/Switch Assembly .............................................................................................. 5-3Drain Pump Motor .............................................................................................................. 5-4Interference Filter ............................................................................................................... 5-4Heating Element & Temperature Sensor ........................................................................... 5-5Heating Element Relay ...................................................................................................... 5-5Drive Motor ........................................................................................................................ 5-6Interlock Switch.................................................................................................................. 5-6

DIAGNOSTICS & TROUBLESHOOTING .............................................................................. 6-1

WIRING DIAGRAM ................................................................................................................. 7-1

TECH TIPS ............................................................................................................................. 8-1Manual Door Latch ............................................................................................................ 8-1Door Plunger ...................................................................................................................... 8-1

Page

1-1

MODEL & SERIAL NUMBER DESIGNATIONS

MODEL NUMBER

SERIAL NUMBER

GENERAL

MODEL NUMBER K H W S 01 P MT 0

PRODUCT GROUP

K = KITCHENAID

PRODUCT IDENTIFICATION

H = HORIZONTAL AXIS - DOMESTIC

FEATURE CODE

W = WASHER

FEATURE CODE

S = SUPERBA

SERIES

YEAR OF INTRODUCTION

P = 2004

COLOR CODE

MT = METEORITE

WH = WHITE

ENGINEERING CHANGE (NUMERIC)

MODEL NUMBER (PEDESTAL)

SERIAL NUMBER (PEDESTAL)

MODEL NUMBER L A B 27 0 0 P MT 0

PRODUCT GROUP L = Domestic LaundryPRODUCT IDENTIFICATION

A = Laundry Accessory

FEATURE CODE B = Pedestal Base

PRODUCT WIDTH

FILLER

FILLER

YEAR OF INTRODUCTION

COLOR CODE MT = Meteorite, Q = White

ENGINEERING CHANGE

SERIAL NUMBER CS P 42 09793

DIVISION RESPONSIBILITY

CS = Schorndorf, Germany

YEAR OF PRODUCTION

P = 2003

WEEK OF PRODUCTION

42 = 42ND WEEK

PRODUCT SEQUENCE NUMBER

SERIAL NUMBER C P 01 10001MANUFACTURING SITE C = CLYDE, OHYEAR OF PRODUCTION P = 2003WEEK OF PRODUCTIONPRODUCT SEQUENCE NUMBER

1-2

MODEL & SERIAL NUMBER LABELAND TECH SHEET LOCATIONS

The Model/Serial Number label and Tech Sheet locations are shown below.

Model & SerialNumber LabelLocation

Tech Sheet Location(Behind Toe Panel)

1-3

SPECIFICATIONS

FULL ONE YEAR WARRANTY ON MECHANICAL PARTS

For one year from the date of purchase, when this Pedestal is installed with the listed washer ordryer and operated according to the instructions provided in the washer or dryer Owners Manualor Use and Care Guide, supplier will repair or replace any of its mechanical parts if defective inmaterial or workmanship.

WARRANTY RESTRICTION

If the Pedestal is subject to other than private family use and or used with any other product thanthose listed in the installation instructions, the warranty is null and void.

PEDESTAL WARRANTY

Model Number

Color

Electrical RequirementsHeating PowerMax. CurrentRated CurrentVoltageFrequency

Gallons/Normal Cycle

Capacity

Volume

Max. Spin Speed

DimensionsHeightHeight (Feet Extended)WidthDepthWeight

Installation Options

ProgramsProgram SelectorTemperature SelectorSpin Speed

KHWS01PMT / WH

MT = Meteorite, WH = White

1,000W12A15A120V60 Hz

15.8 Gal./60 L

19.8 lbs. (9 kg.)

3.7 cu. ft. (IEC equivalent)

1150 RPM

37.4 (950mm)38.2 (970mm)27 (686mm)30.3 (770mm)245 lbs. (111kg.)

PedestalStackable

Rotary 12 ProgramsButton (5 levels)Button (5 levels)

1-4

KITCHENAID WASHER WARRANTY

TWO-YEAR FULL WARRANTY

For two years from the date of purchase, when this washer is operated and maintained according to instructions

attached to or furnished with the product, KitchenAid will pay for replacement parts and repair labor costs to

correct defects in materials or workmanship. Service must be provided by a KitchenAid designated service com-

pany.

THIRD THROUGH FIFTH YEAR LIMITED WARRANTY

ON MOTOR AND CENTER POST ASSEMBLY BEARINGS

For the third through fifth year from the date of purchase, when this washer is operated and maintained accord-

ing to instructions attached to or furnished with the product, KitchenAid will pay for replacement parts for the

motor and center post assembly bearings if defective in materials or workmanship.

THIRD THROUGH TENTH YEAR LIMITED WARRANTY ON TOP AND

CABINET ASSEMBLY, GEARCASE ASSEMBLY, AND OUTER TUB

For the third through tenth year from the date of purchase, when this washer is operated and maintained accord-

ing to instructions attached to or furnished with the product, KitchenAid will pay for replacement parts for the

following components if defective in materials or workmanship: the top and cabinet assembly due to rust; any

part of the gearcase assembly; the outer tub should it crack or fail to contain water.

LIFETIME LIMITED WARRANTY ON STAINLESS STEEL WASH DRUM

For the lifetime of the washer, when this washer is operated and maintained according to instructions attached to

or furnished with the product, KitchenAid will pay for replacement parts for the stainless steel wash drum should

it chip or rust due to defects in materials or workmanship.

KitchenAid will not pay for:

1. Service calls to correct the installation of your washer, to instruct you how to use your washer, or to replace

house fuses or correct house wiring or plumbing.

2. Repairs when your washer is used in other than normal, single-family household use.

3. Damage resulting from accident, alteration, misuse, abuse, fire, flood, acts of God, improper installation, in-

stallation not in accordance with local electrical and plumbing codes, or use of products not approved by

KitchenAid.

4. Any labor costs during the limited warranty periods.

5. Replacement parts or repair labor costs for units operated outside the United States and Canada.

6. Pickup and delivery. This product is designed to be repaired in the home.

7. Repairs to parts or systems resulting from unauthorized modifications made to the appliance.

8. In Canada, travel or transportation expenses for customers who reside in remote areas.

KITCHENAID AND KITCHENAID CANADA SHALL NOT BE LIABLE

FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states and provinces do not allow the exclusion or limitation of incidental or consequential damages, so

this exclusion or limitation may not apply to you. This warranty gives you specific legal rights and you may also

have other rights which vary from state to state or province to province.

Outside the 50 United States and Canada, this warranty does not apply. Contact your authorized

KitchenAid dealer to determine if another warranty applies.

If you need service, first see Troubleshooting in the Use and Care Guide. Additional help can be found by

checking Assistance or Service in the Use and Care Guide, or by calling our Customer Interaction Center at

1-800-422-1230, from anywhere in the U.S.A. or write: KitchenAid Brand Home Appliances, Customer Interac-

tion Center, 553 Benson Road, Benton Harbor, MI 49022-2692. In Canada, call KitchenAid Canada at 1-800-

807-6777.

2-1

INSTALLATION INFORMATIONINSTALLATION REQUIREMENTS

TOOLS AND PARTS

Assemble the necessary tools and suppliesbefore beginning the washer installation. Theparts supplied are in the washer basket.

Tools needed for connecting the water inlethoses

Pliers (that open to 1-9/16 [39.5 mm]) Flashlight (optional)

Tools needed for installation

Open end wrench 5/8 (17 mm) and1/2 (13 mm)

Level Wood block (2 x 4) Ruler or measuring tape

Parts supplied

OPTIONAL PEDESTAL

A pedestal (LAB2700PMT/LAB2700LQ) maybe purchased separately for this washer. Thispedestal will add about 13 (33 cm) to theheight of the unit for a total vertical height ofapproximately 51 (130 cm).

Beaded Strap Transport Bolt Hole Plug (4)

Optional Pedestal

Alternate parts

If You Have You Will Need To Buy

Laundry tub or standpipe taller than 96 (2.4 m)

Sump pump system (if not already available).

Overhead sewer

Standard 20 gal. (76 L), 30 (76.2 cm) tall drain tub or utility sink and sump pump (available from local plumbing supplier).

Floor drainSiphon break, #285834; additional drain hose #8318155; and connector kit #285835.

Drain hose too short Drain hose extension kit #285863.Water faucets beyond reach of fill hoses

2 longer water fill hoses: 6 (1.8 m) #76314, 10 (3.0 m) #350008.

OPTIONAL STACK KIT

To stack your washer and dryer, you will needto purchase Stack Kit, Part Number 8541503.

LOCATION REQUIREMENTS

Selecting the proper location for the washerimproves performance, and minimizes noiseand possible washer walk.

The washer can be installed under a customcounter, or in a basement, laundry room, closet,or recessed area (see Drain System).

Companion appliance location requirementsshould also be considered. Proper installationis your responsibility.

You will need

A water heater set to deliver 120F (49C)water to the washer.

A grounded electrical outlet located within5 ft. (1.5m) of where the power cord isattached to the back of the washer (seeElectrical Requirements).

Continued on the next page.

2-2

Washer Dimensions

Custom Undercounter Installation

The dimensions shown are for the recom-mended spacing.

Recessed Or Closet Installation


Recessed Area Or Closed Installation

27"(68.6 cm)

50-1/2"(128.3 cm)

38"(96.5 cm)

31-1/2"(80.0 cm)

1"(2.5 cm)

1"(2.5 cm)

39" min(99.0 cm)

27"(68.6 cm)

1. Side view - closet or confined area2. Closet door with vents

"34(86.4 cm)

1 2

3"(7.6 cm)

3"(7.6 cm)

48 in.2(310 cm 2 )

24 in.2(155 cm 2 )

1"(2.5 cm)

4"(10.2 cm)

31-1/2"(80 cm)

Hot and cold water faucets located within4 ft. (1.2 m) of the hot and cold water fillvalves, and water pressure of 20-100 psi(137.9-689.6 kPa).

A level floor with a maximum slope of 1(2.5 cm) under entire washer. Installing thewasher on carpeting is not recommended.

A sturdy and solid floor to support the washerwith a total weight (water and load) of 400lbs. (180 kg).

Do not operate your washer in temperaturesbelow 32F (0C). Some water can remain inthe washer and can cause damage in low tem-peratures.

Installation Clearances

The location must be large enough to allowthe washer door to be fully opened.

Additional spacing should be considered forease of installation and servicing.

Additional clearances might be required forwall, door, and floor moldings.

Additional spacing of 1 (2.5 cm) on all sidesof the washer is recommended to reducenoise transfer.

Companion appliance spacing should alsobe considered. Recessed Or Closet Installation

Washer On Pedestal

1. Recessed area2. Side view - closet or confined area

1"(2.5 cm)

31-1/2"(80 cm)

1"(2.5 cm)

1"(2.5 cm)

27"(68.6 cm)

4"(10.2 cm)

18 min."(45.7 cm)

21

2-3

Recessed Or Closet InstallationWith Stacked Washer & Dryer


* Min. top and bottom air openings for closet door. ** External exhaust elbow requires additional space.*** Wall, door and floor molding may require

additional spacing.

48 in.2 *(310 cm 2 )

3" (7.6 cm)

6" (15.2 cm)

76" (193 cm)

27" (68.6 cm)

3" (7.6 cm)

1" (2.5 cm)

5-1/2"**(14 cm)1"*** (2.5 cm) 1"*** (2.5 cm)

24 in.2 *(155 cm 2 )

Cabinet Installation

The dimensions shown are for the recom-mended spacing. For cabinet installation witha door, the minimum ventilation openings inthe top are required.

7" (17.8 cm)

9"(22.9 cm)

7" (17.8 cm)

4"(10.2 cm)

31-1/2"(80.0 cm)

27"(68.6 cm)

1"(2.5 cm)

1"(2.5 cm)

1"(2.5 cm)

30" min.(76.2 cm)

1 2

30" min.(76.2 cm)

28" min.(71 cm)

1 2

DRAIN SYSTEM

The washer can be installed using the standpipedrain system (floor or wall), the laundry tubdrain system, or the floor drain system. Selectthe drain hose installation method you need(see Alternate Parts).

Standpipe Drain SystemWall Or Floor (View 1 & 2)

The standpipe drain requires a minimum diam-eter standpipe of 2 (5 cm). The minimumcarry-away capacity can be no less than 17 gal(64 L) per minute.

The top of the standpipe must be at least 30(76.2 cm) high and no higher than 96 (2.4 m)from the bottom of the washer.

Laundry Tub Drain System (View 1)

The laundry tub needs a minimum 20 gal.(76 L) capacity. The top of the laundry tub mustbe at least 30 (76.2 cm) above the floor.

Floor Drain System (View 2)

The floor drain system requires a siphon breakthat may be purchased separately (see Alter-nate Parts ).

The siphon break must be a minimum of 28(71 cm) from the bottom of the washer. Addi-tional hoses might be needed.

2-4

Electrical Shock Hazard

Plug into a grounded 3 prong outlet.

Do not remove ground prong.

Do not use an adapter.

Do not use an extension cord.

Failure to follow these instructions canresult in death, fire, or electrical shock.

WARNING

A 120-volt, 60-Hz., AC-only, 15- or 20-am-pere, fused electrical supply is required. Atime-delay fuse, or circuit breaker, is recom-mended. It is recommended that a separatecircuit serving only this appliance be pro-vided.

This washer is equipped with a power supplycord having a 3 prong grounding plug.

To minimize possible shock hazard, the cordmust be plugged into a mating, 3 prong,grounding-type outlet, grounded in accor-dance with local codes and ordinances. If amating outlet is not available, it is the per-sonal responsibility and obligation of thecustomer to have the properly groundedoutlet installed by a qualified electrician.

If codes permit and a separate ground wireis used, it is recommended that a qualifiedelectrician determine that the ground path isadequate.

Do not ground to a gas pipe.

Check with a qualified electrician if you arenot sure the washer is properly grounded.

Do not have a fuse in the neutral or groundcircuit.

For a grounded, cord-connectedwasher:

This washer must be grounded. In the eventof a malfunction or breakdown, groundingwill reduce the risk of electrical shock byproviding a path of least resistance for elec-tric current. This washer is equipped with acord having an equipment-grounding con-ductor and a grounding plug. The plug mustbe plugged into an appropriate outlet that isproperly installed and grounded in accor-dance with all local codes and ordinances.

WARNING: Improper connection of theequipment-grounding conductor can resultin a risk of electric shock. Check with aqualified electrician or serviceman if you arein doubt as to whether the appliance isproperly grounded.

Do not modify the plug provided with theappliance. If it will not fit the outlet, have aproper outlet installed by a qualified electri-cian.

For a permanently connected washer:

This washer must be connected to a groundedmetal, permanent wiring system, or an equip-ment-grounding conductor must be run withthe circuit conductors and connected to theequipment-grounding terminal or lead on theappliance.

1. 3 prong grounding plug2. 3 prong grounding-type wall receptacle3. Grounding prong 4. Power supply cord

12

3

4

ELECTRICAL REQUIREMENTS

GROUNDING INSTRUCTIONS

2-5

INSTALLATION INSTRUCTIONS

Installing The Washer

Excessive Weight Hazard

Use two or more people to move andinstall washer.

Failure to do so can result in back orother injury.

WARNING

IMPORTANT: Position the washer so that therear of the unit is within approximately 3 feet(90 cm) of the final location.

There are 4 bolts in the rear panel of the washerthat support the suspension system duringtransportation. These bolts also retain the powercord inside the washer until the bolts are re-moved. To remove the bolts:

1. Using a 1/2 (13 mm) wrench, loosen eachof the bolts.

2. Once the bolt is loose, move it to the centerof the hole, and completely pull out thebolt, including the plastic spacer coveringthe bolt, and the cable attached to the bolt.The power cord will be attached to all 4bolts inside the washer.

3. Once all 4 bolts are removed, pull thepower cord through the opening of the rearpanel, and close the hose with the at-tached cap.

REMOVE TRANSPORT SYSTEM 4. Close the bolt holes with the four transportbolt hole plugs.

CONNECT THE INLET HOSES

Connect the inlet hoses to the water fau-cets.

Make sure the washer basket is empty.

1. Using a pair of pliers, check the tightnessof the hose couplings that are attached tothe washer. NOTE: Do not overtighten thecouplings, or damage to the coupling canresult.

2. Attach the hose with the red color indicatorto the hot water faucet, and the hose withthe blue color indicator to the cold waterfaucet. Screw on the couplings by handuntil they are seated on the washer.

3. Using a pair of pliers, tighten the couplingsan additional two-thirds turn. NOTE: Donot overtighten the couplings, or damageto the coupling can result.

4. Turn on the water and check the couplingsfor leaks.

NOTE: Replace the inlet hoses after 5 years ofuse to reduce the risk of hose failure. Recordthe hose installation, or replacement dates onthe hoses for future reference. Periodicallyinspect and replace hoses if bulges, kinks,cuts, wear, or leaks are found.

2-6

LEVEL THE WASHER

Properly leveling your washer prevents exces-sive noise and vibration. To level the washer:

1. Check the levelness of the washer byplacing a level on the top edge of thewasher, first side-to-side, then front-to-back.

If the washer faucets and the drainstandpipe are recessed, place the hookedend of the drain hose in the standpipe.Tightly wrap the beaded strap around thewater inlet and drain hoses.

NOTE: Do not force excess drain hose into thestandpipe.

1 2 3

If the washer is against a wall, move thewasher out slightly before tipping back. Ifthe washer is not level, first prop the frontwith a wood block (2 x 4) and adjust thefeet as necessary; then prop the back andadjust feet as necessary. Repeat this stepuntil washer is level.

2. After the washer is level, use a 5/8 (17mm) open-end wrench to turn the nuts onthe feet tightly against the washer cabinet.All 4 feet must be tightened. If the nuts arenot tight against the washer cabinet, thewasher may vibrate.

3. Slide the washer to its final location.

4. Confirm the levelness of the washer.

COMPLETE THE INSTALLATION

1. Check the electrical requirements. Be surethat you have the correct electrical supplyand the recommended grounding method(see Electrical Requirements).

2. Check to be sure all parts are now in-stalled. If there is an extra part, go backthrough the steps to see which step wasskipped.

3. Check to be sure you have all of your tools.

4. Dispose/recycle all packaging materials.

5. Check to be sure the water faucets are on.

6. Check for leaks around faucets and inlethoses.

7. Plug into a grounded 3 prong outlet.

ROUTE THE DRAIN HOSE

The drain hose is connected to your washer.Proper routing of the drain hose protects yourfloors from damage due to water leakage.

Carefully read and follow these instructions.

To prevent drain water from going back intothe washer:

Do not straighten the drain hose, and do notforce excess drain hose into the standpipe.The hose should be secure, but loose enoughto provide a gap for air.

Do not lay excess hose on the bottom of thelaundry tub.

SECURE THE DRAIN HOSE

1. Drape the power cord over the washer top.

2. Secure the drain hose to the laundry tubleg, or to the standpipe with the beadedstrap that is provided.

2-7

INSTALLING THE WASHER ON THE PEDESTAL


Use two or more people to move anduninstall washer.


WARNING

IMPORTANT: If the washer is already installed,it must be uninstalled. See Installation Instruc-tions that came with the washer for tools re-quired.

1. Turn off the hot and cold water to thewasher.

13" (33 cm)

27" (68.6 cm)

18-9/16"(47.2 cm)

23-5/8"(60 cm)

2-5/8"(6.7 cm)

UNINSTALLING THE WASHER 2. Unplug the power supply cord.

3. Slowly loosen the fill hoses at the faucetsto relieve the water pressure.

4. Remove the HOT and COLD fill hosesfrom the back of the washer. Drain waterin the hoses into a bucket.

5. Squeeze the ears of the drain hose clampwith pliers to open and slide the clampdown the hose. Disconnect the drain hosefrom the washer and drain any water in thehose into a bucket.

6. Pull the washer away from the wall so itcan be tipped on its back.

7. Protect the floor with a large piece ofcardboard cut from the pedestal carton.Lay the washer on its back so that thecardboard is under the entire lower backedge of the washer.

IMPORTANT: Check that all 4 pads arepresent as shown. If they are not, do notinstall the pedestal, and contact your dealer.

2-8

1. Open the pedestal drawer, and removethe envelope taped inside the drawer.This envelope contains four (4) #12 x 5/8(1.6 cm) hex-head sheet metal screwsthat will be used in step 4.

2. Remove the phillips screw from bothdrawer slides and save the screws. Re-move the drawer from the slides and set itaside. Push the drawer slides back intothe pedestal.

3. Remove the four feet from the washer, butDO NOT install the feet that were suppliedwith the new washer.

4. Partially install the two lower hex-headsheet metal screws. Leave a space ofabout 3/8 (1 cm) between the screw headand the bottom of the washer.

5. Move the pedestal against the washerbottom, and slide the pedestals keyholeslots over the lower two partially installedscrews.

Position the pedestal toward the front ofthe washer and install the two remaininghex-head sheet metal screws. Do nottighten completely.

Align the sides of the pedestal so that theyare even with the sides of the washer.Reach inside the pedestal drawer open-ing, and securely tighten all four pedestalscrews.

Washer Bottom

Install Screws

6. Tip the washer and pedestal assemblyback to an upright position and removeprotective cardboard.

7. Slide the washer close to its final location.

8. Follow the Installation Instructions thatwere supplied with the washer, and finishinstalling or reinstalling the unit.

9. Locate the 1/4 hex nut on the top of eachpedestal foot. Reach inside the pedestaland use a ratchet or open-end wrench,and adjust the feet up or down, as neces-sary to level the washer and pedestal.

lower screws inkeyhole slots


Use two or more people to move andinstall pedestal.


WARNINGINSTALLING THE PEDESTAL

2-9

10. When the washer is level, use a 9/16open-end wrench to securely tighten thelocknuts on all four feet against the pedes-tal.

11. Pull both drawer slides out and reas-semble the drawer to the drawer slideswith the two (2) phillips screws you re-moved earlier. NOTE: Use of the two (2)dividers is optional.

12. Close the pedestal drawer.

locknut

2-10

NOTES

3-1

PRODUCT OPERATIONTHEORY OF OPERATION

INTRODUCTION

The KitchenAid Ensemble Front-Loading Au-tomatic Washer presents a number of newfeatures and operating characteristics quitedifferent from previous models. In addition tothe introduction of front-loading operation, thewasher contains a number of unique operatingfeatures designed to increase clothes cleaningability while offering very high water and en-ergy conservation.

WATER SYSTEM

The water system consists of the hot and coldwater inlet valves, a water temperature sensor,a water flowmeter and control, and the dis-penser distribution system along with a tradi-tional pressure switch.

WATER INLET VALVES

The hot and cold water inlet valves are locatedat the back of the washer. These valves re-ceive a control signal from the Central ControlUnit to manage the temperature of incomingwater. The temperatures are determined bythe specific wash cycle selected and a tem-perature sensor located in the wash tub. Toimprove cleaning of heavily soiled clothing andto provide a sanitizing feature, the water tem-perature can be increased through the use of aheating element located in the bottom of thetub.

FLOWMETER

Water flow, or the quantity of water introducedthroughout any cycle, is monitored by a flow-meter and Central Control Unit. When theflowmeter registers a maximum of 10.5 gal(40 L), and the Central Control Unit has notdetected the pressure switch trip, the watervalves will be shut off and an error code willshow in the digital display.

DISPENSER DISTRIBUTIONSYSTEM

All wash and rinse water is introduced into thewash tub through a Dispenser Distribution Sys-tem located in the top left corner of the washer.The system consists of a motor that turns acam gear. The cam follower will divert theincoming water to one or more of the followwater inlet modes:

Detergent Dispensing Bleach Dispensing Fabric Softener Dispensing Rinse Dispensing (no additives)

The flowmeter is also used to introduce addi-tional water into the tub for higher water levels,based on cycle requirements.

Flowmeter

DispenserMotor

CamActuatorWater

DistributionLever

CamFollower

3-2

The dispenser drawer has four separate com-partments for adding laundry products to thewash load. These compartments are:

1. Prewash Detergent Compartment2. Main Wash Detergent Compartment3. Bleach Compartment4. Fabric Softener Compartment

Laundry products are diluted and dispensedautomatically at the proper time during thewash cycle. The separator in the Prewash andMain Wash Detergent Compartment can bemoved to accommodate either liquid or pow-dered detergents.

The drawer release lever can be installed in thestack position to accommodate stacking amatching dryer on top of the washer.

The water enters the wash tub through themain inlet tube.

AIR VENT SYSTEM

As a safety feature, the washer is designed toallow fresh air to circulate through the tub. Aninlet vent at the rear of the washer brings airinto the tub. The fresh air is vented through thedispenser assembly vent tube and out the frontof the dispenser drawer cutout.

Main InletTube

Vent Tube

Air Vent

Vent Tube

1

2 4

3

Release LeverStack Position

Release Lever

3-3

PRESSURE SWITCH

The pressure switch is located in the top rightrear corner of the washer. This switch senseswater level in the wash tub. The control signalfrom the pressure switch is sent to the CentralControl Unit and is used to determine theamount of water introduced into the wash tubduring the wash cycle.

The pressure switch also senses the suds levelin the wash tub. If excessive sudsing occurs,the washer starts an automatic suds routine.The display will show the word Sud. Theautomatic suds routine adds additional rinseand drain operations until the suds level isreduced.

If an overfill condition is detected by the pres-sure switch, the CCU will turn on the drainpump and attempt to stop filling.

Pressure Switch

3-4

TOUCH PAD/LED ASSEMBLY

The Touch Pad/LED Assembly is removed asa single assembly and is connected to theCentral Control Unit by a ribbon cable. Thisassembly contains all of the buttons, LEDs andribbon cable and printed circuit boards for theuser to operate the washer. This interfaces theconsumer inputs to the Central Control Unit.

CENTRAL CONTROL UNIT (CCU)

The Central Control Unit is located at the toprear of the washer and is enclosed in a controlbox. There are no serviceable parts inside thecontrol box. If diagnostic tests indicate anycomponent of the CCU is defective, the entirecontrol box must be replaced.

The CCU receives input from the touchpad/LED assembly and directly controls the dis-penser, drain pump, water inlet valves, doorlocking and unlocking solenoids, and heatingelement relay. The CCU monitors the pressureswitch, flowmeter, temperature sensor and doorlock switches.

The CCU sends the customer selection input tothe Motor Control Unit for proper motor opera-tion.

MOTOR CONTROL UNIT (MCU)

The Motor Control Unit is located inside aplastic control box located in the lower frontcorner of the washer cabinet. The control boxis shown with the access door open.

The MCU operates the drive motor at varyingspeeds and direction based on inputs receivedby the CCU to complete the cycle selected.The MCU also monitors a tachometer on themotor to confirm that the drive motor is operat-ing at the proper speed and direction.

DRIVE MOTOR

The drive motor is a three-phase asynchro-nous induction type that operates at variousspeeds and direction based on input voltagesand frequencies. A tachometer on the motorshaft sends a feedback signal to the MotorControl Unit indicating the rotation speed anddirection.

Touchpad/LEDAssembly

Ribbon Cable

Central Control Unit

Motor Control Unit

Drive Motor

3-5

PUMP MOTOR

A separate pump/pump motor is used to drainthe wash tub.

The pump motor is 120 VAC and is attacheddirectly to the pump. The pump has a cleanoutfilter located at the front that allows for theremoval of large objects that may have passedfrom the basket.

ECO VALVE

The washer has a specially designed floating(ball) valve that closes during the wash portionof the cycle so that 100% of the water anddetergent mixture is used on the wash load.The Eco Valve insures that no water or deter-gent is wasted.

SUSPENSION SYSTEM

The wash tub is held in position with four shockabsorbers attached to the bottom four cornersof the tub assembly. In addition, the wash tubis suspended from the top frame of the washerwith two springs attached to the sides of theunit.

Stability for this suspension system is providedby three concrete counter weights. Two arelocated at the front of the wash tub. One ispositioned at the back of the tub. These counterweights eliminate the need for the traditionalbalance ring.

Pump Motor

Large ObjectFilter

Floating (Ball) Valve

Spring Spring

Top Front Counterweight

Bottom Front Counterweight

Front Shock Absorbers

3-6

DOOR LOCK/SWITCH ASSEMBLY

The Door Lock/Switch Assembly is located onthe right side of the door opening.

INTERLOCK SWITCHES

The front and rear interlock switches are lo-cated immediately behind the toe and rearpanels of the washer. The switches provide agrounding circuit to the drive motor and heatingelement when either panel is removed forservicing.

HEATING ELEMENT RELAY

A relay is used to turn the heating element onand off. The heating element relay is located inthe lower right-hand side of the washer cabi-net. The CCU operates a solenoid to close themain relay contacts, providing 120 VAC to theheating element.

The assembly contains a solenoid operatedlatching mechanism that will electrically lockthe door during a wash cycle.

HEATING ELEMENT &TEMPERATURE SENSOR

A heating element is used to increase the watertemperature during certain wash cycles. Thetemperature sensor is used with the heater tomonitor water temperature in the tub.

Heating Element

TemperatureSensor

Door Switch

Door LockSwitches

Door SwitchDoor LockSwitches

HeatingElement Relay

Rear Interlock Switch

3-7

Control On - This button must be pressedbefore initiating any cycle selection.

Status Indicators - Show which portion of thecycle the washer is operating. They also indi-cate when additional items can be added to thewash cycle and when the controls are locked.

Wash Cycle Selector - Selects the variousWash Cycles. Each cycle is designed for differ-ent types of fabric and soil levels (see thePreset Cycle Settings- table on Page 3-9).

Display - Provides information, such as thetime remaining for selected wash cycle andvarious error codes.

Status Indicators

Control On

Wash CycleSelector

Hold To StartDisplay

Off/PauseSoil Level

(Change Any Time)

CUSTOMER INTERFACE & CYCLE SELECTIONSoil Level - Changes the length of the washcycle. + will add time to a normal wash cycle; will shorten a normal wash cycle.

Hold-To-Start - Initiates a wash cycle. Pressand hold the START button for one second.

OFF/Pause - Pressing this button will allowchanging any option, or changing a wash cycleafter the wash cycle has begun. Press theOFF/Pause button, select the desired option,and press and hold the START button for1 second. To cancel a cycle and select a newone, press the OFF/Pause button, select thenew cycle, select the desired options, andpress and hold the START button for 1 second.

3-8

Sanitary - Cleans heavily soiled colorfast fab-rics. This cycle combines a super hot watertemperature and fast speed tumbling to helpensure the removal of heavy soils and stains.It is recommended that you set your hot waterheater to 120F (49C) to ensure proper perfor-mance during this cycle. The Sanitary cyclealso helps kill bacteria, even when no bleach isused. Extra high speed spin helps shortendrying time.

Whitest Whites - Designed for cleaning loadsof soiled white fabrics with the addition ofbleach. Hot washing temperatures assure op-timal bleach activity. An additional rinse pro-vides optimal rinse performance to avoid chlo-rine residues on your laundry. This cycle com-bines fast speed tumbling, longer wash time,and extra high speed spin to shorten dryingtime.

Heavy Duty - Washes loads of sturdy, color-fast fabrics, and heavily to normally soiledgarments. This cycle combines fast speedtumbling, longer wash time, and extra highspeed spin to shorten drying times. If the watertemperature is lower than needed for this cycle,the heater will warm the water to the optimumtemperature.

Normal/Casual - Washes normally soiled cot-tons and linens. This cycle combines mediumspeed tumbling and high speed spin.

Rapid Wash - Washes small loads of lightlysoiled garments that are needed in a hurry.This cycle combines fast speed tumbling, ashortened wash time, and extra high speedspin to shorten drying time.

Delicate - Washes no-iron fabrics in garmentslabeled Permanent Press, or Wrinkle Free,or that indicate using a Gentle cycle on thecare label. This cycle combines low speedtumbling and low speed spin to reduce wrin-kling.

Silk - Cleans washable silk garments. (Checklabel instructions to make sure that garment iswashable.) This cycle gently tumbles and drainswithout spinning to gently clean garments andminimize wrinkling. Since there is no spinningaction, garments will contain a higher amountof water at the end of this cycle.

Wool - Cleans washable woolen garments.(Check label instructions to make sure that gar-ment is washable.) This cycle features gentletumbling and low speed spin to provide opti-mum garment care.

Handwash - Cleans hand-washable and spe-cial-care garments. Similar to the way gar-ments are hand washed in a sink, the washaction of this cycle combines periods of lowspeed tumbling and soaking. The low speedspin reduces wrinkling.

CYCLES

3-9

Soak - Removes small spots of set-in stains onfabrics. This cycle provides a soak time withwarm or cold water, and then drains the water.Extra water, a short tumbling phase for equaldistribution of the laundry, and a soaking timewithout basket movement, improves the re-moval of set-in stains. Drain without spin as-sures gentle treatment, even for delicate ar-ticles.

Rinse/Spin - Provides rinse and spin only.This cycle combines fast speed tumbling andextra high speed spin. If desired, you canreduce the spin speed by selecting the speed

you want from the SPIN SPEED modifier. ARinse/Spin cycle is useful for loads that needrinsing only or for adding fabric softener to aload.

Drain/Spin - Drains the washer, or drains andspins a wash load. The spin speed is preset toextra high. If desired, you can reduce the spinspeed by selecting the speed you want fromthe SPIN SPEED modifier. NOTE: Loads ofsynthetics, delicate fabrics, handwashables,and woolens should be drained with no spin orlow spin speed to avoid fabric stress.

CycleSoil Level

(Cycle Time)Water Temp Spin Speed

SanitaryNormal (1:55)

Super Hot/Cold Extra High

Whitest Whites

Normal (1:00)

Hot/Cold Extra High

Heavy DutyNormal (1:15)

Hot/Cold Extra High

Normal/ Casual

Normal (0:40)

Warm/Cold High

Rapid WashLess Soil

(0:40)Warm/Cold Extra High

DelicateNormal (0:35)

Warm/Cold Medium

SilkNormal (0:26)

Cold/Cold No Spin

WoolNormal (0:30)

Cold/Cold Medium

HandwashNormal (0:30)

Cold/Cold Extra Low

SoakNormal (0:30)

Warm/Cold No Spin

Rinse/SpinNormal (0:21)

Cold/Cold Extra High

Drain/SpinNormal (0:11)

N/A Extra High

PRESET CYCLE SETTINGS

3-10

You can select more than one option for acycle. Some options cannot be added tosome cycles.

If an option is available with a selected cycle,the light for that option will glow when se-lected.

If an option is unavailable with a selectedcycle, there will be a short tone and the lightfor that option will not glow when selected.

Prewash - For heavily soiled loads that needpretreatment. This option adds a 15 minuteprewash and drain to the main wash cycle.

Add detergent to the Prewash and MainWash compartments of the dispenser drawer.

When using Prewash, do not use liquid de-tergent in the Main Wash compartment. Usepowdered detergent for the main wash cycle.

OPTIONS

OPTIONSYou can customize your wash by adding Op-tions to your cycle selections. You can add orchange an option after starting a cycle anytimebefore the selected option begins.

NOTE: The Prewash and Auto Soak optionscannot be selected in the same cycle.

Auto Soak - For loads of heavily soiled cotton,linen, polyester or nylon with set-in stains.During Auto Soak, water will be added to thebasket and the laundry will be equally distrib-uted by a short tumbling phase. Laundry willthen be soaked in phases without basket move-ment. After soaking, the washer drains withoutspinning.

Add detergent to both the Prewash and MainWash compartments of the dispenser drawer.

Use powdered detergent for the main washcycle, because liquid detergent will seep intothe washer during Auto Soak.

For cycles with hot wash temperatures, thesoak temperature will be set to WARM; oth-erwise, the soak temperature will be thesame as the wash temperature.

The Auto Soak and Prewash options cannotbe selected in the same cycle.

Extra Rinse - Used to ensure the removal ofdetergent or bleach residue from garments.This option provides an additional rinse withthe same water temperature as the first rinse.

Rinse Hold - Use this option to avoid wrinklingof your laundry when a load cannot be re-moved from the washer immediately. The washcycle is paused before the final drain and spinphase so that the laundry stays in the rinsewater until the cycle is continued. This providesoptimal wrinkle care of your wet laundry. Thedoor stays locked during the Rinse Hold cycle,and the indicator light will flash. Press RINSEHOLD to finish the cycle and unload the washer.

3-11

Preset cycle settings for Water Temperature,Wash/Rinse, and Spin Speed can be changed.You can change a modifier after starting acycle anytime before the selected modifierbegins.

To change the water temperature, select theWATER TEMP button until the desired set-ting glows.

To change the spin speed, select the SPINSPEED button until the desired setting glows.

To change the loudness of the End of CycleSignal, select CYCLE END SIGNAL.

Wash/Rinse Temp - Select a water tempera-ture based on the type of load being washed.Use the warmest water safe for fabrics. Followgarment label instructions.

Warm rinses leave the loads dryer than coldrinses. Warm rinses increase wrinkling. In coldclimates, a warm rinse makes the load morecomfortable to handle. Cold rinses save en-ergy.

MODIFIERS

MODIFIERS

To change cycle time, select SOIL LEVELbutton.

Automatic Temperature Control (ATC) - Elec-tronically senses and maintains a uniform wa-ter temperature. ATC regulates incoming hotand cold water. ATC is automatically turnedON when a cycle is selected.

ATC ensures consistent cleaning.

ATC works for all wash and rinse tempera-ture settings.

Wash Water Temperature

Suggested Fabrics

Super Hot 153F (67C)

Sturdy colorfast fabrics Heavy soils

Hot 122F (50C)

or above

Whites and pastels Heavy soils

Warm 104F (40C)

Bright colors Moderate to light soils

Cold 77F (25C)

Colors that bleed or fade Light soils

WATER TEMPERATURE GUIDE

3-12

NOTES

4-1

COMPONENT LOCATIONS

This section instructs you on how to service each component inside the KitchenAid EnsembleFront-Loading Automatic Washer. The components and their locations are shown below.

COMPONENT ACCESS

Pressure Switch


Interference FilterInlet Valves

Flowmeter

DetergentDispenser Motor& Assembly

Tub Assembly

Basket

Drive Motor

Motor Controller

Drain Pump

Heating ElementRelay

Front Interlock Switch

Rear Interlock Switch Heating Element& TemperatureSensor

Airtrap

Door LockSwitches

Door Switch

Not Shown: ConsoleTouchpad/LED Assembly

4-2

REMOVING THE CONSOLE ANDTHE TOUCHPAD / LED ASSEMBLY


Disconnect power before servicing.

Replace all parts and panels beforeoperating.

Failure to do so can result in death orelectrical shock.

WARNING

1. Unplug washer or disconnect power.

2. Turn off the water supply to the washer.

3. Remove the three T-20 hex-head torxscrews from the top cover of the washer.

4. Pull back on the cover and release thetabs in the console from the slots in thecover, then lift the cover off the unit.

5. To remove the console:

a) Lift the locking tab and disconnect theribbon cable connector from the cen-tral control unit.

b) Remove the ribbon cable from the fiveclips.

c) Pull the detergent dispenser drawerout as far as it will go, then press downon the release tab, and remove thedrawer from the unit.

Top Cover Screws

Tabs

Console

Connector @ DS3

Touchpad/LEDRibbon Cable

5 Clips

Release Tab

DetergentDispenser

Drawer

4-3

e) Press the locking tab on the right rearside of the console, and pull out on theconsole to disengage the tab from itsslot.

d) Remove the T-20 torx screw from therecessed hole of the console.

Console Screw

f) Pull out at the bottom of the consoleand lift it to unhook the top edge fromthe cabinet, and remove the console.

Console Locking Tab

Pull Out

Lift

6. To remove the touchpad / LED assem-bly:

a) Use a small screwdriver and unsnapthe three top locking tabs from thetouchpad/LED assembly.

b) Starting from the right, unsnap the fourlower locking tabs from the touchpad/LED assembly, and lift the assemblyfrom the console. NOTE: If the push-buttons are attached to the assembly,unsnap them from the old assembly,and install them on the console at theircorrect locations.

Top 3 Locking Tabs

Lower 4 Locking Tabs

Touchpad / LED Assembly


FRONT VIEW

BACK VIEW


4-4

REMOVING THE DOOR LOCK / SWITCH ASSEMBLY,AND THE FRONT PANEL & BELLOWS





WARNING



3. Remove the top cover and the console(see page 4-2 for the procedures).

4. Remove the three T-20 hex-head torxscrews from the toe panel and remove thepanel.

Toe Panel

Screws

6. Starting at the bottom, use a small screw-driver, and pry the retaining wire fromaround the front of the bellows. NOTE:There is a tension spring at the bottom ofthe wire that can be separated to removethe wire.

5. Open the washer door.

Door Lock/Switch Assembly

Bellows

Retaining Wire

Tension Spring

4-5

e) Close the washer door.

f) Remove the four T-20 hex-head torxscrews from the top and bottom of thefront panel and remove the panel fromthe unit.

Top Screws

Bottom Screws

8. To remove the front panel and bellows:

a) Remove the top cover and the console(see page 4-2 for the procedures).

b) Remove the bellows retaining wire (re-fer to steps 5 and 6 for the procedure).

c) Pull the bellows off the lip of the frontpanel.

d) Remove the door lock/switch assem-bly (see step 7).

7. To remove the door lock/switch as-sembly:

a) Remove the bellows retaining wire (re-fer to steps 5 and 6 for the procedure).

b) Pull the bellows out and remove thethree T-20 torx screws and flat wash-ers from the door lock/switch assembly.

c) Push the switch assembly out of thefront panel and then slide the assem-bly tabs from the connector holder.

d) Disconnect the three wire connectorsfrom the switch terminals and removethe assembly.

Door LockSwitches

(2 Screws)

ConnectorHolder

2-WireConnector

3-WireConnector

4-WireConnector

Door Lock/Switch Assembly

Remove BellowsFrom Panel Lip


Switch Assembly Tabs

Door Switch(1 Screw)

Front Panel

4-6

g) Remove the end of the dispenser tubefrom the bellows.

h) Use a 7mm socket, and turn the bel-lows retainer clamp screw counter-clockwise until the clamp is looseenough to remove from around thebellows.

Dispenser Tube

Bellows RetainerClamp Screw

i) Remove the bellows retainer clamp.

j) Remove the bellows from the front ofthe tub.

Remove BellowsRetainer Clamp

Remove Bellows

4-7

REMOVING THE FLOWMETER





WARNING



Flowmeter

4. Loosen the two clamps and remove thetwo hoses from the ends of the flowmeter.

5. Disconnect the wire connector from theflowmeter.


Wire Connector

Flowmeter

4-8

REMOVING THE DETERGENT DISPENSERMOTOR & ASSEMBLY





WARNING




4. To remove the detergent dispensermotor:

a) Unhook the spring from the end of thewater distribution lever.

b) Carefully pull the cam actuator and thewater distribution lever off the motorshaft, then pull the water distributionlever off the lever connection pin.

DetergentDispenser

Motor

Pull Off Shaft

DisconnectSpring

RemoveFrom Pin

WaterDistribution

Lever

c) Remove the two motor screws andremove the motor from the detergentdispenser.

CamActuator

Motor Screws

4-9

d) Remove the motor and switch wiresfrom the wire clip.

e) Disconnect the two wire connectorsfrom the motor terminals. NOTE: Theconnector with the blue stripe (motorconnector) is installed above the con-nector with no color indicator (dispenserswitch connector).

5. To remove the detergent dispenser as-sembly:

a) Remove the front panel from the washer(see pages 4-4 and 4-5 for the proce-dure).

b) Remove the detergent dispenser mo-tor (see step 4).

Wire Clip

c) Use a small screwdriver and raise thelocking arm so that it clears the tab.Pull the inlet hose connector and rub-ber o-ring out of the detergent dis-penser.

d) Loosen the clamp and pull the tub hosefrom the detergent dispenser.

e) Remove the main inlet tube from thebellows.

f) Remove the two screws from the de-tergent dispenser and remove the dis-penser from the washer.

Tub Hose

DetergentDispenser

Screws

Main InletTube

Locking Arm

Rubber O-Ring

Tab

Motor (BlueStripe)

Disp. Sw.(No Color)

4-10

REMOVING THE INLET VALVES





WARNING




Inlet Valves

4. Disconnect the four wire connectors fromthe inlet valve terminals.

5. From behind the washer, remove the inletvalve screw, then slide the valves to theright and unhook them from the panel, andremove them.

6. Loosen the clamp and disconnect the hosefrom the water valves.

DisconnectThe 4 Wires

Rear Of Washer

Inlet ValveScrew

Disconnect Hose

4-11

REMOVING THE CENTRAL CONTROL UNIT





WARNING




4. Remove all of the wire connectors fromthe central control unit (see the photo atthe top of the right column). NOTE: Eachconnector has a locking arm or lockingtabs that you must release to remove theconnector from the unit.

6. Pry up on the two end locking tabs with asmall screwdriver and unhook the centralcontrol unit from the washer.


SerialCommLink

Temp.Sensor

Inlet Valves

Disp.Sw/Mtr

DrainPump Door Lock

SolenoidsUnlockWire Clip

UnlockWire Clip

Wire Clip

Wire Clip

DoorSwitch Flowmeter

MotorControl

Unit

PressureSwitch

LineFilter

Door LockMain

Switches

HeatingElement

Relay

5. Unlock the two wire clips and remove thewires from each of the clips (4 total).

Locking Tabs


4-12

REMOVING THE INTERFERENCE FILTER





WARNING




Interference Filter

4. Disconnect the three connectors from theinterference filter terminals. NOTE: Thegreen 2-wire connector has a locking armat the bottom that you must press to re-lease the connector.

5. Remove the two T-20 hex-head torx screwsfrom the interference filter and remove thefilter from the washer.

T-20 Torx Screws

Black WhiteWires

2-WireConnector

4-13

REMOVING THE PRESSURE SWITCH





WARNING




4. Pull the pressure hose off the pressureswitch inlet.

5. Press on the two locking arms at thebottom of the wire connector, and pull theconnector off the pressure switch termi-nals.

Pressure Switch

Wire Connector

Pressure Hose

6. Pry the standoff on the wire channel out ofits chassis mounting hole.

7. Turn the pressure switch 90 counter-clockwise so that the square locking tab isaligned with the chassis cutout. Pull thetab out of the cutout, and remove theswitch.

Wire Channel

Rotate 90 CCW

4-14

REMOVING THE MOTOR CONTROLLER





WARNING




4. Open the wiring access door on the frontof the motor controller housing.

5. Disconnect the four wire connectors fromthe motor controller. NOTE: Each connec-tor has a locking arm or locking tabs thatyou must release to remove the connectorfrom the unit.

6. Cut the wire tie and pull the cut tie out of theslot in the standoff. NOTE: Be careful notto cut any of the wires in the tie.

7. Lift the locking tab on the motor controllerhousing, and slide the housing tabs for-ward as far as they will go.

8. Lift the motor controller housing so thetabs are out of their chassis slots, andremove the housing from the washer.

Motor Controller

WiringAccessDoor

CutWireTie

2-Wires

Grn/Yel

4-Wires

3-Wires

Lift Housing Tab

Motor Controller Housing

Toe Panel

Screws

4-15

REASSEMBLY NOTE: After reinstalling themotor controller housing, slide a wire tie throughthe slot in the standoff and secure the wires tothe standoff.

Wire Standoff

4-16

REMOVING THE TEMPERATURE SENSOR& THE HEATING ELEMENT




Heating Element & Temperature Sensor

4. Use a 13/32 (10 mm) socket and loosenthe hex nut on the heating element bracket.

5. To remove the temperature sensor:

a) Disconnect the sensor connector.

b) Pull the sensor out of the heating ele-ment bracket hole.

Element Wires

Ground Wire





WARNING

6. To remove the heating element:

a) Remove the temperature sensor (seestep 5).

b) Disconnect the element wires and thegreen ground wire from the terminals.

c) Pull the heating element and tempera-ture sensor out of the tub.

Hex Nut

SensorConnector

Pull Out Sensor

HeatingElement

Toe Panel

Screws

4-17

REMOVING THE HEATING ELEMENT RELAY





WARNING




Heating Element Relay

4. Rotate the element relay holder so youcan access the relay board.

5. Unhook the wires from the holder, then liftthe relay, and unhook it from the slots inthe back of the holder.

6. Press the locking arms and disconnect thewire connectors from the relay.

Lift TheRelay ToRemove It

WireConnectors

Unhook Wires

Toe Panel

Screws

4-18

REMOVING THE DRAIN PUMP ASSEMBLY





WARNING




Drain Pump Assembly

4. Raise the drain pump wiring cover anddisconnect the wire connector.

5. Loosen the clamps, and disconnect thedrain and tub hoses from the drain pump.

6. Remove the T-20 torx screw from thedrain pump.

7. Slide the drain pump forward in its mount-ing slots and lift it out of the washer. Do notremove the rubber washers from the slots.

Pump Wire Connector

Wiring Cover

Tub HoseDrain Hose

Torx Screw

Mounting Slot

Toe Panel

Screws

4-19

REMOVING THE AIRTRAP





WARNING



3. Pull the washer away from the wall so thatyou can access the rear panel.

4. Remove the twelve T-20 hex-head torxscrews from the rear panel and removethe panel from the washer.

Rear Panel Screw (1 of 12)

5. Pull the pressure tube off the airtrap fitting.

6. Remove the T-10 torx screws from theairtrap.

7. Press the locking arm to unlock the airtrapand pull it back and off the tub. NOTE:Replace the rubber o-ring if it is cracked orworn.

Airtrap

4-20

5. Remove the wires from the switch holderclip, and disconnect the wire connectorsfrom the switch terminals. NOTE: The topconnector has a locking tab on it.

Remove WiresFrom Clips

WireConnectors

Switch Holder

REMOVING AN INTERLOCK SWITCH





WARNING



3. Depending on the interlock switch you areservicing, remove the front panel (seepages 4-4 and 4-5 for the procedure), orthe rear panel (see page 4-19 for theprocedure).

4. Press in on the locking tab. Slide theswitch holder down in the chassis slots,and remove it from the chassis.

Press Tab In

Slide SwitchHolder Down

Rear Panel Switch

Front Panel Switch

4-21

6. Push out on the locking tabs of the switchholder, rotate the switch up, and remove itfrom the holder.

Locking Tabs

Rotate Switch Up

Switch Holder

4-22

REMOVING THE DRIVE MOTOR



3. Pull the washer away from the wall so thatyou can access the rear panel.

4. Remove the rear panel from the washer(see page 4-19 for the procedure).

5. Remove the two T-20 hex-head torx screwsfrom the bottom brace and remove thebrace.





WARNING

Drive MotorBottom Brace

6. Remove the drive belt from the end of thedrive motor shaft and then remove the beltfrom the drive pulley.

7. Disconnect the green ground wire fromthe drive motor frame.

8. Remove the 1/2 hex-washer-head mount-ing bolt from the drive motor.

Drive MotorDrive Pulley Belt

Mounting Bolt

Ground Wire

Pivot Stud

4-23

10. Cut the drive motor wire tie from aroundthe motor wires and pull the cut tie out ofthe slot in the standoff. NOTE: Be carefulnot to cut any of the wires in the tie.

11. Press the two locking arms down anddisconnect the power connector from themotor.

12. Disconnect the two green ground wiresfrom the motor terminals.

2 Ground WiresWire Tie

Power Connector

9. Pull the drive motor toward you and re-move the pivot studs from the tub holes;then turn the motor around so that you canaccess the motor wires.

Pivot Stud

4-24

REMOVING THE TUB AND BASKET ASSEMBLY



3. Remove the detergent dispenser assem-bly (see page 4-8 for the procedure).

4. Remove the heating element & tempera-ture sensor (see page 4-16 for the proce-dures).

5. Remove the drain pump assembly (seepage 4-18 for the procedure).

6. Remove the airtrap from the washer (seepage 4-19 for the procedure).

7. Remove the drive motor and belt (seepage 4-22 for the procedure).





WARNING

9. Loosen the clamp and pull the end of theair inlet hose from the tub.

Top Brace

8. Remove the T-20 hex-head torx screwsfrom the top (and bottom, if not alreadydone in step 7) braces and remove bothbraces from the rear of the washer.

Air Inlet Hose

4-25

12. Remove the three 1/2 hex-head boltsfrom the rear counterweight and removethe weight.

13. Remove the two rear shock absorbersfrom the tub. To remove a shock absorber:

a) Pry the locking tab down with a smallscrewdriver.

10. Loosen the clamp and pull the end of thedrain hose from the tub.

11. Remove the three T-20 torx screws fromthe drive motor shield and remove theshield from the bottom of the tub.

Drain Hose

Motor Shield

Rear Counterweight

b) Twist the top section so the tabs alignwith the slots in the tub.

c) Lower the top of the strut down throughthe slot, and rotate the shock absorberagainst the floor of the cabinet.

Locking Tab

Align TabsWith Slots


4-26

14. Remove the screw from the green groundwire eyelet and remove the wires from theclips in the tub.

16. At the front of the washer, remove the sixT-20 hex-head torx screws (total) from thetop front brace and remove the brace fromthe washer.

Ground Screw

Unhook Ground Wire

15. Cut the two wire ties at the front of the tub,and pull the cut ties out of the standoffs.NOTE: Be careful not to cut the wiresinside the wire ties.

Wire Ties (In Standoffs)

Top Front Brace

IMPORTANT NOTE: When you remove thebottom front counterweight in the followingstep, be sure to support it with one hand whileyou remove the screws with the other hand;otherwise, the weight will fall, and could causean injury or damage the floor covering.

17. While supporting the bottom front counter-weight with one hand, remove the three1/2 hex-head bolts with the other hand,and remove the weight.

18. Remove the three 1/2 hex-head boltsfrom the top front counterweight, and re-move the weight.

Top Front Counterweight

Bottom FrontCounterweight

SUPPORT WEIGHTWHILE REMOVING

4-27

19. Using the procedure in step 13, removethe two front shock absorbers from thetub.

20. Lift the tub and basket assembly and un-hook the two suspension springs, thenremove the assembly from the washer,and place it front-down on a padded sur-face so that the back pulley faces up.NOTE: The suspension springs are in-stalled in the front slots of the cabinet, aswell as in the tub. Do not use the backslots; they are used with other models.

21. Remove the 15/16 hex-washer nut fromthe drive pulley and remove the pulleyfrom the basket shaft.

Front Slot Front Slot

Front Slots

22. Mark the edges of the 23 tub clamps witha pencil so that you can reinstall the clampsin the same locations later.

23. Use a screwdriver blade, and pry off the 23tub clamps.

Drive Pulley NutDrive Pulley

Pencil Marks

Tub Clamp Pry Clamp Out

Screwdriver

Tub Clamp


4-28

24. Lift the rear half of the tub off the front half.

25. Lift the basket from the front half of the tub.

Front Half Of Tub

Rear Half Of Tub

Basket

26. To replace the heater element wire holder,remove the T-20 torx screw.

27. To replace the tub gasket, pry the gasketout of the slot and remove it. NOTE: Thebasket hub is molded into the rear half ofthe tub. If it is worn and needs to bereplaced, you will need to replace the rearhalf of the tub.

Heating Element Wire Holder

Tub Gasket

Basket Hub

4-29

REASSEMBLY NOTES:

1. When reassembliing the tub, install themetal clips over the flanges of the two tubsections with a hammer.

Tub ClampTub Flanges

2. When reinstalling the tub assembly, hookthe two suspension springs into the frontholes of the tub and cabinet.

Front Slot Front Slot

Front Slots

3. When reinstalling the bottom front coun-terweight, first tape the flat nut in place inthe tub slot so it does not fall out.

Bottom Front Counterweight Flat Nut

4. When reinstalling the heating element inthe tub, make sure that it is held in place bythe wire holder (see the photo in step 27 onthe previous page).

HeatingElement

4-30

NOTES

5-1

COMPONENT TESTINGBefore testing any of the components, performthe following checks:

Control failure can be the result of corrosionon connectors. Therefore, disconnecting andreconnecting wires will be necessary through-out test procedures.

All tests/checks should be made with a VOMor DVM having a sensitivity of 20,000 ohms-per-volt DC, or greater.

Check all connections before replacing com-ponents, looking for broken or loose wires,failed terminals, or wires not pressed intoconnectors far enough.

Resistance checks must be made with powercord unplugged from outlet, and with wiringharness or connectors disconnected.

Unless stated otherwise, make all resis-tance checks by disconnecting the compo-nent connector at the Central Control Unit(CCU).

WARNINGElectrical Shock Hazard


Replace all parts and panels before operating.

Failure to do so can result in death or electrical shock.

PRESSURE SWITCH

Refer to page 4-13 for the procedure for servic-ing the pressure switch.


2. Disconnect the hose and wire connectorfrom the pressure switch.

3. Set the ohmmeter to the R X 1 scale.

4. Touch the ohmmeter test leads to thepressure switch connector pins shownbelow. The meter should indicate 0 foreach measurement.

Water Level Setting Test Points

Empty Pins 4 and 6

Suds Detect Pins 1 and 2

L1 Pins 4 and 5

Overflow Pins 3 and 4

Pin 1 End

5-2

DETERGENT DISPENSERMOTOR & SWITCH

Refer to page 4-8 for the procedure for servic-ing the degergent dispenser motor.


2. Disconnect the detergent dispenser mo-tor and switch connector from the CCU.

3. Set the ohmmeter to the R x 100 scale.

4. Touch the ohmmeter test leads to theindicated wire connector terminals. Themeter should indicate as follows:

Dispenser motor at pins 1 and 3 = 1400to 1600 .Dispenser switch at pins 5 and 6 = 0 .

Refer to page 4-10 for the procedure for servic-ing the inlet valves.


2. Disconnect the inlet valve solenoid con-nector from the CCU.


4. Touch the ohmmeter test leads to theindicated wire connector terminals. Themeter should indicate between 750 and850 .

INLET VALVE SOLENOIDS





HOT COLD

7 5 3 1

65 3 1(Connector viewed From Wire End)

(Connector viewed From Wire End)

5-3





Refer to page 4-4 for the procedure for servic-ing the door lock/switch assembly.



3. To test the door switch:

a) Disconnect the connector from the CCU.

b) Touch the ohmmeter test leads to thetwo connector terminals. The metershould indicate as follows:

Door closed = 0 .Door open = infinite (open circuit).

DOOR LOCK/SWITCH ASSEMBLY

Door Switch Actuator

Pins1 - 3

Pins 4 - 7

Door Lock Switches

Pins 1 & 2

5. To test the door lock main switches:

a) Turn the washer on and select a cycle.b) Press START and you should hear the

door lock solenoids engage.c) Unplug the washer from the wall out-

let.d) Disconnect the door lock main switch

connector from the CCU.e) Touch the ohmmeter test leads to the

indicated connector terminals. Themeter should indicate as follows:

Main switch 1 at pins 4 and 5 = 0 .Main switch 2 at pins 6 and 7 = 0 .

45 67

2 1

1 2 3

c) Reconnect the door lock/unlock sole-noid connector to the CCU.

4. To test the door lock/unlock solenoids:

a) Disconnect the connector from the CCU.

b) Touch the ohmmeter test leads to theindicated connector terminals. Themeter should indicate as follows:

Lock solenoid at pins 1 and 3 = 60 .Unlock solenoid at pins 2 and 3 = 60 .

c) Reconnect the door switch connectorto the CCU.




5-4

INTERFERENCE FILTER





Refer to page 4-12 for the procedure for servic-ing the interference filter.


2. Disconnect the wire connectors from theinterference filter terminals.

3. Set the ohmmeter to the R x 10K scale.

4. Touch the ohmmeter test leads to theinterference filter connector pins. Themeter should indicate approximately450K .

DRAIN PUMP MOTOR

Refer to page 4-18 for the procedure for servic-ing the drain pump assembly.


2. Disconnect the drain pump motor connec-tor from the CCU.


4. Touch the ohmmeter test leads to the twodrain pump motor connector pins. The metershould indicate 15 .

MotorTerminals

2 1(Connector viewed From Wire End)

5-5

HEATING ELEMENT &TEMPERATURE SENSOR

Refer to page 4-16 for the procedure for servic-ing the heating element & temperature sensor.


2. Disconnect the wire connectors from theheating element and temperature sensorterminals.


4. Touch the ohmmeter test leads to the twoheating element terminals. The metershould indicate between 10 and 20 .

5. Disconnect the heating element tempera-ture sensor connector from the CCU.

6. Touch the ohmmeter test leads to the twotemperature sensor connector terminals.The meter should indicate as shown in thefollowing chart.

HeatingElement

TemperatureSensor Connector

HEATING ELEMENT RELAY

Refer to page 4-17 for the procedure for servic-ing the heating element relay.


2. Disconnect the heating element relay con-nector from the CCU.


4. Touch the ohmmeter test leads to the tworelay connector pins. The meter shouldindicate 15 .





Temperature Results32F (0C) 35.9K

86F (30C) 9.7K 104F (40C) 6.6K 122F (50C) 4.6K 140F (60C) 3.2K 158F (70C) 2.3K 203F (95C) 1K

2 1

2 1


5-6

INTERLOCK SWITCH





Actuator

Refer to page 4-20 for the procedure for servic-ing an interlock switch.


2. Disconnect the wires from the interlockswitch terminals.

3. Set the ohmmeter to the R X 1 scale.

4. Touch the ohmmeter test leads to the twointerlock switch terminals. The metershould indicate an open circuit with theactuator in, and a closed circuit (0 ) withthe actuator out.

DRIVE MOTOR

Refer to page 4-22 for the procedure for servic-ing the drive motor.


2. Disconnect the wire connector from thedrive motor terminals.


4. Touch the ohmmeter test leads to thefollowing drive motor terminals. The metershould indicate between 3 and 8 .Terminals 1 & 2Terminals 1 & 3Terminals 2 & 3

NOTE: Terminals 4 and 5 are for the tachom-eter.


12345

6-1

DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS


Disconnect power beforeservicing.

Replace all parts and panelsbefore operating.

Failure to do so can result indeath or electrical shock.

IMPORTANT

Electrostatic Discharge (ESD)Sensitive Electronics

ESD problems are present everywhere. ESDmay damage or weaken the electronic con-trol board. The new control assembly mayappear to work well after repair is finished,but failure may occur at a later date due toESD stress.

Use an anti-static wrist strap. Connectwrist strap to green ground connectionpoint or unpainted metal in the appliance.

-OR-

Touch your finger repeatedly to a greenground connection point or unpainted metalin the appliance.

Before removing the part from its pack-age, touch the anti-static bag to a greenground connection point or unpainted metalin the appliance.

Avoid touching electronic parts or terminalcontacts; handle electronic control boardby edges only.

When repackaging failed electronic con-trol board in anti-static bag, observe aboveinstructions.

DIAGNOSTIC GUIDE

Before servicing, check the following:

Make sure there is power at the wall outlet.

Has a household fuse blown or circuit breakertripped? Time delay fuse?

Are both hot and cold water faucets openand the water supply hoses unobstructed?

All tests/checks should be made with a VOMor DVM having a sensitivity of 20,000 ohmsper volt DC or greater.

Check all connections before replacing com-ponents. Look for broken or loose wires,failed terminals, or wires not pressed intoconnectors far enough.

The most common cause for control failure iscorrosion on connectors. Therefore, discon-necting and reconnecting wires will be nec-essary throughout test procedures.

Connectors: Look at top of connector. Checkfor broken or loose wires. Check for wires notpressed into connector far enough to en-gage metal barbs.

Resistance checks must be made with powercord unplugged from outlet.

6-2

NO WATER DETECTED ENTERING MACHINE OR PRESSURE SWITCH TRIP NOTDETECTED

If after 30 seconds the control does not detect water entering machine, the valves will beturned off and the error code will be displayed.

OR

If the control has turned the water valves on, and after 8 minutes, the flow sensor has de-tected 10.5 gallons of water passing through it, but has not detected the pressure switch trip,the valves will be turned off, and the error code will flash.

Press PAUSE/CANCEL twice to clear the display.

Possible Causes / Procedure

If there is no water in the unit:

- Make sure that both valves at the water source(s) are turned on all the way.- Check for plugged or kinked inlet hoses or plugged screens in the inlet valves.- Verify inlet valve operation.

If there is water in the unit:

- Verify drain pump operation.- Verify that the pressure switch hose is in good condition and properly connected to tub

and pressure switch.

1. Verify there is not a siphon problem.


3. Verify wire harness connections to inlet valves, pressure switch, drain pump, flow meter,and Central Control Unit (CCU).

4. Check all hoses for possible leaks.

5. Plug in washer or reconnect power.

6. Verify pressure switch operation.

7. Verify flow meter operation by blowing air through the part and measuring the resistance.

8. Verify CCU operation by running a Diagnostic test or any cycle.

FAILURE/ERROR DISPLAY CODES

EXPLANATION AND RECOMMENDED PROCEDUREDISPLAY

FH

F/H

6-3

DRIVE MOTOR TACHOMETER ERROR

The control is unable to properly detect motor speed and the machine will shut down. If a fail-ure occurs during high-speed spin, the door will be unlocked after three minutes.


1. Verify the shipping system including shipping bolts, spacers and cables are removed.


3. Check wire harness connections between the drive motor and the Motor Control Unit(MCU), and between the MCU and the Central Control Unit (CCU).


5. Check the MCU by looking for operations of the drive motor.

6. Check the drive motor for powered rotations.

F 06

F/06

DISPLAY EXPLANATION AND RECOMMENDED PROCEDURE

WATER TEMPERATURE SENSOR ERROR

If during the water heating step in the wash cycle, the water temperature sensor (NTC) valueis out of range, the F/05 error code will be displayed.



2. Check the water temperature sensor. Refer to the Water Temperature Sensor section.Check connections to the water temperature sensor.

3. Check resistance of heating element, if present on this model. (abnormal = infinity)

F 05

F/05

F 02

F/02

LONG DRAIN

If the drain time exceeds eight minutes, the water valves are turned off and F/02 is flashed.Press PAUSE/CANCEL two times to clear the display.

NOTE: After four minutes the Sud error will be displayed, then four minutes later the F/02 error code will be displayed..


1. Check the drain hose and make sure it is not plugged or kinked.


3. Check the electrical connections at the pump and make sure the pump is running.

4. Check the drain pump filter for foreign objects.


6. If the above does not correct the problem, go to step 7.


8. Replace the pump.

6-4

MOTOR CONTROL UNIT (MCU) HEAT SINK THERMAL TRIP

If the therm

Documents

4317352 KAL-4 KitchenAid Ensemble Front-Loading Automatic Washer