Related Manuals for Whirlpool R-92
Summary of Contents for Whirlpool R-92
- Page 1 CONSUMER SERVICES TECHNICAL R-92 EDUCATION GROUP PRESENTS WHIRLPOOL & KITCHENAID IN-DOOR ICE SYSTEM JOB AID Part No. 4322658A...
- Page 2 FORWARD This Job Aid, “Whirlpool & KitchenAid In-Door Ice System,” (Part No. 4322658A), provides the technician with information on the operation and service of the Whirlpool & KitchenAid In-Door Ice System. It is to be used as a training Job Aid and Service Manual. For specific information on the model being serviced, refer to the “Use and Care Guide,”...
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Page 3: Table Of Contents
Troubleshooting Chart B—2002 Optics Design ..............5-9 Troubleshooting Chart C—Component Diagnostics Mode ..........5-10 Troubleshooting The Motor ....................5-11 WIRING DIAGRAMS & STRIP CIRCUITS ................6-1 Whirlpool Wiring Diagram ....................6-1 KitchenAid Wiring Diagram ....................6-2 Strip Circuits ........................6-3 CONFIRMATION OF LEARNING EXERCISES ..............7-1... - Page 4 — NOTES — - iv -...
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Page 5: General
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. - Page 6 WARNING IMPORTANT Electrostatic Discharge (ESD) Sensitive Electronics ESD problems are present everywhere. ESD may damage or weaken the elec- tronic control assembly. The new control assembly may appear to work well after Electrical Shock Hazard repair is finished, but failure may occur at Connect green ground wire to ground a later date due to ESD stress.
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Page 7: Product Introduction
PRODUCT INTRODUCTION OVERVIEW Air Delivery The primary objective of the In-Door Ice Sys- tem is to increase the usable space in the Air is delivered to the ice maker mold through freezer compartment of the current freestand- a duct. This duct hooks onto the rear air duct ing side-by-side refrigerator/freezer. - Page 8 Water Delivery The water tube is made of polypropylene with an overmolded santoprene nozzle. Due to the Water is delivered to the ice maker mold by rigid nature of the polypropylene, this tube is means of a “tube-within-a-tube” design. A con- mated to a more flexible polyethylene tube with duit system consisting of three separate pieces a John Guest fitting high on the back panel.
- Page 9 Ice Stripper Ice Level Shutoff The ice stripper has been modified in order to The mechanical shutoff arm on the older ice direct ice into the new ice container. The main makers has been replaced with an electronic differences from the current stripper are: an ice level control system.
- Page 10 ICE STORAGE ICE DISPENSING The ice container has been redesigned and Major changes have been made to the power relocated to the freezer door. It is secured in train. The motor has been redesigned and re- place on the door liner with a sliding spring- located to the freezer door.
- Page 11 Drive Shaft / Coupling gage when the container is placed on the door, the motor drive shaft coupling will be de- The drive shaft / coupling connects the motor pressed. The next time ice is dispensed, the to the ice container auger. The coupling at the motor drive shaft coupling will spring up, and top of the motor drive shaft is spring-loaded to engage the ice container coupling.
- Page 12 — NOTES —...
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Page 13: Theory Of Operation
THEORY OF OPERATION The new ice making system consists of the fol- The ice maker loads, the motor, heater, and lowing: an ice maker with an integrated con- water valve, are still controlled by the stamped trol module, an electronic ice level sensor, an circuit module, which is part of the ice maker. - Page 14 — NOTES —...
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Page 15: Component Access
COMPONENT ACCESS COMPONENT LOCATIONS Ice Maker Door Infrared Emitter Water Fill Freezer Door Nozzle Ice Maker Infrared Receiver Ice Bin Ice Container Auger Coupling Motor Drive Coupling Hex Drive Shaft Motor... -
Page 16: Removing The Ice Maker & The Water Fill Tube
REMOVING THE ICE MAKER & THE WATER FILL TUBE d) Remove the wire shield screw from the WARNING bottom of the ice maker. Wire Shield Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or Wire Shield Screw electrical shock. - Page 17 h) If you do not want to completely re- b) Slowly pull the end of the water fill move the ice maker rotate the ice nozzle out of the fitting in the top of the maker so the square end with the mo- freezer liner, then continue to pull the tor faces the front, and hang the flange rest of the tube out of the liner.
- Page 18 c) Install a length of flexible tubing on the b) Position the water fill nozzle so that the spout of the squeeze bottle. bend is toward the mullion, and insert the inner half of the grooved shoulder d) Insert the end of the flexible tubing into into the square cutout of the liner.
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Page 19: Removing The Emitter & Receiver Modules
REMOVING THE EMITTER & RECEIVER MODULES c) Pull the module out and remove the WARNING connector from the board. Connector Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. -
Page 20: Removing & Reinstalling The Motor
REMOVING & REINSTALLING THE MOTOR d) Disconnect the harness connector from WARNING the motor terminals. Harness Screw Connector (1 of 4) Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. - Page 21 To reinstall the motor: d) Plug the harness connector into the mo- tor. NOTE: The connector is designed a) Remove the two screws from the hex to fit only one way on the motor termi- drive shaft coupling holder and remove nals.
- Page 22 h) Replace the ice container on the freezer penser is activated. At that time, the door plate. NOTE: The coupling in the motor will turn, and the spring-loaded ice container does not have to align with coupling on the end of the hex drive the coupling on the end of the hex drive shaft will pop up and engage the ice shaft when the ice container is installed.
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Page 23: Accessing The Selector Switch Pack & Dispenser Switches
ACCESSING THE SELECTOR SWITCH PACK & DISPENSER SWITCHES Remove the screws from the ice and water WARNING dispenser compartment front panel and turn it over. The selector switch pack and dispenser switches are now accessible for testing. Ice Dispenser Switch Electrical Shock Hazard Disconnect power before servicing. - Page 24 — NOTES — 4-10...
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Page 25: Diagnostics & Troubleshooting
DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS OPTICS DIAGNOSTICS MODE The optics system can have one of two types of optics board designs installed: the original Diagnostics are used to determine whether the design, or the 2002 design. optics circuits are operating properly. If the Use the following flow chart to determine which optics circuits are malfunctioning, the ice maker of the board designs are installed. -
Page 26: Optics Diagnostics For Original Design Boards
OPTICS DIAGNOSTICS FOR Open the freezer door and activate the freezer door switch 3 times. NOTE: This ORIGINAL DESIGN BOARDS step must be completed within 10 sec- KIT #4388635 SUBS TO #4389102 onds of opening the freezer door. EMITTER—PART #2198585 RECEIVER—PART #2198586 To initiate an optics check, perform the follow- Freezer Door... - Page 27 Open the freezer door and actuate the If the LED still flashes twice, there could be freezer door switch 3 times. NOTE: This dirt or frost on the optics, something could be step must be completed within 10 sec- blocking the infrared beam path, or the optics onds of opening the freezer door.
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Page 28: Optics Diagnostics For 2002 Design Boards
OPTICS DIAGNOSTICS FOR Close the flapper door on the emitter mod- ule so that the infrared beam has a clear 2002 DESIGN BOARDS path to the receiver board. KIT #4389102 EMITTER—PART #2220398 RECEIVER—PART #2220402 To initiate an optics check, perform the follow- ing steps: Open the freezer door. -
Page 29: Component Diagnostics Mode
COMPONENT DIAGNOSTICS MODE Slide the ice maker out of the mounting rails and leave the wiring harness con- WARNING nected. Jumper the thermostat, as shown below. Connect power to the unit. Remount the ice maker, making sure that the water fill tube is inside the fill cup. Make sure there is a clear path across the Electrical Shock Hazard bin for the infrared beam to travel to the... -
Page 30: Optics Diagnostics Mode Charts
OPTICS DIAGNOSTICS MODE CHARTS NOTES: Optics Diagnostics will not respond: • For 5 minutes after the ice maker begins a “harvest” cycle. To reset the control, wait until the ice maker “parks,” then unplug the refrigerator for 5 seconds, and repeat the test. •... -
Page 31: Component Diagnostics Mode Chart
COMPONENT DIAGNOSTICS MODE CHART — Chart C — Component Diagnostics Mode For Original & 2002 Design Boards COMPONENT DIAGNOSTICS MODE (RUN OPTICS DIAGNOSTICS PROCEDURE FIRST) 1. Disconnect the power supply. 2. Slide the ice maker out and remove the cover. 3. - Page 34 5-10...
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Page 35: Troubleshooting The Motor
TROUBLESHOOTING THE MOTOR f) Disconnect/reconnect the 6-pin harness WARNING to the motor 3 - 5 times to remove any oxidation buildup on the connector pins. g) Check power in the circuit (see “Check- ing The Switch Pack on page 5-14 ). Motor hums but does not rotate. - Page 36 NOTE: When you are instructed to make a WARNING reading at the motor connector, press the tips of the red and black test leads into the indi- cated harness connector slots so they touch the bare metal wire connectors. Reach around the front of the door and press the ice dispenser lever to activate the dispenser switch.
- Page 37 Press the Unlocked button on the ice and Touch the DC meter’s black test lead to water dispenser front panel. wire harness pin 1, and the red test lead to pin 2, then press the ice dispenser lever. Touch the AC meter test leads to wire The meter should read +115 VDC ±10%.
- Page 38 The Locked/Unlocked switch allows AC WARNING voltage to be sent to the motor through the ice dispenser lever switch when it is in the Unlocked position. If the Unlocked switch is defective, the dispenser lever will not operate the motor. To check the switch: a) Check pins BU/BK and GY using an AC voltmeter.
- Page 39 To check to make sure that DC voltage is d) Touch the DC voltmeter’s black test lead being supplied to the switch pack: to RD/WH and the red test lead to BR/ WH, then press the ice dispenser lever. a) Press the Unlocked button. The meter should read +115 VDC b) Touch the DC voltmeter’s black test lead ±10%.
- Page 40 To install a wire terminal, position the WARNING terminal with the slot facing the retainer tab, and slide it into the connector. Press down on the retainer tab to lock it in place. Wire Wire Terminal Screwdriver Retainer Slot Electrical Shock Hazard Disconnect power before servicing.
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Page 41: Wiring Diagrams & Strip Circuits
WIRING DIAGRAMS & STRIP CIRCUITS WHIRLPOOL WIRING DIAGRAM ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. -
Page 42: Kitchenaid Wiring Diagram
KITCHENAID WIRING DIAGRAM ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. -
Page 43: Strip Circuits
STRIP CIRCUITS CRUSHED MODE Crushed Ice Selection Light RD/WH OR/BU Interlock Dispenser Lock Ice Lever Voltage Rectifier Motor Switch Switch Switch Bridge Converts 115 VAC to – Rotation PK/BK BR/WH BU/BK 115 VDC CUBED MODE Cubed Ice Selection Light OR/BU BR/WH Interlock Dispenser Lock... - Page 44 — NOTES —...
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Page 45: Confirmation Of Learning Exercises
CONFIRMATION OF LEARNING EXERCISES Trace the circuit for the crushed ice operation by closing the necessary switches. Refer to the Wiring Diagram NOTES at the bottom of the page. To Light Switch ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. - Page 46 Trace the circuit for the cubed ice operation by closing the necessary switches. Refer to the Wiring Diagram NOTES at the bottom of the page. To Light Switch ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2.
- Page 47 PRODUCT SPECIFICATIONS 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...
- Page 48 CORPORATION...