HD1000XSC7 Whirlpool Miscellaneous

I've replaced several Kitchen-Aid hot water dispensers because of no hot water. This time, I decided I'd dig deeper.

I noticed that the thermal fuse was the first item on the Part-Select list. I assumed it was the most frequently ordered part.

I removed the hot water tank from under the sink. I disassembled the tank and shell. I disassembled the tank and heating elelment. I tested the heating without the thermal fuse. I reassmbled the tank, replaced the thermal fuse, reassembled the tank and shell assemblly. Then I re-installed the entire heating unit back under the sink. Due to leaks, I had to redo the water supply connection. Then it worked fine! Note: I decided to replace the thermostat because the casing had become cracked and brittle. I ordered that seperately.

The exploded diagrams on the Part-Select site were extremely helpful in both diagnosing the problem and making the repair. Thanks for your help.

Unplug unit, turn off water, use 1/4" open end wrench to push down on collet holding in copper tubing - pull out copper tubing (per instructions in units manual), use pliers to squeeze clamp on water deliver plastic tube and remove. Bring unit up on counter, remove three screws holing top on and also remove on/off/temp knob and two screws holding nameplate trim ring on around knob. Locate thermal fuse wire (from thermostat to one leg of the heating element) and remove. Check continuity of both heating element and thermal fuse. No continuity in thermal fuse - replace -. Install new thermal fuse assembly by connection one end to the heating element and other end to thermostat. Re-assemble in reverse order of dissembly.

Turned off water to the dispenser, unfastened dispenser from water supply copper tubing and flexible tubing hot water outlet. Removed dispenser, drained out water, removed screws holding metal jacket, slid metal holding tank and insulation out far enough to expose wiring. Then removed thermal fuse wire & tested with ohm meter, no circuit. Ordered a thermal fuse and installed it (slip on connectors at each end) Assembled the dispenser and put it back under the sink. The only problem was the flexible tube had hardened from heat of metal tank and leaked where it fastened to the tank. Cut off 1/2 in and used a screw hose clamp to fix the problem.