Whirlpool BOTTOM-MOUNT REFRIGERATOR Troubleshooting guide

CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS
R-86
1997 "F" Model
22cu.ft.
BO
TT
OM MOUNT
BOTT
TTOM
Refrig
erator/Freez
er
s
ge
ze
rs
JOB AID
Part No. 4322228
i
INTRODUCTION
This Job Aid, 1997 "F" Model, 22 cu. ft. BOTTOM MOUNT REFRIGERATOR/FREEZERS, (Part No.
4322228) provides specific information for the installation, service and repair of 1997 "F" Model 22
cu. ft. refrigerator/freezers.
1997 "F" Model, 22 cu. ft. BOTTOM MOUNT REFRIGERATOR/FREEZERS has been compiled to
provide the most recent information on design, features, troubleshooting, service and repair procedures.
Whirlpool required sweep charge procedures are to be strictly adhered to when repairing the sealed
system. For a complete explanation of those procedures, refer to the Job Aid, SWEEP CHARGE
PROCEDURES FOR THE 90's, (Part No. 4321717) and its companion video (Part No. 4321718.)
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide detailed information that will enable the service technician to
properly diagnose malfunctions and repair 1997 "F" Model 22 cu. ft. bottom mount refrigerator/freezers.
The objectives of the Job Aid are:
The service technician will •
•
•
•
•
Understand proper safety precautions.
Follow proper refrigerant recovery procedures.
Successfully troubleshoot and diagnose malfunction.
Successfully perform necessary repairs.
Successfully return the refrigerator/freezer to proper operational status.
TO THE INSTRUCTOR/INDEPENDENT STUDENT
At the end of certain sections of this Job Aid you will find a "Confirmation of Learning Exercise." A
pencil will be necessary to complete these exercises. Certain exercises may require that service
procedures be performed if an appropriate appliance is available.
CORPORATION
WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY
FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE
OTHER THAN AUTHORIZED SERVICE TECHNICIANS.
© 1997 Whirlpool Corporation, Benton Harbor, MI 49022
ii
TABLE OF CONTENTS
INTRODUCTION .................................................................................................................. ii
TABLE OF CONTENTS ...................................................................................................... iii
SECTION ONE
GENRAL INFORMATION
Safety .......................................................................................................................................... 1
R134a Service Information ........................................................................................................ 2
Installation Considerations ....................................................................................................... 3
SECTION TWO
THEORY OF OPERATION
Temperature Control ..................................................................................................................
Refrigerant Flow .....................................................................................................................
Air Flow ..................................................................................................................................
Defrost System.......................................................................................................................
5
5
6
7
SECTION THREE
COMPONENT ACCESS
Accessing
Accessing
Accessing
Accessing
the Component Compartment ............................................................................... 9
the Heat Exchanger and Wiring Harness ........................................................... 10
Components in the Freezer Compartment ......................................................... 10
Component in the Refrigerator Section ............................................................. 13
SECTION FOUR
DIAGNOSIS AND TROUBLESHOOTING
Troubleshooting Guide ............................................................................................................ 15
Diagnostic Information ............................................................................................................ 17
SECTION FIVE
TECH TIPS
Typical External Sweat Patterns ............................................................................................
Wiring Harness Schematic .....................................................................................................
Wiring Diagram .........................................................................................................................
Strip Circuits .............................................................................................................................
Serial and Model Number Designators ..................................................................................
Product Specification and Warranty Information Sources ..................................................
iii
19
20
21
21
23
24
iv
v
SECTION ONE
GENERAL INFORMATION
SAFETY
! WARNING
To avoid the risk of electrical shock,
property damage, personal injury or death:
•
The power cord must be plugged into a 3-prong grounding-type
wall receptacle, grounded in accordance with the National
Electrical
Code, ANSI/NFPA 70 - latest edition and local codes
and
ordinances.
•
It is the personal responsibility of the consumer to have a proper
3-prong wall receptacle installed by a qualified electrician.
•
DO NOT, UNDER ANY CIRCUMSTANCES, REMOVE THE
POWER CORD GROUNDING PRONG.
•
A separate adequately fused and grounded circuit should be
available for this appliance.
Grounding
•
Do not remove any grounding wires
from individual components while
servicing, unless the component is
to be removed and replaced. It is
extremely important to replace all
grounding wires when components
are replaced.
Type
Wall
Receptacle
Power Supply
Cord
with 3-Prong
Grounding Plug
! WARNING
ELECTRIC SHOCK HAZARD
Disconnect the electrical power before servicing any components .
Failure to do so can result in death or electrical shock.
! WARNING
PERSONAL INJURY HAZARD
This unit has several sharp edges in areas where you will be working to
remove components for service. Wear protective gloves where sharp
edges are present.
1
R134a REFRIGERANT
Service Information
This product uses R134a refrigerant. This refrigerant requires synthetic Ester oil in the compressor.
This cooling system does not tolerate contamination from any of the following:
•
•
•
•
•
•
•
•
Other Refrigerants
Moisture
Petroleum-based Lubricants
Silicone Lubricants
Cleaning Compounds
Rust Inhibitors
Leak Detection Dyes
Any Other Type of Additive
As a result the following precautions should be observed:
•
•
•
•
•
•
Use equipment dedicated to R134a sealed system service only.
Do not leave a replacement compressor open to the atmosphere for more than 10 minutes.
Always replace the filter-drier when performing any repairs on the sealed system.
USE ONLY R134a REFRIGERANT FOR BACKFLUSHING AND SWEEP PROCEDURES.
If the rubber plugs on the service replacement compressor appear to have been tampered
with or removed, DO NOT USE THE COMPRESSOR. Get another one.
The filter-drier MUST be cut from the sealed system. Never unbraze the filter-drier from
system tubing. Applying heat will drive moisture back into the sealed system.
HEALTH AND SAFETY HANDLING
Allowable Overall Exposure Limit
Vapor Exposure to Skin
Liquid Exposure to Skin
Vapor Exposure to Eyes
Liquid Exposure to Eyes
Above Minimum Exposure Limit
Safety and Handling
Spill Management
Fire and Explosion Hazards
Storage Conditions
Disposal Procedure
R134a
1,000 ppm
No Effect
Can Cause Frostbite
Very Slight Irritation
Can Cause Frostbite
Can Cause Asphyxiation,
Tachycardia and Cardiac
Arrhythmias.
Wear appropriate Skin and
Eye protection. Use adequate
Ventilation.
Remove or Extinguish Ignition
or Combustible Sources.
Evacuate or Ventilate Area.
May Decompose if contact with
Flames and Heating
elements. Container May
Explode IF Heated Due to
Pressure Rise. Combustion
Products are Toxic.
The Procedures / Rules for R12
also Apply to R134a.
Reclaim
SEE SWEEP CHARGE PROCEDURES FOR THE 90's,
Part No. 4321717 FOR COMPLETE INSTRUCTION ON
SERVICING THE SEALED SYSTEM.
2
INSTALLATION CONSIDERATIONS
Leveling the Unit and Aligning the Doors
Leveling the Refrigerator
1. Remove the toe grille by pulling forward to
release it from the metal clips at both ends.
2. Remove the bottom hinge cover by prying the
cover away from the hinge bracket. (Fig. 1)
Screw Adjusts the
Roller Setting
3. a. If the floor IS level side to side, level the
front of the cabinet by turning the leveling
screw clockwise until the front of refrigerator is 1/4 inch (6.4 millimeters) higher
than the back, or 1/2 bubble using a level.
Make sure the front of the cabinet is level
side to side.
Roller
Stabilizing Leg
Fig. 1
b. If the floor is NOT level side to side, use shims under the rear roller(s) to level the back of the
cabinet side to side first, then level the front of the cabinet by turning the leveling screw
clockwise
until the front of refrigerator is 1/4 inch (6.4 millimeters) higher than the back, or 1/
2 bubble
using a level. Make sure the front of the cabinet is level side to side.
4. Open and close both doors completely to assure proper alignment.
5. Rotate stabilizing leg until they are firmly in place against the floor.
6. Replace the bottom hinge cover by snapping it onto the hinge bracket.
7. Replace the toe grille by inserting the metal clips in the slots in the back of the grille and snapping
it into place. Top of the toe grille is indicated on the back.
Ice Maker Installation
Ice Maker Kit AMKIT97 is used only on the "F" model 22 cu. ft. Bottom Mount Refrigerator/Freezer.
The AMKIT97 features a wiring harness, shut-off arm and fill valve specifically designed for this unit.
The ice bin comes standard in the refrigerator/freezer, not as part of the AMKIT97 ice maker kit.
Installation of this kit requires the use of ¼" copper tubing between the household water supply and
the single solenoid water valve mounted on the base rail at the rear of the cabinet.
Installation Tips:
1. Allow 12 hours after installation before expecting the first harvest of ice. Time required depends
on the freezer temperature and the amount of food in the freezer and refrigerator compartments.
2. The storage bin supplied with the product will hold approximately eight (8) pounds of ice
cubes.
3. The storage bin fills in three to four days depending on the frequency of use. Two to four
pounds of ice will be made in a 24-hour period with a 0° to 2° F freezer food temperature.
4. To temporarily meet demands for increased ice production, turn the freezer control to a colder
setting. Return the freezer control to the normal setting as soon as possible.
3
SECTION ONE
CONFIRMATION OF LEARNING
EXERCISES
In the blank to the left of the statement, place a T if the statement is TRUE or an F if the statement
is FALSE.
___1. It is permitted to remove the round grounding prong on a three-prong plug if the wall
receptacle is not a three-prong grounding type.
___ 2. It is permitted to use leak detection dyes to determine the location of leaks in an R134a
sealed system.
___ 3. The front rollers can be adjusted to level the refrigerator/freezer by turning a hex-head
screw
located behind the toe grille at the left and right sides of the cabinet.
___ 4. The ice storage bin is provided with the refrigerator/freezer, not the Ice Maker Kit.
___ 5. The AMKIT97 is the only modular ice maker kit used on this unit.
4
SECTION TWO
THEORY OF OPERATION
TEMPERATURE CONTROL
Refrigerant Flow
Freezer temperature is regulated by an air sensing thermostat inside the control box located at the
top front of the freezer compartment. This thermostat actuates the compressor to circulate refrigerant
through the sealed system. (Fig. 2) The thermostat should be set to maintain 0° - 2°F freezer food
temperature.
Evaporator
Inlet
Evaporator
Capillary
Tube
Heat
Loop
Process
Tube
Filter Dryer
Condenser
Condenser
Outlet
Compressor
Fig. 2
5
Air Flow
Refrigerator temperature is regulated by an automatic air damper control. The air damper control is
a thermostat that manually actuates the air damper door. This control governs the amount of
refrigerated air entering the refrigerator compartment. (Fig. 3) The control should be set to maintain
28°F to 40°F fresh food temperature.
Refrigerator Air Supply
Tunnel To Fresh Food
Compartment Automatic
Control Damper
and Diffuser
Refrigerator
Return Air Tunnel
Evaporator Fan
Assembly
Freezer Air
Supply Grille
Evaporator
Freezer Return Air
Through Bottom of
Evaporator Cover
Fig. 3
6
Defrost System
Automatic defrost every eight hours of compressor run time is accomplished by a radiant electric
heater suspended beneath the evaporator. (Fig. 4)
Evaporator
Retaining
Clip
Fig. 4
Retaining
Clip
Defrost Heater
The defrost timer is located in a box at the right side of the cabinet behind the toe grille. (Fig. 5) The
defrost timer actuates the defrost heater through the bi-metal thermostat. (Fig. 6)
Bi-Metal
Thermostat
Defrost
Timer
Fig.6
Fig.5
The bi-metal thermostat is attached to the outlet side of the evaporator coil tubing and opens at 48°F
to terminate the defrost heating. After 33 minutes from the start of defrost cycle, the timer restores
operation to the compressor circuit. The bi-metal thermostat contacts close at 13°F, enabling the
defrost heater to operate during the next defrost cycle. The defrost heater is suspended on the right
side and across the bottom of the evaporator. The defrost heater also provides warming to the
defrost drain area to keep it clear during the defrost cycle.
7
SECTION TWO
CONFIRMATION OF LEARNING
EXERCISES
In the blank to the left of the statement, place a T if the statement is TRUE or an F if the statement
is FALSE.
___1. This refrigerator/freezer is provided with a refrigerant heat loop that is foamed in place
around the freezer compartment door.
___ 2. Air flow from the freezer compartment to the refrigerator compartment is regulated through
a motorized air damper door.
___ 3. The defrost timer is located inside the freezer compartment control box.
___ 4. The defrost cycle is designed to occur after eight hours of compressor run-time.
___ 5. The defrost bi-metal thermostat is designed to open at 48°F and close at 13°F.
Label all of the components in the illustration below.
8
SECTION THREE
COMPONENT ACCESS
Accessing the components in the 22 cu. ft. Bottom Mount Refrigerator/Freezer is generally quite
similar to other typical Whirlpool units.
Accessing the Component Compartment
Components located in the component compartment are assembled on a slide out tray at the bottom
of the unit. The compressor, filter-drier, condenser, condenser fan and water supply valve are located
in this area. To gain access to these components the compartment, heat exchanger and condenser
fan covers must be removed and the tray slid out.
1. Remove the six (6) hex-head screws
securing the condenser fan cover to the
cabinet. (Fig. 7-a)
Heat
Exchanger
Cover
2. Remove the four (4) screws securing the
heat exchanger cover to the back of the
unit. (Fig. 7-b)
(b)
Hex
Head
Screws
3. Remove the five (5) screws securing the
component compartment cover to the
cabinet. (Fig. 7-c)
Compartment
Cover
Condenser
Fan Cover
4. Remove the two (2) screws securing the
(c)
(a)
water supply valve to the base rail. (Fig.
Hex
Hex
8) NOTE: If a water supply valve is
Head
Head
mounted on the bracket, it is not Screws
Screws
necessary to
disconnect the copper
supply tubing or the
plastic
supply
Fig. 7
tubing.
4. Push the filter-drier out of its retaining bracket and gently move it out of the way. NOTE: Take
care not to kink any of the tubing connected to the filter-drier.
5. Remove the two (2) compressor mounting bolts securing the slide out tray to the lower rear
cabinet rail. (Fig. 8)
6. Carefully slide the tray out from the unit. (Fig. 8) NOTE: The tray can only slide out a few
inches without kinking the tubing. To slide the tray completely out, the sealed system must be
purged and the tubing disconnected.
Filter-Drier
Water Supply
Valve Mounting
Bracket
Screws
PULL
OUT
Fig. 8
Compressor
Mounting Bolts
9
Slide-Out
Tray
Accessing the Heat Exchanger and Wiring Harness
The heat exchanger and wiring harness are located under the metal cover on the back of the cabinet.
Remove the four (4) screws securing the cover to the back of the cabinet. (Fig. 9 & 10)
Heat
Exchanger
Cover
Heat
Exchanger
Screws
Screws
Wiring
Harness
Fig. 9
Fig. 10
Accessing Component in the Freezer Section
The evaporator, automatic ice maker, and other associated components are all accessible inside the
freezer section.
Removing the Automatic Ice Maker
LOOSEN
THESE SCREWS
1. Remove the hex-head screw securing the bottom
bracket to the freezer liner.
2. Loosen the two (2) screws in the slotted brackets at
the top of the automatic ice maker three or four
turns.
(These screws must be removed if the
evaporator cover
is to be removed.) (Fig. 11)
3. Slide the automatic ice maker up and off the screws.
Fig. 11
REMOVE
THIS SCREW
4. Disconnect the automatic ice maker wiring harness connector and remove the automatic ice
maker from the unit.
5. Remove the extension from the water inlet tube.
Servicing the Evaporator and Other Related Components
The evaporator, evaporator fan, defrost bi-metal and defrost heater are located behind the evaporator
cover.
1. Remove the automatic ice maker, if present. (See procedure above.)
2. Remove the eight (8) screws securing the evaporator cover, ice maker wiring harness cover
and air diffuser in the freezer section. (Fig. 12)
10
3. Pull the evaporator cover up and out of the unit.
Screws (4)
Screws (3)
Screw (1)
Fig. 12
Removing the Evaporator Fan Motor
The evaporator fan motor is mounted on a bracket that is attached to a shroud mounted to the back
wall of the freezer section. (Fig. 13)
1. Removing the two (2) hex-head screws that secure the fan motor bracket to the shroud.
2. Disconnect the wiring harness connectors from the evaporator fan motor terminals.
Fan
Shroud
Screw
Fig. 13
Screw
Servicing the Evaporator, Defrost Bi-metal and Defrost Heater
The evaporator, defrost bi-metal (Fig. 14) and defrost heater
(Fig. 15) are serviceable parts on these units.
Bi-Metal
Thermostat
Removing the Defrost Bimetal
1. Disconnect the wiring harness connectors
from the defrost bi-metal leads.
2. Slide the bi-metal mounting clip from the outlet
tubing of the evaporator.
11
Fig. 14
Removing the Defrost Heater Element
1. Disconnect the wiring harness connectors from the defrost heater element leads.
2. Carefully unsnap the evaporator tubing from the four (4) plastic clips that secure the evaporator
to the heat shield at the back of the freezer compartment and remove the Styrofoam blocks
on
the right side of the evaporator. Do not break this block. It will need to be reinstalled when
replacing the evaporator in the freezer section.
3. Tip the bottom of the evaporator up and, with a pair of needlenose pliers, remove the two clips
that secure the heater element to the bottom of the evaporator. (Fig. 15) This will free the
heater element from the evaporator.
Evaporator
Retaining
Clip
Fig. 15
Retaining
Clip
Defrost Heater
Removing the Thermostat
The thermostat that controls the refrigeration system is located on the ceiling of the freezer
compartment.
1. Carefully pull the control knob from the
thermostat. (Fig. 16)
2. Remove the one (1) screw securing the
control box cover to the control box
assembly and remove the control box cover.
Control Box
Cover
Control
Knob
3. Remove the two (2) screw securing the
thermostat to the mounting bracket and
the one (1) screw securing the ground
wire to the mounting bracket. (Fig. 17)
Screw
(Under Control Knob)
4. Disconnect the wiring leads from the
thermostat terminals.
Fig. 16
5. The thermostat can now be removed from the unit.
12
Ground Wire
Screw
Thermostat
NOTE: The wire leads for the Return Air
Heater and the Auxilliary Return
Air Heater elements are located
inside the freezer thermostat control box. The wire leads for the
"regular" element are one (1) red
and one (1) white. The wire
leads for the auxilliary element
are both black.
Screw
Screw
Fig. 17
Accessing Component in the Refrigerator Section
Damper Control Cover
Removing the Cold Air Inlet Damper
The cold air inlet control damper is located at the
top center of the refrigerator section. This assembly contains a mechanical thermostat that
operates a dampening door to regulate the flow
Damper
of cold air into the refrigerator compartment.
Insulation
1. Remove the damper control knob.
Damper Control
Cover Seen
From Inside
2. Press in on the two (2) side tabs securing the
control cover to the back panel of the
Tab
refrigerator section. (Fig. 18) Then, tip the
control cover forward and pull it up to dislodge
the two (2) tabs at the bottom.
Tab
3. Remove the Styrofoam insert and the
two (2) screws securing the damper
control assembly to the back panel
of the refrigerator compartment. (Fig. 19)
Fig. 18
Tabs
Damper Control
Assembly
Screw
Damper
Insert
Screw
Fig. 19
13
Accessing the Defrost Timer
The defrost timer is mounted to the timer cover box at the left side of the unit behind the toe grille.
1. Remove the toe grille.
Fig. 20
2. Remove the two (2) hex head screws securing the
cover of the defrost timer box. (Fig. 20)
Timer Cover
3. Disconnect the wiring harness connector from the
defrost timer terminals. (Fig. 21)
4. Remove the two (2) hex head screws securing the
defrost timer to the cover and remove the defrost
timer. (Fig. 21)
Screws
Screws
Fig. 21
Defrost
Timer
Harness
Connector
SECTION THREE
CONFIRMATION OF LEARNING
EXERCISES
In the blank to the left of the statement, place a T if the statement is TRUE or an F if the statement
is FALSE.
___1. The thermostat to control temperature in the freezer section is located in the refrigerator
compartment.
___ 2. The heat exchanger and main wiring harness is accessible behind a panel attached to the
back of the cabinet.
___ 3. The defrost timer is located in a box behind the toe grille at the bottom of the unit.
___ 4. The automatic damper control that regulates air flow into the refrigerator compartment
must be disconnected from the wiring harness when it is to be replaced.
___ 5. The defrost bi-metal thermostat is attached to the back wall of the freezer compartment.
If a 1997 Model F 22 cu. ft. Bottom-Mount refrigerator/freezer is available, perform the following
service procedures.
A. Perform all the steps necessary to pull the component compartment slide out tray out a few
inches to access the compressor and condenser fan.
B. Perform all steps necessary to remove the defrost heater element from the evaporator.
C. Perform all steps necessary to remove the temperature control thermostat
control
box.
from the
D. Perform all steps necessary to remove the damper door assembly and damper control
thermostat.
14
SECTION FOUR
TROUBLESHOOTING AND DIAGNOSTICS
TROUBLESHOOTING GUIDE
POSSIBLE CAUSE
PROBLEM
1.
Operating Sound Level
A.
See Owners manual for explanation of normal operating sounds.
2.
Freezer Warm - Compressor Off
A.
B.
C.
D.
Temperature Control defective or setting too warm
Defrost control stalled in defrost mode (defective)
Compressor defective
Overload and/or relay defective
3.
Too Cold in Refrigerator
A.
B.
C.
D.
E.
F.
Refrigerator damper control knob set too cold
Refrigerator damper control not closing
Freezer temperature control knob set too cold
Restricted condenser air
Refrigerant shortage or restriction
Overcharge
4.
Freezer Warm - Compressor Cuts
Off on Overload
A
B.
C.
D.
E
F.
G.
H.
I.
J.
K.
Heavy usage and/or high ambient
Restricted condenser air
Compressor machine compartment back cover is missing
Cabinet elevated off floor
Condenser fan motor inoperative
Condenser fan blade loose or missing
Improper voltage
Relay or overload faulty
Compressor motor winding open
Non-condensables in system
Overcharge
5.
Freezer Too Warm - Compressor
Operating
A.
B.
C.
D
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
Control knob set too warm
Control out of calibration
Restricted condenser air
Inoperative condenser fan motor
Door left open
Heavy usage
Freezer fan motor inoperative
Defrost thermostat open
Defrost heater open
Freezer or condenser fan blade loose or off
Evaporator heavily frosted
Defrost control stuck in compressor run mode
Drain plugged
Loss of refrigerant or restriction
Inefficient compressor
6.
Too Warm in Refrigerator
A.
B.
C
D.
E.
F.
Refrigerator setting too warm
Damper doesn’t open
Freezer control set too warm
Supply air duct blocked
Return air duct blocked
Heavy usage or high ambient temperature
7.
Freezer Too Cold
A.
B.
Freezer temperature control knob set too cold
Freezer temperature control out of calibration
8.
Long off Cycle - Too Warm at Start
A. Low ambient temperature
B. Freezer temperature control knob set too warm
C. Freezer temperature control out of calibration
15
POSSIBLE CAUSE
PROBLEM
9.
Short off Cycle
A.
B.
C.
D.
E.
High ambient and/or heavy usage
Freezer control knob set too cold
Freezer control out of calibration
Light on constantly
Poor door seal
10. Long or Continuous Operation
A.
B.
C.
D.
E.
F.
Heavy Usage and/or high ambient
Inadequate condenser air flow
Freezer temperature set too cold
Freezer temperature control out of calibration
Freezer temperature control relay frozen closed
Loss of refrigerant or restriction
11. Short Run Cycle
A.
B.
Low ambient and/or light usage
Freezer temperature control setting too warm or control out of
calibration
12. Condensation on Cabinet Exterior
A.
High humidity installation (design accepts bead of water on
exterior of cabinet after 4 hours with a 0° to 2°F. (-18° to -17°C.)
freezer food temperature and 38° to 40°F. (3°C to 4°C) refrigerator food temperature in 84% R.H. conditions (See example
of typical sweat pattern under above conditions on page 19.)
B. Freezer control set too cold
C. Freezer control out of calibration
D. Poor door gasket seal
E. Insulation void
13. No Ice/Low Ice Production
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
14. Over Production of Ice
A. Bail Shut-Off Arm Not in Actuator
B. Misformed Bail Shut-Off Arm
C. Shut-Off Lever Broken or Bypassing Vertical Cam
D. Broken Module Actuator
15. Hollow Ice Cubes
A. Water Fill Volume Too Low
B. Improper Freezer Air-Flow
C. Thermostat Out of Calibration
16. Flooding or Ice Slabs in Bucket or Freezer
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
Freezer not cold enough
Broken Locking Tab on Vertical Cam
Module Shut-Off Switch and Contacts Shorted and Burned
Motor Stalled or Stripped
Check Ejector Position
Bail Shut-Off Arm In Vacation Mode - No Ice
Bail Shut-Off Arm Binds When Raised or Lowered
Little/No Alumilastic on Thermometer
Housing to Mold Screws Not Seated
Heater Not Staked In Mold
Wrong Heater Temperature
Broken S/O Lever (Miscalibrated Shut-Off Switch)
Thermostat Out of Calibration
Jammed Cube Stalled in Water-Fill Cycle
Leaky Water Valve
Fill Volume of Water Excessive
Motor Stalled in Water-Fill Cycle (12:00 Ejector Position)
Contaminated Module
Refrigerator or Ice Maker Not Level
Excessive Water Pressure
Module Shut-Off Switch and Contacts Shorted and Burned
Broken Locking Tab on Vertical Cam (Stalled in Water-fill)
Fill-Tube Not Properly Located in Fill Cup
Fill Cup Water Opening Flashed Over/Plugged
Cubes Fell Over Back of Ice Maker, Melting Into Freezer
16
DIAGNOSTIC INFORMATION
! WARNING
ELECTRIC SHOCK HAZARD
Disconnect the electrical power before servicing any components.
Failure to do so can result in death or electrical shock.
PERFORMANCE DATE
*(NORMAL OPERATING CONDITIONS)
AMB
WATTS
70°
90°
110°
160±20
165±20
185±20
SYSTEM PRESSURE
(PSIG)
LOW
HIGH
SIDE
SIDE
0
85±20
1
135±20
2
180±20
*Normal operating conditions are viewed when
air and temperature controls are at mid-setting,
freezer section temperature is between 0°- 5°F
and unit is cycling.
NOTE: Watt and pressure readings will vary
and
are influenced by existing
condition of
the appliance, such as
iced-up evaporator, condition of
the condenser, defrost cycle, pulldown time and customer
use.
SERVICE INFORMATION
1. Do not interchange the compressor suction and process stubs.
2. Refrigerant charge must be applied to high side only.
3. Ice Maker and Water Valve not original equipment on all models.
4. CAUTION:Ice Maker cycle MUST be initiated electrically. Do not try to manually start cycle.
5. Service defrost bi-metal (55°F) open.
6. Defrost timer may contain a capacitor in series with motor. Do not continuity test when checking
for failed timer motor. Instead, energize timer and listen for gear movement.
7. Part number can be found on component.
GENERAL COMPONENT INFORMATION
BE SURE AND USE CORRECT REPLACEMENT PARTS
120VAC
COMPONENT
COMPRESSOR
RUN WINDING
START WINDING
PTC RELAY
OVERLOAD
RUN CAPACITOR
THERMOSTAT
DEFROST TIMER MOTOR
DEFROST HEATER
BI-METAL
EVAPORATOR FAN
CONDENSER FAN
RETURN HEATER
WATTAGE
@120VAC
--------450
-10.9
10
1
17
OHMS
RESISTANCE
-2.6
4.35
----1320
30
---13300
TECUMSEH
TP1380Y
12049703
--10097202
10377015
C8931604
C8946703
10530702
10428409
10442407
10654206
10884501
10624901
-- NOTES --
18
SECTION FIVE
TECH TIPS
TYPICAL EXTERNAL SWEAT PATTERNS
1
LEFT SIDE
1
FRONT
CLASSIFICATIONS OF
CONDENSATION
1 = Haze or fog
2 = Beading
3 = Beads or small drops
4 = Drops running together
RIGHT SIDE
TOP REF. DOOR
1
BOTTOM REF. DOOR
1
CENTER MULLION
TOP FRZ. DOOR
BOTTOM FRZ. DOOR
LOWER MULLION
BACK
19
2
WIRING HARNESS SCHEMATIC
20
WIRING DIAGRAM
21
STRIP CIRCUITS
1. Defrost Circuit - Defrost Heater Energized
2. Cooling Circuit - Freezer Thermostat Calling For Cooling (at instant of compressor start).
3. Cooling Circuit - Freezer Thermostat Calling For Cooling (Running).
4. Refrigerator Lights Circuit - Refrigerator Door Open
22
5. Freezer Light Circuit - Freezer Door Open
6. Return Air Heater Circuit
B
B
AUX. RETURN AIR
HEATER
7. Automatic Ice Maker/Water Supply Valve Circuit
T
23
SERIAL AND MODEL NUMBER DESIGNATORS
The serial number for all Whirlpool and KitchenAid brand refrigerator/freezers contain the following
designations:
EC G 39 40174
Manufacturer Site/Source
Calendar Year
Calendar Week
Sequential Serial Number
The model number for the KitchenAid brand 22 cu. ft. bottom mount refrigerator/freezers contain the
following designations:
Model Number
K
BR
S
22
Marketing Channel
(if present)
KitchenAid Brand = K
Product Identification
BR = Bottom Mount Freestanding
Reversible Door Swing
Merchandise Scheme/Series
S = Superba
Capacity
Features - Accepts Ice Maker Kit
Year of
Introduction
Color
WH = White
AL = Almond
BL = Black
Engineering Changes (Numeric)
24
K
F
WH
0
The model number for the Whirlpool brand 22 cu. ft. bottom mount refrigerator/freezers contain the
following designations:
E
Model Number
B
22
D
K
X
F
W
Marketing Channel
(if present)
Product Group
E = Refrigeration
Product Identification
Bottom Mount Freezer
Capacity
Model Series
D = DesignerStyle - Glass
Ice Maker Adaptable
Door Swing (Right Reversible)
Year of Introduction (1997)
Color
W = White
N = Almond
B = Black
Energy/Power Designator
Engineering Changes (Numeric)
FOR TECHNICAL ASSISTANCE
ON WHIRLPOOL AND KITCHENAID BRANDS
WHILE AT THE CUSTOMER'S HOME CALL;
THE TECHNICAL ASSISTANCE LINE: 800-253-2870
Have your store number ready to identify you as an Authorized Servicer
25
0
0
ANSWER SHEET
CONFIRMATION OF LEARNING
EXERCISES
Section One
Section Two
Section Three
True or False Statements:
True or False Statements:
True or False Statements:
F
1. ___
T
1. ___
F
1. ___
F
2. ___
F
2. ___
T
2. ___
T
3. ___
F
3. ___
T
3. ___
T
4. ___
T
4. ___
F
4. ___
5. ___
T
T
5. ___
F
5. ___
Section One
Label the Components:
Evaporator
Inlet
Evaporator
Capillary
Tube
Heat
Loop
Process
Tube
Filter-Drier
Condenser
Outlet
Condenser
Compressor
26
CORPORA
vi