Electrolux Side by Side Refrigerator Service Manual
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Electrolux Side by Side Refrigerator Service Manual

Electrolux Side by Side Refrigerator Service Manual

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Summary of Contents for Electrolux Side by Side Refrigerator

  • Page 1 Service Manual Side by Side Refrigerator Dishwasher 5995393583 (0311)

  • Page 2: Table Of Contents

    Table of Contents SAFE SERVICING PRACTICES..........1 SECTION A - INSTALLATION........... 2 UNCRATING ......................2 MODEL AND SERIAL NUMBER................2 AIR CIRCULATION ....................2 ELECTRICAL INFORMATION ................3 LEVELING ......................3 DOOR REMOVAL ....................4 To Remove Refrigerator Door ..............4 To Remove Freezer Door ................
  • Page 3 Table of Contents DEFROST THERMOSTAT ..................19 To Test Defrost Thermostat ..............19 To Remove Defrost Thermostat ..............19 DEFROST HEATER....................20 How To Remove Defrost Heater ..............20 SECTION C - ELECTRONIC CONTROLS ......ELECTRONIC CONTROL SYSTEM ................ 22 Damper Assembly..................
  • Page 4 Table of Contents OPERATION - UPDATED REVISION L ..............28 User Interface - Version A................28 Freezer ..................28 Fresh Food ................... 29 Temperature Alarm ................ 29 Air Filter Control ................29 Fast Freeze/Fast Ice Mode .............. 29 Over Temperature Shut Off ............. 30 User Interface - Version B................
  • Page 5 Table of Contents SECTION E - REFRIGERATION SYSTEM......48 DEFINITIONS ....................48 Recovery ....................48 Recycling ....................48 Reclaim ....................48 SAFETY WARNINGS ..................... 49 Compressor Testing ................. 49 Charging Sealed Systems ................ 49 Soldering ....................49 BASIC COMPONENTS ..................50 Perimeter Hot Tube ..................
  • Page 6 Table of Contents Refrigerant Leaks ..................76 Leak Detection ..................76 R-134a Properties ..................76 HFC-134a, CFC-12 Pressure Temperature Chart ........... 77 R-134a HEALTH AND SAFETY INFORMATION ............78 Inhalation Toxicity ..................78 Cardiac Sensitization................. 78 Spills or Leaks ..................79 Skin and Eye Contact ................
  • Page 7 Table of Contents To Replace Water Fill Switch ............90 To Replace Ejector Blades ............90 To Replace Hold Switch ..............90 To Replace Ice Maker Control Arm Shut-Off Switch ...... 91 To Replace Ice Maker Thermostat ..........91 To Replace Thermal Cut-Out (TCO) ..........91 To Replace Mold Heater ..............
  • Page 8 Table of Contents Water Tanks ....................124 Front Filter System ..................125 Rear Filter System ..................125 To Test The Water Fill System ................. 126 Resistance Check ..................127 Voltage Check for Water to Ice Maker ............127 Digital Meter ..................... 127 Voltage Drop From Heater................

  • Page 9: Safe Servicing Practices

    Electrolux Home Products cannot be responsible, nor assume any liability, for injury or damage of any kind arising from the use of this manual.

  • Page 10: Section A - Installation

    Section A - Installation UNCRATING Uncrating instructions are clearly printed on the shipping carton. Under no circumstances should a refrigerator be uncrated until these instructions have been read. Additional handling and installation information is provided in the "Installation Tips" affixed to the refrigerator door and in the Owner's Guide, located in one of the drawers inside the refrigerator.

  • Page 11: Electrical Information

    Section A - Installation ELECTRICAL INFORMATION The refrigerator must be plugged into its own 115 Volt, 60 Hz, AC only electrical outlet. The circuit should be protected by a 15 or 20 Amp circuit breaker or time delay type fuse. N OTE If voltage varies by ±10% of 115 volts, performance of the refrigerator may be affected.

  • Page 12: Door Removal

    Section A - Installation DOOR REMOVAL N OTE If installation requires the removal of the doors, trace around all hinges with a soft lead pencil for easy relocation. Disconnect electrical supply. Open both doors, then remove toe grille. Close doors. To Remove Refrigerator Door: Remove two Hinge Cover screws.
  • Page 13 Section A - Installation Remove Hinge Cover screws, then remove cover. Disconnect wiring harness connector plug at top hinge. Place your thumbs on flat sides of each connector, bending both sides back and forth, then with firm grasp, pull both pieces apart. Trace around hinge with soft lead pencil.

  • Page 14: Door Alignment

    Section A - Installation DOOR ALIGNMENT Due to their large size,Side by Side cabinets may flex when installed on an uneven floor. To correct alignment, proceed as follows: Level refrigerator, front to back and side to side. Open doors and rock refrigerator after each adjustment to relieve cabinet strains.

  • Page 15: Section B - Refrigerator Cabinet

    Section B - Refrigerator Cabinet BASIC CONSTRUCTION Counter Depth models have clean back cabinets and/or forced air condensers. The condenser is located under the cabinet bottom. The cabinet wrapper consists of a one-piece top and sides formed of prepainted steel, with an interlocking, snap- in, galvanized steel back panel.

  • Page 16: Insulation And Inner Liner

    Section B - Refrigerator Cabinet INSULATION AND INNER LINER The cabinet wrapper and compartment liner are bonded together with a core of "Urethane" foam insulation to form a slim three-ply wall of single-unit construction. The one piece freezer and the one piece food inner liners are vacuum formed of tough corrosion-proof ABS/HIPS plastic material.

  • Page 17: Front And Rear Rollers

    Section B - Refrigerator Cabinet FRONT AND REAR ROLLERS The front roller is mounted with two screws to the cabinet base and one screw to the front of the cabinet. (See Roller Roller Figure B4.) The adjustment screw at the top of the roller is Assembly Mounting turned clockwise to raise the cabinet, and...

  • Page 18: Cabinet Touch-Up Procedure

    Section B - Refrigerator Cabinet CABINET TOUCH-UP PROCEDURE Vinyl gaskets are used on all models. Lacquer repairs can be made on all areas of the cabinet except any painted surface that comes in contact with the vinyl gasket. Since prolonged contact of vinyl gaskets with lacquer will soften the lacquer, repairs in these areas should not be attempted.
  • Page 19 Section B - Refrigerator Cabinet CABINET TOUCH-UP PROCEDURE (CONT.) Patched area should be allowed to dry three or more hours before rubbing with compound or polish. This procedure also applies to the complete refinishing of the cabinet, except gasket contact areas. All damaged areas should be repaired as outlined in steps 1 through 6 on the previous page.

  • Page 20: Section C - Electrical Components

    Section C - Electrical Components ELECTRICAL GROUNDING All refrigerators are equipped with a power supply cord incorporating a three-prong grounding plug and a ground wire which is attached to the refrigerator cabinet for protection against shock hazard. Each electrical component is either cabinet mounted or connected through a ground wire to the cabinet to complete the ground.

  • Page 21: To Check/Replace Relay

    Section C - Electrical Components To Check/Replace Relay Disconnect electrical supply to refrigerator. Remove bale wire holding relay to compressor. Remove relay assembly from compressor. (See Figure C2.) Use small, flat-bladed screwdriver to disconnect leads to relay assembly. Use flat headed screwdriver to gently pry capacitor from relay assembly.

  • Page 22: Run Capacitor

    Section C - Electrical Components Use small, flat-bladed screwdriver to disconnect leads to relay assembly. N OTE On some models you will have to remove bale wire and cover, to gain access to relay and overload protector. Use ohmmeter to check resistance between tab terminal and female pin terminal.

  • Page 23: Compressor Start Circuit

    Section C - Electrical Components If ohm readings are out of range, replace capacitor. Reverse procedures to re-assemble. Compressor Start Circuit When the compressor circuit is first energized, the solid state relay has low resistance (3-12 ohms), and both the run and start windings are energized to start the compressor.

  • Page 24: Compressor Electrical Check

    Section C - Electrical Components • With an open relay, the compressor will not start since there is little or no current to the start windings. The overload protector will open due to high locked rotor run winding current. • With a shorted relay or capacitor, the compressor will start, and the overload protector will open.

  • Page 25: Evaporator Fan & Motor Assembly

    Section C - Electrical Components EVAPORATOR FAN & MOTOR ASSEMBLY The fan and motor assembly are located behind the freezer compartment air duct directly above the evaporator in the freezer compartment. The fan is a 12 VDC suction type, pulling air up through the evaporator and blowing it through the freezer and refrigerator compartments.

  • Page 26: Defrost Thermostat

    Section C - Electrical Components DEFROST THERMOSTAT The defrost thermostat is a temperature sensing device. Wired in series with the electronic control board and the evaporator defrost heater, it senses the rise in evaporator temperature during a defrost cycle and cycles the defrost heater off after all Ice Maker Duct frost is melted.

  • Page 27: Defrost Heater

    Section C - Electrical Components Remove faulty thermostat. N OTE The Defrost Thermostat Replacement Kit comes with a new thermostat, two solderless connectors and two pieces of heat shrink to allow for splicing the new thermostat to the connector plug. 10.
  • Page 28 Section C - Electrical Components Remove two rail assembly supports (two screws on each one). Remove four screws from evaporator cover. Remove five screws on evaporator air duct cover. Figure C8 Disconnect two leads to defrost heater. N OTE Defrost Heater This is a good time to test the heater.

  • Page 29: Electronic Control System

    Section C - Electrical Components Defrost Heater (Cont.) 14. Slide drain trough off evaporator. 15. Remove retainer clamp form bottom of evaporator holding heater in place. 16. Grab heater from bottom and pull free of evaporator. It’s very snug so you’ll need to use a little force.

  • Page 30: Defrost Termination Thermostat (Dtt)

    Section C - Electronic Controls Defrost Termination Thermostat (DTT) Bi-metal disc thermostat attached via a clamp to the evaporator tubing. During the defrost cycle, the device is a closed circuit between the defrost heater and Neutral. The DTT is designed to open at a predetermined temperature ending the defrost cycle Standard Compressor Motorized pump (115VAC) that creates the high and low pressures required for heat exchange.

  • Page 31: Alarm

    Section C - Electronic Controls Alarm Audible Transducer (Piezo) Control, Main Board Power Supply ... AC Input Voltage – 115 V AC @ 60 Hz. Control, User Interface Power Supply ... Input - 5VDC (from Main Board) Numeric Display Version A …2 digit, 7 segment numeric with degrees symbol, minus sign segment and a 4 segment character to represent F and C (magnetically activated reed switch that detects Fresh Food Door state).

  • Page 32: Alarms And Signals

    Section C - Electronic Controls ALARMS AND SIGNALS Temperature Alarm Enabling is automatic and started at the time product is plugged in POR (power on Reset) but is delayed until actual Freezer temperature = Freezer temperature set point and actual Fresh Food temperature = Fresh Food temperature set point. Once set points are reached, Alarm LED (Green) will come ON, steady state, indicating Alarm is active.

  • Page 33: Door Ajar & High Temp

    Section C - Electronic ControlsDoor Door Ajar & High Temp Fresh Food and/or Freezer doors have been open for at Alarm least 5 minutes and temperatures have exceeded Door Ajar recommended limits. (See Example 3.) High High Temp Reset Power Failure Example 3 Power Failure (flashing yellow) If power fails, this light blinks.

  • Page 34: Power Failure (Flashing Yellow)

    Section C - Electronic Controls Alarm OFF Alarm has been turned Off by user. (See Example 7. ) Alarm Door Ajar High High Temp Reset Power Failure Example 7 SHOW ROOM SETTING Activation Press and hold Fresh Food Temperature UP (WARMER) Key while pressing the fresh food temperature DOWN (COLDER) key 3 times within 5 seconds.

  • Page 35: Change Between Fahrenheit & Centigrade

    Section C - Electronic ControlsDoor Change Between Fahrenheit and Centigrade (on some models) To change form Fahrenheit to Centigrade, press the Mode key. To change form Centigrade to Fahrenheit, press the Mode key. Advance Into Defrost Cycle Manually Activation Press and hold Freezer Temperature UP (WARMER) Key while pressing the fresh food temperature DOWN (COLDER) key 5 times within 6 seconds.

  • Page 36: Fresh Food

    Section C - Electronic Controls Fresh Food Temperature UP key increments temperature setting one degree, F or C, each key press. Setting Upper Limit = 47°F (8°C). Temperature DOWN key decrements temperature setting one degree, F or C, each key press. Setting Lower Limit = 33°F (1°C). Each key press (Temperature UP or DOWN) displays temperature setting.

  • Page 37: Over Temperature Shut Off

    Section C - Electronic Controls Over Temperature Shut Off Compressor operation is terminated at ambient temperatures over 85°C (185°F). Compressor operation continues at 65°C (149°F). User Interface - Version B (One position read out for freezer and food Compartment) Freezer Temperature Colder key increments setting one number each key press.
  • Page 38 Section C - Electronic Controls Number Setting to Temperature Conversion 1 = 47°F (8°C). 2 = 44°F (6.5°C). 3 = 43°F (5.5°C). 4 = 41°F (4°C). 5 = 37°F (3.5°C). 6 = 36°F (3°C). 7 = 35°F (2.5°C). 8 = 34°F (2°C). 9 = 33°F (1°C).

  • Page 39: Diagrams

    Section C - Diagrams Diagram A - Control System...
  • Page 40 Section C - Diagrams Diagram B Controller, User Interface Board Reference ONLY See Drawing Version A Reed Switch Pin 1 Version B Reed Switch Pin 1 Karl Truitt 3/03...
  • Page 41 Section C - Wiring Diagrams...

  • Page 42: Wiring Diagrams

    Section C - Wiring Diagrams...
  • Page 43 Section C - Performance Data PERFORMANCE DATA NO LOAD AND NO DOOR OPENINGS AT MID-POINT CONTROL SETTING Type A with Run/Start Capacitor 85°F (18°C) Ambient 90°F (32°C) Ambient Operating Time 32 TO 40% 55 TO 65% 0° TO 4°F -1° TO 3°F Freezer Temperature -18°...

  • Page 44: Service Diagnostic Mode

    Section C - Service Diagnostics SERVICE DIAGNOSTIC MODE - SIGMA ELECTRONIC CONTROL With a series of key presses, a service technician will be able to view data, via the display and exercise loads to help troubleshoot the product. Following is a list of capabilities.

  • Page 45: Deactivation

    Section C - Service Diagnostics N OTE Note: If you are in test 1 and press the freezer UP key it will go to test 8. If you are at the start of test 1 and press the food compartment UP key it will beep at you. Deactivation Press and hold Freezer Temperature “UP”...

  • Page 46: Test 4 Fresh Food Temperature, Last 24 Hours

    Section C - Service Diagnostics Variable 4. Freezer sensor circuit condition; Flash “1” Freezer sensor OK Flash “2” Freezer sensor open Flash “3” Freezer sensor shorted Variable 5. Disables buffer to allow technician to place his finger on the freezer sensor and observe an immediate temperature rise.

  • Page 47: Test 6 - Defrost

    Section C - Service Diagnostics N OTE Stepper motors require alternating polarities of DC current to operate. This is accomplished with a circuit on the main board. Applying straight 12 V DC to the damper motor will not make the motor run and it could damage the motor windings. Only test the damper motor through the refrigerator control system.

  • Page 48: Manual Defrost

    Section C - Service Diagnostics the servicer to restart system recording new data, press and hold the fresh food UP (WARMER) key while pressing the fresh food DOWN (COLDER) key 3 times within 30 seconds. Manual Defrost Activation - Press and hold Freezer Temperature UP (WARMER) Key while pressing the fresh food temperature DOWN (COLDER) key 5 times within 6 seconds.

  • Page 49: Control Removal & Installation

    Section C - Removal & Installation CONTROL REMOVAL & INSTALLATION CAUTION Before servicing any part of the control system the product must be unplugged, the fuse pulled or circuit breaker turned off to prevent damage to the the product the control system or personal injury to the To service the control board, open the food door and remove the cover over the water lines going to the water filter.

  • Page 50: To Service The Power Board

    Section C - Removal & Installation To service the power board (Main power supply), open the food and freezer doors. Remove the kick plate from the bottom of the cabinet. Looking through the opening at the bottom of the cabinet on the left side you will see the plastic box containing the power board.
  • Page 51 Section C - Removal & Installation Now the damper can be remover from the product. Figure 1 N OTE Stepper motors require alternating polarities of DC current to operate. This is accomplished with a circuit on the main board. Applying straight 12 V DC to the damper motor will not make the motor run and it could damage the motor windings.

  • Page 52: Food Compartment Light Switch

    Section C - Removal & Installation Food Compartment Light Switch The food compartment light switch is a Magnetic Reed switch located on the control board at the top of the food compartment. REED SWITCH If the reed switch would fail, the control board will need to be replaced.

  • Page 53: System Exploded View

    Section C - System Exploded View Defrost Thermostat Bracket Shoulder Screw Conderser Fan Shoulder Screws Bracket Silencer Compressor Bracket Speed Run Capacitor Drier-Filter Fan Shroud Clamp PTC Starter Condenser Defrost Drain Pan Front Roller Roller Pin Roller Pin Power Cord Rear Roller...

  • Page 54: Section D - Air Circulation

    Section D - Air Circulation AUTOMATIC DEFROST MODELS Principals Of Automatic Defrost Operation All Counter Depth refrigerators operate on the principle that moisture or frost transfers or migrates to the coldest surfaces (evaporator) in the freezer compartment. For example, a small amount of water spilled in the freezer compartment will freeze immediately.
  • Page 55 THIS IS A BLANK PAGE...

  • Page 56: Section E - Refrigeration System

    Federal Register May 14, 1993. N OTE Electrolux Home Products, Inc. does not permit the use of recovered refrigerant in the servicing of our products for in-warranty and out-of-warranty repairs, or for products covered by service contracts. Therefore, only new refrigerant or refrigerant that has been reclaimed back to new specifications by a refrigerant manufacturer is to be used.

  • Page 57: Safety Warnings

    Section E - Refrigeration System SAFETY WARNINGS Compressor Testing Whenever testing a compressor, extreme caution should be used to prevent damaging the terminals. A compressor with a damaged terminal or a grounded winding can expel a terminal from its insulated housing when the compressor is energized.

  • Page 58: Basic Components

    Section E- Refrigeration System All joints to be soldered must have proper fit. Clearance between tubes to be soldered should be from .001” to .006”. It is not practical to actually measure this; however, you do not want a dry fit to be loose. Tubing joints should overlap about the distance of their diameter except for restrictor tubes (capillary tube), which should be inserted 1.25”.

  • Page 59: Refrigerant Cycle

    Section E - Refrigeration System Refrigerant Cycle The refrigerant cycle is a continuous cycle that occurs whenever the compressor is in operation. Liquid refrigerant is evaporated in the evaporator by the heat that enters the cabinet through the insulated walls and by the heat from product load and door openings.

  • Page 60: Testing For Refrigerant Leaks

    Section E - Refrigeration System TESTING FOR REFRIGERANT LEAKS If the system is diagnosed as short of refrigerant and the system has not been recently opened, there is probably a leak in the system. Adding refrigerant without first locating and repairing the leak or replacing the component will not permanently correct the difficulty.

  • Page 61: Compressor Replacement

    Section E - Refrigeration System If dry nitrogen or carbon dioxide is not available, follow steps 1 through 3 on previous page, then steps 4 and 5 below: Connect gauges to charging hose fittings. Pull vacuum on hot tube. Leave vacuum on each side of system for 24 hours. Any loss of vacuum indicates leak.

  • Page 62: To Use Dry Nitrogen To Flush The System

    Section E- Refrigeration System CAUTION The end of the flushing hose on this tank regulator must be equipped with a hand shut- off valve (Robinair No. 40380). Close hand shut-off valve and adjust nitrogen regulator to correct pressure before proceeding with flushing procedure. To Use Dry Nitrogen To Flush The System: Remove compressor and filter-drier.

  • Page 63: Installing A New Compressor

    Section E- Refrigeration System Disconnect the suction and discharge lines from the compressor and remove the filter-drier. Connect process coupling to outlet and inlet tube of condenser. Connect hose to outlet process coupling and charging cylinder. Connect another hose to inlet coupling and recovery system. Open charging cylinder and allow refrigerant to flow through condenser until discharge into bag is clear.
  • Page 64 Section E- Refrigeration System Before installing the replacement compressor remove the discharge plug and check for the pop sound of the inert gas leaving the compressor. CAUTION DO NOT use compressor if you do not hear this sound.. If the compressor checks OK, reinstall the plug. Do not remove any of the plugs again until the compressor is in position and you are ready to braze the lines.
  • Page 65 Section E- Refrigeration System Bracket Motor Bracket Shoulder Screw 10. Reform both suction and Grommet Condenser discharge lines to align Motor Motor Washer Screws Support Silencer with new compressor. If Motor Fan Blade Filter Drier Bracket they are too short, use Speed Nut additional lengths of Spacers...

  • Page 66: Evaporator Replacement

    Section E- Refrigeration System EVAPORATOR REPLACEMENT CAUTION Always use the TORCH GUARD heat shield part number 5304418872, behind evaporator before attempting to solder. The excessive heat from soldering will warp the plastic liner. The evaporator is located in the lower section of the freezer and is secured to the drain pan by a bracket at the top.
  • Page 67 Section E- Refrigeration System Cut suction line in front of weld at evaporator. To replace the Using a file, score and break the cap tube just evaporator, cut in front of the weld. (See Figure 2.) suction line at this point.

  • Page 68: Heat Exchanger Replacement

    Section E- Refrigeration System Push evaporator back in place and reinstall Now make your plastic clamp at top. (See Figure 4.) There is weld on the no need to replace the rivot. suction line. Make your weld Slide fan and bracket assembly in place and on the cap tube connect defrost heater.
  • Page 69 Section E- Refrigeration System To replace the heat exchanger: Recover refrigerant from sealed system. Cut suction line off at liner. Remove evaporator and Disconnect wiring harness at liner plug. save for reuse. Remove defrost limiter and disconnect defrost heater. Remove fan motor and wiring. Cut heat exchanger off flush with liner.

  • Page 70: Perimeter Hot Tube Repair Kit

    Section E- Refrigeration System 14. Seal hole and end of old heat exchanger with Permagum. (See Figure 6.) Using the permagum 15. Replacr Drier-Filter. provided in kit, seal hole and end of old heat 16. Evacuate and recharge system. exchanger. 17.

  • Page 71: Installing The Heater Wire - Step 2

    Section E- Refrigeration System Install copper bypass tube and replacement filter-dryer as shown in figure below. Use Cut at filter-drier inlet Cut at weld between 45% silver solder for all connections. condenser and hot tube Drill or pierce three holes in cabinet to hold clamps.
  • Page 72 Section E- Refrigeration System 5. Disconnect Plastic Sleeve. Figure 1 6. Pull braid out while pushing equal amount of braided heater into tube at other end until heater wire inside braid appears. Installing The Heater Wire - Step 3 1. Remove wires (with terminals) from compressor starter/ overload.

  • Page 73: Condenser Replacement

    Section E- Refrigeration System CONDENSER REPLACEMENT Disconnect electrical supply to refrigerator. Remove compressor access panel. Recover refrigerant by using EPA approved recovery system. Remove condenser fan mounting screws. Unplug fan motor harness located in back of fan motor. Remove fan motor, fan blade, and water valve assembly. After refrigerant is completely recovered, disconnect inlet and discharge lines from condenser.

  • Page 74: Filter-Drier Installation

    Section E- Refrigeration System FILTER-DRIER INSTALLATION Any time the sealed system is opened and the refrigerant charge is removed, the liquid line filter-drier must be replaced and the system thoroughly evacuated before recharging. CAUTION DO NOT unbraze the old filter-drier from the system. This will vaporize and drive moisture from the desiccant back into the system.

  • Page 75: Evacuating And Recharging

    Section E- Refrigeration System EVACUATING AND RECHARGING CAUTION Check the serial plate for the correct refrigerant type. It is extremely important to verify the type of refrigerant in the system before starting any sealed system repairs. CAUTION With the possible exception of the vacuum pump, all service equipment that comes in contact with R-134a during evacuation and recharging must be dedicated.

  • Page 76: Equipment Needed For Evacuation & Recharging

    Section E- Refrigeration System Equipment Needed for Evacuation & Recharging: • Heated charging cylinder • Standard 3-port manifold gauge set: 4 charging hoses Tee fitting with valve core stem removed (Robinair No. 40396) Hand shut-off valve (Robinair No.40380) • Two stage vacuum pump •...

  • Page 77: Charging The System

    Section E- Refrigeration System To achieve the required levels of evacuation, a properly maintained two stage vacuum pump in good condition is required. It is absolutely essential to maintain your vacuum pump according to the manufacturer’s instructions including required oil changes at the recommended intervals. Vacuum pump oil should always be changed after evacuating a contaminated system.

  • Page 78: Preparing The Charging Cylinder

    Section E- Refrigeration System Preparing The Charging Cylinder: Make certain that hand shut-off valve to vacuum pump is closed. Close high-side manifold gauge valve. Set charging cylinder scale to pressure indicated on cylinder pressure gauge. Observe refrigerant level in sight glass. Subtract amount to be charged into system and note shut off point.
  • Page 79 Section E- Refrigeration System COMPOUND PRESSURE GAUGE GAUGE EVAPORATOR FITTING GAGE MANIFOLD HAND SHUTOFF VALVE TUBE HEATED CHARGING CYLINDER FILTER DRIER COMPRESSOR CONDENSER PROCESS TUBE ADAPTERS Figure E2 2 STAGE VACUUM PUMP...

  • Page 80: R-134A Service Information

    Section E R-134A SERVICE INFORMATION N OTICE Instructions given here are furnished as a guide. Persons attempting to use these instructions to make repairs to the sealed refrigeration system should have a working knowledge of refrigeration and previous training on sealed system repair. Verify Refrigerant Type In The System CAUTION R-134a and R-12 are completely incompatible.

  • Page 81: Miscibility Of R-134A And Ester Oil

    Section E Products using R-134a refrigerant will generally have a longer capillary tube to maintain a similar flow rate and some models will have a larger condenser to reduce the discharge pressures and lower start-up sound transmission. Miscibility Of R-134a And Ester Oil A special synthetic oil known as Ester oil is used as a lubricant in refrigeration systems operating on R-134a.

  • Page 82: Water In The Refrigeration System

    Section E Water In The Refrigeration System Even in very small quantities, water in any refrigeration system can cause the following problems: • Ice plugs in capillary tubes. • Copper plating in compressor. • Reactions with organic materials in systems. •...

  • Page 83: Vacuum Pump Maintenance

    Section E Vacuum Pump Maintenance It is absolutely essential to maintain your vacuum pump according to the manufacturer’s instructions including required oil changes at the recommended intervals. Vacuum pump oil should always be changed after evacuating a contaminated system. Vacuum pump performance should be checked periodically with a micron gauge.

  • Page 84: Refrigerant Leaks

    Section E Refrigerant Leaks A system with R-134a and Ester oil will become saturated with moisture much faster than a system with R-12 and mineral oil. The compressor in an R-134a system will have to be replaced if the product has had a low side leak. R-134a refrigerant molecules are smaller than R-12 molecules.
  • Page 85 Section E HFC-134a, CFC-12 PRESSURE TEMPERATURE CHART °F °C HFC-134a CFC-12 °F °C HFC-134a CFC-12 -51.1 21.8* 19.0* 12.8 51.1 52.0 -48.3 20.4* 17.3* 15.6 57.3 57.7 -45.6 18.7* 15.4* 18.3 63.9 63.8 -42.8 16.9* 13.3* 21.1 70.9 70.2 -40.0 14.8* 11.0* 23.9...

  • Page 86: R-134A Health And Safety Information

    Section E R-134a HEALTH AND SAFETY INFORMATION Inhalation Toxicity HFC-134a poses no acute or chronic hazard when it is handled in accordance with DuPont recommendations and when exposures are maintained at or below the DuPont Acceptable Exposure Limit (AEL) of 1,000 ppm (8 and 12 hour Time- Weighted Average or TWA).

  • Page 87: Spills Or Leaks

    Section E Spills Or Leaks If a large release of vapor occurs, such as from a large spill or leak, the vapors may concentrate near the floor or low spots and displace the oxygen available for breathing, causing suffocation. Evacuate everyone until the area has been ventilated. Use blowers or fans to circulate the air at floor level.

  • Page 88: Combustibility Of Hfc-134A

    Section E Combustibility Of Hfc-134a HFC-134a is nonflammable at ambient temperatures and atmospheric pressure. However, tests have shown HFC-134a to be combustible at pressures as low as 5.5 psig (139.3 kPa absolute) at 177°C (350°F) when mixed with air at concentrations generally greater than 60% volume air.

  • Page 89: Refrigerant Recovery Systems

    Section E • Filled cylinders should periodically be analyzed for air (nonabsorbable gas or NAG). Refrigerant Recovery Systems Efficient recovery of refrigerant from equipment or containers requires evacuation at the end of the recovery cycle. Suction lines to a recovery compressor should be periodically checked for leaks to prevent compressing air into the recovery cylinder during evacuation.

  • Page 90: Section F - Ice Maker

    Section F - Ice Maker REAR MOUNTED ICE MAKER FOR COUNTER DEPTH MODEL REFRIGERATORS The automatic Ice Maker is mounted in the freezer compartment. It is attached to a bracket extending up from the back of the Auger motor cover. The Ice Maker is designed to produce ice automatically.

  • Page 91: Mold Heater

    Section F - Ice Maker Mold Heater A Mold Heater, rated at 120 watts at 110volts, 110 ohms ± 10% or 120 watt at 230 volts, 340 ohms ± 10%, and covered with an aluminum sheath, is embedded in the grooved section on the underside of the Mold.

  • Page 92: Sensing Arm & Linkage

    Section F - Ice Maker mechanical failure. A thermal mastic bond is provided where the Thermostat is mounted against the Mold. A gasket prevents water from leaking into the support housing. Sensing Arm & Linkage The Sensing Arm is cam-driven and operates a switch that controls the quantity of ice produced.

  • Page 93: Timing Cam & Coupler

    Section F - Ice Maker Timing Cam & Coupler Three separate cams are combined in one molded Delrin part: Inner Cam operates Shut-Off Switch lever arm. Center Cam operates Hold Switch. Outer Cam operates Water Fill Switch. One Cam end is attached to a large Timing Gear. The other Cam end is coupled to the Ejector.

  • Page 94: Installing Water Supply Line To Ice Maker

    Section F - Ice Maker Installing Water Supply Line To Ice Maker Supply line installation must comply with all applicable plumbing codes. Refer to the Ice Maker Installation Instructions in appendix A. The ¼” tubing, and any other plumbing materials required, should be obtained locally.

  • Page 95: Parts Replacement

    Section F - Ice Maker The correct water fill volume is 78-83 cc. To measure the fill volume, test-cycle the Ice Maker and collect the water. Measure in a container calibrated in cubic centimeters (cc) the fill time is 5.4 seconds. The fill volume is adjusted by increasing or decreasing the length of time the Water Fill Switch remains closed.

  • Page 96: To Replace Ice Stripper

    Section F - Ice Maker To Replace Ice Stripper Remove Ice Maker from Freezer. Remove Ice Maker from refrigerator. Push out on retention tab of mold. Pull back on Ice Stripper to disengage it from front of Mold Support housing. Replace in reverse order.

  • Page 97: To Replace Water Fill Switch

    Section F - Ice Maker To Replace Water Fill Switch Remove Ice Maker from Freezer. Remove front Cover. Remove three screws that attach Mounting Plate to Support Housing. Disconnect two Water Fill Switch wire leads. Remove two switch mounting screws. Remove switch.

  • Page 98: To Replace Ice Maker Control Arm Shut-Off Switch

    Section F - Ice Maker To Replace Ice Maker Control Arm Shut-OFF Switch Remove Ice Maker from Freezer. Remove front Cover. Remove three screws that attach Mounting Plate to Support Housing. Disconnect three Ice Maker Control Arm Shut-Off Switch wire leads. Raise Ice Maker Control Arm Lever.

  • Page 99: To Replace Mold Heater

    Section F - Ice Maker To Replace Mold Heater Remove Ice Maker from Freezer. Remove front Cover. Remove Ice Stripper. (Refer to Section “To Replace Ice Stripper” on page 89) Remove three screws that attach Mounting Plate to Support Housing. Remove three screws that attach Mold to Support Housing.

  • Page 100: Fault Diagnosis

    Section F - Ice Maker FAULT DIAGNOSIS Complaint - Ice Maker Fails to Start Check to see if Ice Maker Control Arm is locked in raised position. Check terminals from Cabinet wiring to Ice Maker for open circuit in wiring or components.

  • Page 101: Complaint-Ice Maker Continues To Eject When Container Is Full

    Section F - Ice Maker Complaint-Ice Maker Continues to Eject When Container is Full. Check for loose linkage to the Ice Maker Control arm Shut-Off Switch. Switch should open when arm is in raised position. Adjust, if required. Check Shut-Off Switch terminals “C” and “NO” for continuity with Ice Maker Control Arm raised.

  • Page 102: Operating Cycle Illustrations - Manual Cycle

    Section F - Ice Maker Operating Cycle Illustrations - Manual Cycle To manually cycle Ice Maker, push ON/OFF switch to the ON position and hold down until the sweep arm advances to the 2 o’clock position. Then let go of switch. Let the Icemaker advance on it’s own through a cycle.
  • Page 103 Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature below 15° F · Thermostat closes. · Motor starting. · Heater starting to heat. · Control Arm in the down position. · ON/OFF switch in the ON position. ·...
  • Page 104 Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature below 15° F · Motor rotating · Power on heater. · Thermostat closed. · Control Arm swinging up. · ON/OFF switch in the ON position. · Shut-Off Switch closed C to NC. ·...
  • Page 105 Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature below 15° F · Ice breaks loose and motor starts to rotate again · Power on heater. · Thermostat closed. · Control Arm is down. · ON/OFF switch in the ON position. ·...
  • Page 106 Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature below 15° F · Power on heater. · Thermostat closed. · Control Arm is swinging up · ON/OFF switch in the ON position. · Shut-Off Switch closed C to NO. ·...
  • Page 107 Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature above15° F · Motor is rotating. · Mold heater is off. · Thermostat opens. · Control Arm is swinging up · ON/OFF switch in the ON position. ·...
  • Page 108 Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature above15° F · Motor is rotating. · Mold heater in series with Water Valve. · Thermostat open. · Control Arm is swinging down. · ON/OFF switch in the ON position. ·...

  • Page 109: Operating Cycle Illustrations - Mechanical

    Section F - Ice Maker · Ice Maker connected to electricity. · Mold temperature above15° F · Motor not rotating. · Mold heater off. · Thermostat open. · Control Arm in down position. · ON/OFF switch in the ON position. ·...
  • Page 110 Section F - Ice Maker Ejector Ejector Water Water Water Water Ice Storage Bin Ice Storage Bin Ice Storage Bin Ice Storage Bin Harvest Cycle Harvest Cycle 1. Holding Switch in normally open 1. Ejector reaches ice. position. 2. Motor stalls until ice loosens. 2.
  • Page 111 Section F - Ice Maker Step 7 Step 8 Ejector Ejector Ice Storage Bin Ice Storage Bin Ice Storage Bin End of Harvest Cycle Harvest Cycle 1. During end of 2nd revolution, 1. Hold Switch closes. Mold Heater resets Thermostat. 2.
  • Page 112 Section F - Ice Maker...

  • Page 114: Section G - Ice & Water Dispenser

    Section G - Ice & Water Dispenser ICE DISPENSER CONTAINER & RAIL ASSEMBLY The Ice Dispenser Container slides into the Rail Assembly mounted directly below the Ice Maker. Ice is ejected from the container by an Ice Auger connected to the Solenoid Assembly, and dispensed at the bottom front of the container where it enters through a Gate on the Crusher Housing.

  • Page 115: To Test Auger Motor

    Section G - Ice & Water Dispenser Remove four (4) motor mounting screws and pull Auger Motor free from Motor Cover. 9. Replace assembly in reverse order. To Test Auger Motor: 1. Read ohms value of motor windings using Multimeter on resistence scale. (Put test leads on terminals where purple and white wires were disconnected from Step 6 of procedure “To Remove Auger Motor”).

  • Page 116: To Remove Lamp Socket And Light Bulb

    Section G - Ice & Water Dispenser To Remove Lamp Socket and Light Bulb: Tabs 1. Disconnect refrigerator from electrical supply. Light Socket 2. Remove Ice Cream Shelf and slide Ice Container forward and off Rail Assembly. Light Bulb 3. Loosen 2 screws holding Ice Maker to rail Motor Cover assembly.

  • Page 117: To Replace Crusher Blades

    Section G - Ice & Water Dispenser To replace Crusher Blades: Crusher Crusher Blade #1 Blade #2 1. Remove Auger Nut to gain access to Crusher Spacers Crusher Blades. Each blade is separated by Spacer. Blade #3 Spacers Crusher Housing (See Figure G6.) Fixed Blade Auger Nut...

  • Page 118: Icon Model Dispenser

    Section G - Ice & Water Dispenser Icon Model Dispenser: (See Figure 3) Cube, Press to get cubed ice. Crush, Press to get crushed ice. Light, Press to turn on light in dispenser. Filter Status, Press and Hold five seconds to reset light. 1 2 3 4 5 6 7 (This light will tell you when to replace the water filter.)
  • Page 119 Section G - Ice & Water Dispenser With the drip tray removed, remove the 3 screws at the bottom of the front panel, two screws on Icon models. (See Figure 8.) Icon Lift up on the front panel, there are tabs on the top of Models the panel that slide into holes in the door panel.
  • Page 120 Section G - Ice & Water Dispenser On models with electrical mechanical selector on the front Model with electrical panel, when you remove the front you can gain access to the mechanical control secector switch (See Figure 12) The switch is of the push button type (See Figure 13) It will have a red indicator on a slide that will slide up and down to indicate the switch position.
  • Page 121 Section G - Ice & Water Dispenser With the board removed, remove the 3 screws from the dispenser housing and pull the dispenser forward. Remove (See Figure 17) screws Remove water line from dispenser housing by pulling straight out. (See Figure 18) Pull housing With the water line removed, the upper part of the forward...
  • Page 122 Section G - Ice & Water Dispenser Use a small punch to Gear driver used to connect remove shaft. door closer to arm on door. Ice Door Closer Figure 22 Figure 23 Figure 21 Tension is held against both the water and ice actuator by a stainless steel, two bladed spring mounted behind the actuator switches.

  • Page 123: Fast Freeze - Fast Ice

    Section G - Ice & Water Dispenser The original heater for the ice chute and housing are Check across the two black wires foamed in place with the one piece door. It is connected to to test the internal chute heater. the door wiring (See Figure 27) harness by a plug coming out of the inner door panel with 2 black wires connected to it.
  • Page 124 Section G - Ice & Water Dispenser The connector on the left side of the board is for the door Wires connecting wiring harness to plug into. (See Figure 30) This wiring harness ice & water switches connects with the Main Harness through the top freezer door Connector hinge.

  • Page 125: How To Test The Electronic Dispenser

    Section G - Ice & Water Dispenser The control board is mounted on the front face and can be serviced by removing the front face and removing the 4 screws holding the cover over the board on standard models. On Icon model remove the two screws going form the front face into the bottom of the retainer.
  • Page 126 Section G - Ice & Water Dispenser To test the input voltage from the door harness to the dispenser and the output voltage to the Auger Motor, Solenoid, Water valve and Extra Ice feature if equipped use the connector on the left side of the Power Board shown in figure 39. To Test; Check voltage between 120 VAC and Auger NEUTRAL for input voltage to the dispenser.
  • Page 127 Section G - Ice & Water Dispenser N OTE Dispenser control board must be set for CUBE to operate the cube ice solenoid light relay. Should read 0 voltage until the light switch button is pressed or an actuator is pushed in, then reading should be 5 VDC + or - 10%.
  • Page 128 Section G - Ice & Water Dispenser There are lighted paddles in the dispenser on all counter depth models (See Figure 41). The lights operate off the dispenser power board. (See Figure 42.) If the lights (There are two lights on each paddle.) fail, the paddle needs to be replaced.
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  • Page 130: Section H - Water Systems

    Section H - Water System WATER SYSTEMS Water for the ice maker and water dispenser is controlled by a dual coil valve and a single coil valve joined together as one. It’s mounted just to the right of the condenser on the cabinet. Plastic tubing connects the water valve to the ice maker fill tube, the ice &...

  • Page 131: Puresource Water Filters

    Section H - Water System PureSource Water Filters Counter Depth models can have either a Front Filter (see Figure H2) or a Rear Filter (see figure H3). The rear water filter must be changed at a minimum of twice a year. But, under certain water conditions such as large concentrations of calcium, alkali, or other particulate matter in the water, a filter may require changing more frequently.

  • Page 132: Front Filter System

    Section H - Water System Front Filter System Figure H5 Rear Filter System Figure H6...

  • Page 133: To Test The Water Fill System

    Section H - Water System Diode Replacement Kit 5303918287 For Ice & Water Model Side by Sides With A Water Filter YELLOW TAN WITH YELLOW TRACER Figure H8 Terminals on Terminals in Terminal on Coil is Installed Terminals and Plug Figure H9 To Test The Water Fill System The wiring harness has two diodes in the line between the fill switch on the ice...

  • Page 134: Resistance Check

    Section H - Water System Resistance Check To test the diodes you can use a ohm meter with at least a 10K ohm or higher scale. Take a reading across the diode, reverse your leads and take another reading, the diode should check 10 times higher in one direction than the other. Voltage Check for Water to Icemaker You can also use a volt meter to check the circuit.

  • Page 135: No Water At Door

    Section H - Water System No Water at Door If the ice maker is operating but you can not get water out the door the test and operation of the diode is the same as for the ice maker except for the voltage readings.
  • Page 136 Section H - Water System at the top of the freezer door down to the dispenser and back up through the same plugs to the diode harness. A bad connection at any of the plugs or wire terminals can stop the valves from operating. One of the problems we have found is at the connector on the water valve coils is pushed on with the valve terminal over top the terminal in the plug.
  • Page 137 Section H - Water System Water/Ice Selector Switch on Dispenser Dispenser Fill Solenoid Actuator Single Coil Valve Switch Water Fill Solenoid Dual Coil Valve Water Yellow Diodes Green Ice Maker Fill Switch Ice Maker Fill Solenoid Dual Coil Valve VOLTAGE READINGS AT GREEN COIL OF SECONDARY VALVE When Ice Maker is Filling: Voltage at Outlet Voltage at Coil...

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