36" (91.4 cm), 42" (106.7 cm), 48" (121.9 cm) side-by-side built-in refrigerators with water filtration (96 pages)
Summary of Contents for KitchenAid 2003 M
KAR-15 TECHNICAL EDUCATION 2003 M MODEL BUILT-IN SIDE-BY-SIDE REFRIGERATOR WITH VARIABLE CAPACITY COMPRESSOR JOB AID 4317344...
FORWARD This KitchenAid Job Aid, “2003 M Model Built-In Side-By-Side Refrigerator With Variable Capacity Compressor” (Part No. 4317344), provides the technician with information on the installation, operation, and service of the Built-In Side-By-Side Refrigerator. It is to be used as a training Job Aid and Service Manual.
Safety First ......................... 1-1 Model & Serial Number Designations ................1-3 Model & Serial Number Label And Tech Sheet Locations..........1-4 KitchenAid Built-In Refrigerator Warranty ................1-5 INSTALLATION INFORMATION ................... 2-1 THEORY OF OPERATION ..................... 3-1 COMPONENT ACCESS ......................4-1 Component Locations ......................
Page DIAGNOSTICS & TROUBLESHOOTING ................6-1 Diagnostics ........................6-1 Pre-Diagnostics Checks ....................6-1 Diagnostics Mode ......................6-1 Service Diagnostics Mode Chart ..................6-2 Water Filter Input (WFI) Test ..................6-2 Electronic Temperature-Controlled Meat Pan Diagnostics ..........6-3 Troubleshooting Chart ....................... 6-4 WIRING DIAGRAMS &...
GENERAL SAFETY FIRST Your safety and the safety of others is very important. We have provided many important safety messages in this Job Aid and on the appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to hazards that can kill or hurt you and others.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE ELECTRONICS ESD problems are present everywhere. ESD may damage or weaken the electronic control assembly. The new control assembly may ap- pear to work well after repair is finished, but failure may occur at a later date due to ESD Electrical Shock Hazard stress.
MODEL & SERIAL NUMBER DESIGNATIONS MODEL NUMBER MODEL NUMBER K S S S 4 2 Q M X PRODUCT GROUP K = KitchenAid Brand PRODUCT IDENTIFICATION BR = Bottom Mount Right Hand Hinge BL = Bottom Mount Left Hand Hinge SS = Side-By-Side Built-In...
MODEL & SERIAL NUMBER LABEL AND TECH SHEET LOCATIONS The Model/Serial Number Label and Tech Sheet locations are shown below. Model & Serial Number Location (Refrigerator Compartment) Tech Sheet Location (On Unit Compartment Cover)
For two years from the date of purchase, when this refrigerator (excluding the water filter cartridges) is operated and maintained according to instructions attached to or furnished with the product, KitchenAid will pay for factory specified replacement parts and repair labor costs to correct defects in materials or workmanship. Service must be provided by a KitchenAid designated service company.
INSTALLATION INFORMATION PRODUCT DIMENSIONS Front View Side View " (64 cm) " (60 cm) " 24" (211 cm) (61 cm) Power Cord " (211 cm)* (see chart following) Width of Refrigerator " (9 cm)* Model Width A (as shown above) 36"...
Opening Dimensions A grounded 3 prong electrical outlet should be placed within 4″ (10.2 cm) of the right side The solid soffit must be within 1″ (2.5 cm) cabinets or end panel. maximum above the refrigerator. If the solid The water shutoff should be located in the base soffit is higher than 1″...
WATER SUPPLY REQUIREMENTS ANTI-TIP BOARDS All installations must meet local plumbing code IMPORTANT: requirements. • The solid soffit must be within 1″ (2.5 cm) The water shutoff should be located in the base maximum above the refrigerator. If the solid cabinet on either side of the refrigerator or soffit is higher than 1″...
LOWERING THE LEVELING LEGS Use the leveling bolts to adjust the leveling legs until the refrigerator is level from left All four leveling legs must contact the floor to to right. support and stabilize the full weight of the refrigerator. Rollers are for moving the refrig- erator, and not for permanent support.
Overlay Models Remove the two door stop screws: one from the bottom side using a 3/8″ open- end wrench, and one from the top side using an Allen wrench. 1. T27 flat-head mounting screws 2. 1/4 in. hex-head mounting screws Adjust the hinges so that the door gap is the same distance at the top and bottom.
Door Swing Adjustment Hold the door open to a position that is less than 90°. Open the refrigerator and freezer doors Replace the door stop screw(s) in the and make sure that they open freely. If a bottom hinge and tighten. door opens too wide, remove the door stop screw(s) from the bottom hinge.
The electronic control monitors the water valve OVERVIEW for total elapsed time and gallons of water The KitchenAid Built-In Refrigerator Constant used. The number displayed on the Water Flow Temperature Management System uses Filter Indicator (WFI) is the percentage of filter two thermistors to monitor temperature changes usage remaining.
TEMPERATURE CONTROL Freezer Temperature Control — Temperature Decreasing The electronic control checks the resistance of When the freezer temperature begins to de- the thermistors, and compares it to both the crease, the process will reverse. The compres- customer temperature settings and the last sor speed decreases, followed by the evapo- thermistor reading taken.
COMPRESSOR COMPRESSOR PROTECTION The main control board supplies a 5 vdc, peak- To protect the compressor and maintain effi- to-peak square wave, at 54 to 150 Hz, to the ciency, minimum compressor off time is pro- inverter board. A standard VOM will read ap- grammed into the main control board.
AIR DOOR When entering a defrost cycle, if the bimetal is open, the time to defrost is reset to 8 hours, and The air door is driven by a reversible DC the control will time through the entire 37 minute stepper motor.
Freezer Thermistor MAX COOL MODE If the control senses an open or a shorted ther- Max Cool changes the refrigerator tempera- ture setting to 34°F (1 °C) and the freezer to mistor, the compressor and the evaporator fan motor will begin to operate on a timed on and –5°F (–21°C) for 24 hours.
In the Holiday Mode the following occurs: MASTER ALARM RESET • Temperature selections remain at the cur- Pressing the Over-Temperature Reset will turn rent setting, but are not displayed. off the audio alarm, but does not affect the in- dicator light the first time the Over-Tempera- •...
AIR CIRCULATION It is important not to block any of the vents with food items. If the vents are blocked, airflow will In order to ensure the proper refrigerator and be restricted, and the temperature manage- freezer compartment temperatures, air must ment system will not function properly.
SEALED SYSTEM SCHEMATIC Suction Line Discharge Condenser Drier Compressor Heat Exchanger Mullion Evaporator Freezer Refrigerator Side Side Condensate Loop...
COMPONENT ACCESS This section instructs you on how to service each component inside the refrigerator/freezer. The components and their locations are shown below. COMPONENT LOCATIONS Condenser Fan Motor Filter/Drier Meat Pan Power Supply Main Control Compressor Board Assembly Inverter Assembly Freezer Door Switch Power Switch...
REMOVING A DOOR SWITCH AND THE POWER SWITCH To remove a door switch: a) With the door closed, remove the hex- head screw from the door linkage at the top of the door. NOTE: The door spring will remain under slight tension when the door is closed.
d) Disconnect the wire connectors from b) Disconnect the wire connectors from the door switch terminals. the switch terminals. NOTE: Be sure to reconnect the wires to the same ter- minal locations, as shown below. 2 Wire Connectors c) Press against the four locking tabs on the body of the power switch, and push the switch out of the bracket.
REMOVING THE INVERTER ASSEMBLY Ground Screw Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Inverter Mounting Screws Unplug refrigerator or disconnect power. Remove the main and louvered decora- Using a large screwdriver, pry down on the tive panels (see page 4-2).
10. Remove the hex-head screw from the inverter’s green ground wire, (see the photo at the top of the right column on page 4-4), and remove the inverter assembly. Electrical Shock Hazard Connect green ground wire to ground screw. Failure to do so can result in death or electrical shock.
REMOVING THE CONDENSER FAN MOTOR Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Condenser Fan Motor Screw (1 of 3) Unplug refrigerator or disconnect power. Remove the main and louvered decora- Remove the speed nut from the condenser tive panels (see page 4-2).
Disconnect the wire connector from the condenser fan motor. Remove the two hex-head screws from the condenser fan motor and remove the motor from the bracket. Bracket Screws Wire Connector...
REMOVING THE ICE MAKER INLET HEATED FILL TUBE Screw (1 of 3) Ice Maker Inlet Heated Fill Tube Cover & Connector Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
REMOVING THE MAIN CONTROL BOARD ASSEMBLY Slide the wire grommet out of the enclo- sure slot and position the assembly so that you can access the board. Remove the wire connectors from the main control board assembly. Wire Grommet Out Of Enclosure Slot Electrical Shock Hazard Disconnect power before servicing.
REMOVING THE ELECTRONIC MEAT PAN POWER SUPPLY BOARD Electronic Meat Pan Power Supply Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before Ground Wire Screw Enclosure Screw operating. Pull the meat pan power supply assembly Failure to do so can result in death or forward as far as it will go, and turn it over electrical shock.
10. Install the electronic meat pan power sup- ply assembly in the unit, and connect the green ground wire to the chassis with its hex-head screw. Electrical Shock Hazard Connect green ground wire to ground screw. Failure to do so can result in death or electrical shock.
REMOVING THE COMPRESSOR AND FILTER/DRIER Electrical Shock Hazard TIP OVER HAZARD Disconnect power before servicing. Refrigerator is top heavy and tips easily Replace all parts and panels before when not completely installed. operating. Keep door taped closed until refrigera- Failure to do so can result in death or tor is completely installed.
Remove the compressor terminal cover. 11. Access the sealed system and discharge To remove the cover, insert a flat-bladed the refrigerant into an approved recovery screwdriver into the top slot, push down on system. the screwdriver to release the catch, and 12.
REMOVING THE BIMETAL, THE EVAPORATOR FAN MOTOR, THE DEFROST HEATER, AND THE EVAPORATOR Cover Screws (2 of 10) Light Lens Cover Tabs And Slots Shelf Studs (1 of 8) Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before Evaporator operating.
10. To remove the evaporator fan motor: 11. To remove the defrost heater: a) Pull the fan blade off the motor shaft. a) Remove the two hex-head screws from the evaporator fan motor shroud. b) Unclip the motor. b) Unclip the bimetal from the evaporator c) Disconnect the wire connector from the inlet tubing.
e) 36″ Models Only: Remove the hex- g) Bend the two hangers at the bottom of head screws from the right evaporator the evaporator and remove the heater cover mounting bracket and remove from the hangers. the bracket. Be careful not to drop the screws down the drain hole at the bot- Defrost Heater tom of the liner.
i) Unfasten the defrost heater from the 12. To remove the evaporator: two metal clips on the right side of the a) Remove the defrost heater from the evaporator, and slide the defrost heater evaporator (see step 11). down and off the evaporator. b) Access the sealed system and dis- charge the refrigerant into an approved recovery system.
REMOVING THE TOUCH AND DISPLAY BOARDS & THE MOTORIZED AIR DOOR b) Disconnect the two wire connectors from the touch control assembly and remove the assembly from the refrig- erator. Wire Connectors Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating.
To remove the motorized air door: c) Disconnect the wire connector from the motorized air door and remove it. a) Remove the hex-head screws from the motorized air door cover and remove REASSEMBLY NOTE: Be sure to position the cover. the motorized air door with the motor and wires as shown in the bottom left photo.
REMOVING THE MEAT PAN AIR BAFFLE & THERMISTOR, THE AIR SUPPLY THERMISTOR, AND THE MEAT PAN ELECTRONIC TOUCH CONTROL ASSEMBLY To remove the meat pan air baffle & thermistor: a) Remove the two screws from the baffle housing assembly, then tilt the top of the assembly forward, and pull the bot- tom tab from the slot.
c) Remove the screw from the cover and To remove the air supply thermistor: remove the cover from the baffle hous- a) Remove the meat pan air baffle assem- ing. bly from the unit (see steps 3a & 3b). Housing Cover b) Remove the four screws from the meat pan air duct and remove the duct.
To remove the meat pan electronic e) Lift the assembly from the bottom and touch control assembly: pull it out, then unclip the top and pull it out so you can access the wiring. a) Remove the meat pan air baffle assem- f) Disconnect the two harness connec- bly from the unit (see steps 3a &...
REMOVING A THERMISTOR Remove the hex-head screw from the thermistor cover. Pull the cover forward at the screw end, and unhook the tab from the slot at the other end of the thermistor cover. Screw Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating.
REMOVING THE ICE MAKER, THE EMITTER, AND THE RECEIVER To remove the ice maker: a) Close the spring-loaded emitter door and open the ice maker door. Emitter Door Electrical Shock Hazard Ice Maker Door Disconnect power before servicing. Replace all parts and panels before operating.
d) Disconnect the two ice maker connec- b) Disconnect the harness connector from tors from the freezer wiring harness the emitter module board and remove and remove the ice maker from the the module. freezer. 2 Wire Connectors Emitter Connector To remove the receiver module: a) Remove the three screws from the re- ceiver module and pull it out of the...
REMOVING THE AUGER MOTOR Remove the spring from the top of the hex drive shaft. Spring Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Remove the containers from the freezer door so you can access the motor housing Unplug refrigerator or disconnect power.
11. Allow the motor and hex drive shaft to drop down and remove them from the unit, then pull the hex drive shaft out of the motor. Hex Drive Shaft Auger Motor 4-27...
REMOVING THE WATER RESERVOIR AND WATER VALVE Unclip the wires and remove the dispenser wiring terminal cover, then disconnect the dispenser wiring connectors. Dispenser Wiring Terminal Cover Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating.
To remove the water valve: c) Disconnect the water reservoir tubing from the John Guest union at the bot- a) Push in on the John Guest retaining tom of the refrigerator. rings and remove the two water outlet tubes from the water valve. b) Disconnect the electrical connectors from the water valve solenoids and remove the water valve.
REMOVING A LIGHT SOCKET Remove the light shield. Remove the bulb from the socket. Grasp the light socket by the rounded portion and pull out on the narrow end, while pressing the locking arm (see the photo below) with a screwdriver blade. Pull out on the socket until it disengages from the opening.
REMOVING THE WATER & ICE DISPENSER c) Bow the front panel out at the center and remove it from the top and bottom channels of the water & ice dispenser. Top Channel Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating.
c) Repeat the previous step for the other b) Push the two locking tabs to unlock corner of the front panel. them and pull the dispenser switch as- sembly down and forward. d) Pull the bottom of the front panel out and then down to remove it from the dispenser.
To remove a microswitch: c) Push the ARD off the retaining bracket. a) Push the two locking tabs to unlock the microswitch and slide the switch off the pins. b) Disconnect the wire connectors from the switch terminals. Microswitches Microswitches Locking Tab Locking Tab To remove the anti-run-on device (ARD):...
REMOVING A DOOR Dispenser Wiring Terminal Cover Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or Dispenser Wiring Connector electrical shock. Unplug refrigerator or disconnect power. Disconnect the water reservoir tubing from Turn off the water supply to the refrigera- the John Guest union at the bottom of the...
With the door closed, remove the hex- Place a support under the door to prevent head screw from the door linkage at the it from falling. top of the door. NOTE: The door spring will 10. Remove the four T27 screws from the remain under slight tension when the door door hinge.
COMPONENT TESTING Before testing any of the components, perform • Check all connections before replacing com- the following checks: ponents, looking for broken or loose wires, failed terminals, or wires not pressed into • Control failure can be the result of corrosion connectors far enough.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. CONDENSER FAN MOTOR EVAPORATOR FAN MOTOR 1 2 3 4 Refer to page 4-14 for the procedure for servic- ing the evaporator fan motor.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. COMPRESSOR & INVERTER Pins Refer to pages 4-4 and 4-12 for the procedures • If the 3 to 6 volts DC is present at the for servicing the inverter and compressor.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. DEFROST HEATER & BIMETAL MOTORIZED AIR DOOR Refer to page 4-18 for the procedure for servic- Refer to page 4-14 for the procedures for ing the motorized air door.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. MAIN CONTROL BOARD Refer to page 4-9 for the procedure for servicing the main control board. NOTE: See the chart for the main control board test specifications.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. POWER SWITCH DOOR SWITCH Refer to page 4-2 for the procedure for servic- ing a door switch. Unplug refrigerator or disconnect power.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. WATER VALVE SOLENOID AIR SUPPLY THERMISTOR Water Dispenser Solenoid Ice Maker Solenoid Refer to page 4-20 for the procedure for servic- ing the air supply thermistor.
Motor Harness Connector Press Tips Into Connector Slots Pin 1 Against Bare Wire Terminals To Check Voltages Electrical Shock Hazard Voltage is present during these tests. Refer to page 4-26 for the procedure for servic- Test Leads ing the auger motor. CHECKING THE AUGER MOTOR Press The Ice To check voltages* at the motor for crushed...
Touch the DC meter’s black test lead to Touch the DC meter’s red test lead to wire wire harness pin 1, and the red test lead to harness pin 1, and the black test lead to pin 2, then press the ice dispenser lever. pin 2, then press the ice dispenser lever.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. ICE MAKER INLET MEAT PAN AIR BAFFLE MOTOR HEATED FILL TUBE AND THERMISTOR Meat Pan Air Baffle Assembly Thermistor Connector 4 Connector Harness...
DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Warmer Warmer FREEZER REFRIGERATOR WATER FILTER Power °C RESET SELECT On/Off PERCENT LEFT Colder Colder PRE-DIAGNOSTICS CHECKS To enter the diagnostics mode: • Press and hold the Water Filter Reset • Confirm the refrigerator and freezer tem- keypad, and then immediately press and peratures before beginning other checks.
SERVICE DIAGNOSTICS MODE CHART Water Filter Component Component Step No. Suggested Diagnostics Routine Status Indicator Tested Freezer Step 1 and Step 2 are internal board tests, which 01 Pass Thermistor means the main controller board will check the 02 Thermistor Open resistance value of each thermistor and display the Refrigerator 03 Thermistor Short...
ELECTRONIC TEMPERATURE-CONTROLLED MEAT PAN DIAGNOSTICS Before entering the Service Diagnostics, lift the If all of the tests pass, the control will return to shelf so that you can view the air baffle. Various Cheeses mode. If any of the tests fail, the succeeding tests do not need to be per- To enter into Service Diagnostics Mode, press formed, and the LED corresponding to the...
TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE TEST PROCEDURE/ACTION RC control set too warm. See “Control Setting” section. RC thermistor. See “RC Thermistor” section. Refrigerator light not shutting off. See “Door Switch” section. Air door stuck closed or inoperative. See “Air Door” section. Blocked air flow.
PROBLEM POSSIBLE CAUSE TEST PROCEDURE/ACTION Holiday Mode. Press the “Holiday Mode” button to return to No Display, No normal mode. Interior Lights, The FC or RC doors have been open for See “Door Open” section. Can Not Change more than ten minutes. Settings Door light switch problem.
COMPONENT SYMPTOM TEST PROCEDURE/ACTION Run control diagnostics to check the air door operation in step 6. A 12 volt square wave is supplied to the air door in a series Stuck closed. of short pulses. It is not possible to obtain a reliable voltage reading with a VOM.
COMPONENT SYMPTOM TEST PROCEDURE/ACTION Check to make sure that it is not on the 7 minute delay. Ohm the compressor. The Inoperative. compressor should be 6 to 7 Ω. If no resis- tance is present, replace compressor. Compressor See “Inverter” section to check the inverter. If a mechanical clanking noise is evident, replace the compressor.
COMPONENT SYMPTOM TEST PROCEDURE/ACTION Run control diagnostics to check the evapo- rator fan operation in step 3. The evaporator Not running. fan receives voltage from the main control board. Voltage should be present at pins 1, 2, 6, & 7 of connector 7 of the main control board during operation (see the diagram on page 7-2).
COMPONENT SYMPTOM TEST PROCEDURE/ACTION Check for loose terminals or connectors at FC or RC compartment too warm. the main control board. Voltage should be present at the respective pin of the respec- tive connector of the main control board FC or RC compartment too cold. during operation (see the diagram on page 7-2 for component and pin locations).
BOTTOM MOUNT TUBING JOINT DIAGRAM Key Number D e s c r i p t i o n Key Number D e s c r i p t i o n Drier Bottom Compressor Discharge Evaporator Inlet Discharge Process Tube Evaporator Outlet Crimp &...
STRIP CIRCUITS COOLING CIRCUITS COMPRESSOR COMPRESSOR INVERTER BOARD POWER POWER ON/OFF ON/OFF RD/WH P7-8 P7-3 P5-3 ELECTRONIC P5-2 CONTROL BOARD THERMISTOR CONDENSER FAN MOTOR CONDENSER POWER POWER FAN MOTOR ON/OFF ON/OFF ELECTRONIC P5-2 P6-1 WH/RD CONTROL BOARD...
EVAPORATOR FAN MOTOR POWER POWER ON/OFF ON/OFF P5-2 P5-3 ELECTRONIC CONTROL BOARD P7-9 P7-10 P7-4 P7-5 YL/BU YL/RD WH/VT YL/BK EVAPORATOR FAN MOTOR DEFROST CYCLE DEFROST HEATER POWER POWER BIMETAL ON/OFF DEFROST ON/OFF HEATER ELECTRONIC P5-2 P6-4 PK CONTROL BOARD ELECTRONIC CONTROL ENABLED CIRCUITS ICE MAKER POWER...
TECH TIPS SERVICING THE ICE BIN AUGER ASSEMBLY Open the freezer door. Screw, Coupler, & Remove the ice bin from the door by Flat Washer pressing in on the release button and lifting it off the platform. Place the ice bin on a work surface with the bottom facing up.
IMPORTANT: The auger assembly is now LATCH ASSEMBLY REMOVAL loose and the ice crusher blades and Use a small screwdriver, and insert the spacers will slide off the auger shaft if you blade under the locking tab of the latching do not hold them in place.
WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-253-2870...