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SERVICE MANUAL REFRIGERATOR - Genuine McCulloch Spares

1. 2 11 AUTO DAMPER CONTROL Exploded VIEW season 2 12 DEFROST TIMER wr P 2 13 Checking the PS een 2 14 MR 2 14 ADAPTIVE DEFROST CONTROL za 2 14 Checking the Adaptive Defrost o ee 2 15 AIR FLOW FORCED AIR SYSTEMS 2 15 DEFROST HEATER REPLACEMENT zu neuere 2 17 DEFROST THERMOSTAT REPLACEMENT ne 2 17 CONDENSER FAN MOTOR ee 2 18 To Check Condenser Motor Direct une 2 18 Condenser Fan Motor 2 19 FREEZER FAN cm en 2 19 Freezer Fan Motor BIadnosis iu ea 2 19 Freezer Far Motor Replacement een 2 20 SECTION 3 CABINET amp RELATED COMPONENTS 3 1 ADJ USTABLE CANTILEVER SHELVES u a 3 1 ADJ USTABLE CANTILEVER SHELF TRIMS essen 3 1 CABINET DOORS AND ASSOCIATED PARTS ss 3 1 Inner Door aie ceci ee 3 1 Outer Door Panel Replacement u ee ka in 3 2 FRONT WHEEL ASSEMBLY ee 3 2 CABINET LEVELING esse ee ee 3 2 DOOR ee ee 3 3 TOE IN amp TOE OUT ADJ USTMENTS asija gs 3 3 HINGE AD USTMEN LS aan 3 3 DOOR ALSGNMENT nu une s 3 4
2. T ALVA i e r is i i m ai js RB WH RD 1 ON CERTAIN PR ONLY LIGHT ups LRD 1 YH80 INTERLOCK SWITCH TEMPERATURE CRISPER LIGHT CONTROL BLU DEFROST OR vn OVERLOAD COMPRESSOR y c og RELAY ON CERTAIN MODELS ONLY 7 7 SCHEMATIC RWD F 7 DISCONNECT THE UNIT FROM THE POWER SOURCE PICTORIAL WIRING DIAGRAM ALLOW 10 PERCENT TOLERANCE ON ALL RESISTANCES T zI on lt E ICE MAKER lt gt RECEPTACLES LE CONTROL RE ADAPTIVE WHIBLK FOUNTAIN WH CUBE INTERLOCK HEATER i mo gpa BR DOOR 7 SOLENOID REF LIGHT WHITE T1 INTERLOCK BLUE SWITCH SWITCH BOARD O O O O O WH eem mt il rn VEI MINER REP SERES FOUNTAIN ACTIVATOR LIGHT SWITCH WH RD CORD BROWN CRISPER LIGHT gt gt ORANGE GRN YEL GRAY A M Ir N A WHITE BLK CERTAIN MODELS ONLY DEFROST HEATER D BLI RD WH a BLU 7 lt gt TH NI N OR N WH RU 5 gt N ram _ gt RUN e em 79 CAPACITOR d Ne COMPRESSOR CERTAIN MODELS WH BLU bu 212 ONLY TNNG 2 a M N 65 1 maker AVE gt VALVE N N condenser fan motor grasp the connector with your thumb inserted between the connector and the lock
3. Air flow problem Check and remove what is Run time normal Refrigerator causing the restriction compartment is not cold See Air Flow Diagram enough but freezer compart ment is normal or possibly colder than normal Sweating Interior sweating See below but refrigerator and freezer are working normally Bad door seals Replace Excessive door openings Advise customer during hot humid weather Storage of excessive un Advise customer covered liquids especially if they are inserted into refrigerator while warm DISCONNECT THE UNIT FROM THE POWER SOURCE Excessive dehydration of food Excessively noisy but operates normally otherwise Void in insulation Overcharged Bad door seals Condenser fan not running Condition requires covering of food Sublimation of ice cubes is normal in no frost freezers but should not be a problem in these units equipped with covered ice storage bins Refrigerator not level or firmly setting on all four corners Structural weakness in floor Compressor mounting defective Poor tubing dress Compressor operation is noisy due to inherent conditions Unit base mounting loose Freezer or condenser fan is noisy May have defective motor Containers inside refrigerator rattle Check and add insulation if possible Evacuate system and recharge with proper amount of refrigerant Replace Check fan motor
4. MAKER RECEPTACLES v KSC TEMPERATURE N V gt CONTROL SY REF LIGHT EAN TI ONLY w NT O gt DEFROST FOUNTAIN are HEATER i R B lt Lp NN SOLENOID REFRIG WHITE 1 LIGHT SW BLUE SWITCH BOARD CONTROL BOARD FOUNTAIN ACTIVATOR LIGHT SWITCH WH CRISPER LIGHT x CERTAIN MODELS DEFROST HEATER TAN 2 FB VIOLET LAOR RUN X RED BLACK RD BLK N _ CAPACITOR RED WHITE RD WH BLU 7 C 5 Nee CERTAIN MODELS NN N Zee T2 N N TI N 7 U Saf COMPRESSOR M gt C U VA WATER a N DISPENSER 7 VALVE N ICE MAKER N N NL condenser fan motor grasp the connector with your thumb inserted between the connector and the locking lever as shown and pull the connector SCHEMATIC WIRING DIAGRAM TO LINE 1 CORD FOUNTAIN HEATER r INTERLOCK SWITCH SOLENOID vcore lt sw rch ON CERTAIN MODELS ONLY M GE SEE CRISPER LIGHT Rp LIGHT SWITCH FREEZER LIGHT TEMPERATURE CONTROL ON CERTAIN MODELS ONLY DEFROST HEATER MY DEFROST THERMOSTAT FOR DIAGNOSTIC CONTINUITY DEFROST CHECK 240K OHMS TIMER OR PTC OVERLOAD CAPACITOR RELAY ON CERTAIN MODELS ONLY 7 5 SCHEMATIC RWD5 DISCONNECT THE UNIT FROM THE POWER SOURCE 5
5. BLY K Beene pe 28 WM V CAPACITOR S N T CERTAIN MODELS ONLY N TU I 2 1 bo 7 V COMPRESSOR S B 2 L M IG X gt IN A x wm WATER we VALVE N ICE MAKER PICTORIAL WIRING DIAGRAM ALLOW 10 PERCENT TOLERANCE ON ALL RESISTANCES ICE MAKER RD GY P LIGHT FOUNTAIN _ INTERLOCK SWITCH BR DOOR SOLENOID REFRIG APORATOR LIGHT Ke SWITCH BOARD LL cc DEFROST d FOUNTAIN ACTIVATOR LIGHT SWITCH CERTAIN MODELS WI CRISPER LIGHT ONLY gt gt DEFROST HEATER ln nn NDISPENSER _ VALVE N x To remove the lead connector from the condenser fan motor grasp the connector with your thumb inserted between the connector and the locking lever as shown and pull the connector SCHEMATIC WIRING DIAGRAM TO LINE 1 CORD FOUNTAIN HEATE INTERLOCK SWITCH BR SOLENOID 9559 ef BR SWITCH RED BLK BOARD VIOLET BLACK BLACK ON CERTAIN MODELS ONLY Ech C CRISPER LIGHT WH FREEZER LIGHT ON CERTAIN MODELS ONLY ADAPTIVE DEFROST FOR DIAGNOSTIC CONTINUITY CHECK 240K OHMS OVERLOAD COMPRESSOR gt CAPACITOR RELAY ON CERTAIN MODELS ONLY 7 6 RWD F 6 SCHEMATIC DISCON
6. F 110 F U24 Hours Running Watts 145 165 6 1 23 25 Dispenser 23 Non Dispenser Power Requirement 115 VAC 60 HZ Temp Control Operating Amps Cut Out 2 Max Cut In 2 F Normal Setting 37 F 9 F Refrigerant Charge R134A oz Condenser Fan Cooled Compressor Oil Capillary Tube Charge oz Length Compressor Diameter BTU hr 1007 Matsushita Defrost thermostat Cabinet Liner High Impact Cut Out 3 F Laminated Polystyrene Cut In 11 F Door Liners High Impact Defrost Timer Laminated Polystyrene Defrost Cycle Cabinet amp Divider Defrost Time Insulation Foam Defrost Heater Ohms Fountain Heater Ohms 4810 Watts 103 inches 0 028inches 1 0 PERFORMANCE TEST DATA The laboratory test data in this chart was obtained under the following conditions 1 power source of 115V AC 60 Hz 2 no door openings 3 no load 4 customer control s set at mid point The pressures and wattages shown were taken a during a normal running cycle b with freezer temperature near 0 F refrigerator temperature if applicable near 37 F c no sooner than 5 minutes after compressor start up In the home measurements will vary depending upon environmental and usage conditions mm Ambient Ambient Suction Pressure psig High Side Pressure psig 110 F Ambient 3 30 4 20 1 5 190 210 155 185 6 2 21 Non Dispenser Maytag Power Requireme
7. and the pumping action of the compressor form a low pressure area The temperature of the refriger ant drops rapidly as it changes to a mix ture of liquid and vapor In the process of passing through the evaporator the refrigerant absorbs heat from the stor age area and is gradually changed from a liquid and vapor mixture saturated refrigerant into a vapor The suction line returns this low pres sure vapor from the evaporator back to the compressor and the cycle starts again Part of the capillary tube is soldered to the suction line which forms a heat exchanger Heat from the capillary tube is thus transferred to the suction line to superheat the refrigerant there and at the same time this further cools the liquid in the capillary tube This cools the re frigerant before it enters the evaporator and also heats the refrigerant before it enters the compressor to ensure a va por state REFRIGERATION SYSTEM GAS HIGH PRESSURE LIQUID HIGH PRESSURE CONDENSER GAS LIQUID LOW PRESSURE GAS LOW PRESSURE 1 9 DIAGNOSIS Sealed system diagnosis of R134A refriger ant systems is to be performed identically to that of R12 systems In fact as shown in the following flow chart the service proce dures are virtually the same except for low side leaks plugged capillary tube or com pressor failure which results in a system flush REFRIGERATOR DIAGNOSIS SEALED SY
8. 1 10 LEAK TESTING se 1 02 N S S 1 13 as 1 13 1 13 Yoder E s mr ee BB re 1 14 este 1 15 Heat EXCHANGED TOO 1 15 1 15 Hess esi sos I AS Id ind 1 15 SEALED SYSTEM REPAIR SUMMARY s gas 1 16 SYSTEM FLUSH PROCEDURE 2 22 nenne 1 16 SWEEP AND FINAL CHARGE 2 seen 1 19 SECTION 2 COMPONENTS u 2 1 COMPRESSOR REPLACEMENT sec ae eh 2 1 REPLACING THE COMPRESSOR sa ee eee ceases 2 1 CONDENSER REPLACEMENT as 2 2 ELECTRICAL SYSTEM zu ee ee ee 2 4 Testing the Compressor Direct ss nee aka 2 4 ee ee m ee ee 2 5 Testing the Overload Protector us an 2 5 STARTING DEVICE AND RUN CAPACITOR 2er 2 6 PTC Device nennen een 2 7 RUN CAPACITOR ee nen ee 2 7 Testing the Capacitor 2 7 Alternate Method Using OBlfiM l fs 2 7 TEMPERATURE CONTROL u 2 8 Checking Operating Temperatures 2 8 Temperature Control Replacement 2 9 599 513 874 EN iv AUTO DAMPER CON TROL MODE IS zu ee 2 10 2 11 Auto Damper Control
9. 3 ounces of refrigerant R134a is added to the system circulated by the compressor for 5 minutes and recovered Since a new drier part Step 1 Set up of valves 13900 1 has already been installed a high side process tube is available Install a tem porary access valve to this process tube close enough to the end of the tube so that the tube can be pinched closed behind the valve and the opening sealed shut after the valve is removed Remember no access valve is to be left on the sealed system nect a 1 4 inch flare tee to the access valve Connect a quick coupler hand valve to each side of the tee To one hand valve connect the hose from the charging cylinder To the other valve connect the hose to the recov ery system The following steps take you through the sweep and final charge temporary access valve C piercing drier process tube connected to flare tee hand valve A to charging cylinder hand valve B to recovery system ACCESS VALVE TO CHARGING CYLINDER TO RECOVERY SYSTEM Step 2 With liquid refrigerant present to valve A valve B closed and valve C open C will remain open throughout sweep procedure open valve A to allow three 3 ounces of refrigerant into the system Close valve A Check low side for leaks After system has equalized about 3 to 5 minutes start system compressor check for high side leaks and allow refrigerant to circulate in the system about 5 minute
10. Higher than normal Low Side Higher than normal Wattage Higher than normal Diagnosis Overcharged system The extent of the pressure increase depends on the amount of overcharge and ambient tem perature An overcharge may also cause the suction line to be frosted during the run cycle resulting in water on the floor after cycling off Symptoms High Side Lower than normal Low Side Higher than normal Wattage Lower than normal Diagnosis nefficient compressor Cool ing surfaces may be covered with a thin film of frost but the temperature will not de scend to cut off temperature of the control even with continuous running Also the condenser will be noticeably cooler to the touch than normal Once the confirmation that an inefficient compressor is made the compressor should be replaced Symptoms High Side Normal Low Side Normal to slightly higher than normal suction line possibly sweats Wattage Normal Diagnosis Separated capillary tube The capillary tube must be connected to the suc tion line to provide proper heat transfer Without this transfer liquid refrigerant in the capillary tube enters the evaporator at a slightly higher temperature thereby lessen ing the ability to remove heat from inside the refrigerator The customer complaint would be long run time slow ice produc tion warmer fresh food temperature in general poor overall performance Another symptom of a separated capillary
11. a low side leak moisture has probably been drawn into the system The compressor must be replaced in addition to the normal repair Also a system flush must be made before proceeding with the sweep charge and final charge PLUGGED CAPILLARY TUBE Moisture or other contaminants in the R134A system can cause the formation of gel like or salt type deposits within the system This causes capillary tube restrictions which may not be removed by the flush procedure detailed later If the restriction cannot be removed from the capillary tube the heat exchanger evaporator and compressor must be replaced 1 5 SYSTEM FLUSH Flushing of the system is required whenever there has been a low side leak plugged capillary tube or com pressor replacement This is a procedure in which R134A refrigerant is flushed through the system and into the recovery system to remove moisture and non condensables which may have entered the open system The compressor must be isolated during the flush procedure in or der to prevent contaminants from being ab sorbed into the ester oil resulting in a con taminated system The system flush procedure will be done in two parts First the condenser including the yoder loop will be isolated by means of process tube adapters and flushed with 4 ounces of R134A After the drier has been replaced the entire sealed system minus the compressor will also be flushed with 4 ounces of the refrigerant This seco
12. and replace part if needed Advise customer Advise customer Level the unit lower the level leveling legs if necessary to make sure that unit is firmly on the floor Advise customer Check and replace if necessary Adjust tubes so they do not touch Advise customer Tighten loose part or parts Adjust pan or install foam pad if necessary Replace Advise customer SECTION 6 SPECIFICATIONS 21 Dispenser Non Dispenser Power Requirement 115 VAC 60 HZ Temp Control Normal Setting Operating Amps Cut Out 2 F 34 F Refrigerant Charge Compressor Oil Capillary Tube Charge oz Length 103 inches Compressor Diameter 0 028 inches 1 0 Laminated Polystyrene Cut In 11 F Laminated Polystyrene Defrost Cycle Cabinet amp Divider Defrost Time Insulation Foam Defrost Heater Ohms Founatin Heater Watts Ohms Defrost Amps Max 4 3 Watts PERFORMANCE TEST DATA The laboratory test data in this chart was obtained under the following conditions 1 power source of 115V 60 Hz 2 no door openings 3 no load 4 customer control s set at mid point The pressures and wattages shown were taken a during a normal running cycle b with freezer temperature near 0 F refrigerator temperature if applicable near 37 c no sooner than 5 minutes after compressor start up In the home measurements will vary depending upon environmental and usage conditions 70 F 90
13. contacts open the circuit to the defrost heater An ohmmeter check will determine if all phases of the defrost cycle are functioning properly The defrost thermostat contacts open at approximately 43 F and close at approximately 15 F The defrost thermostat has a 240K ohm re sistor connected internally across the two terminals This resistor permits checking the detrost heater when the evaporator tem perature is 15 F or higher An ohmmeter can be used to test the de frost heater and thermostat without disas sembling the freezer compartment even if the evaporator temperature is 15 F or higher To check proceed as follows 1 Disconnect the unit from the power source 2 Open the fresh food door and remove any items on the top shelf Remove the light shield and the fascia radiant shield mounting screws in the temperature control housing While holding the front of the housing remove the rear mounting screw Lower the control housing 3 Disconnect the timer wire harness con nector from the defrost timer 4 Set the ohmmeter to R x 1K scale and connect the probes to the No 2 and No 3 terminals of the disconnect plug 5 The meter should read between 20 to 40 ohms The resistance is not critical If there is continuity between terminals No 2 and 3 the defrost heater is in op erative condition If there are no resis tance readings open circuit the defrost heater and thermostat must be checked indi
14. filter valve and the fountain valve are both ener gized simutaneously to provide fil tered water to founatin During the fill cycle of the icemaker the filter valve and icemaker valve are both energized simuatneously to provide filtered wa ter to the Icemaker The filter head assembly is mounted to the back of the fresh food liner us ing two mounting screws Plastic tub ing passes thought an opening in the back of the cabinet The ends of the tubing connect to the inlet and outlet fittings on the filter head Replacing the Filter Cartridge The water filter mounts in the upper fresh food compartment on the un derside of the control housing It is recommended that the filter cartridge be replaced every 6 months or sooner if the water flow to the dispenser or icemaker decidedly decreases or if an objectionable taste or odor occurs 1 Place a cloth or paper towel on the shelf below the filter to catch any drops of water that may fall when replacing the filter 2 Twist the filter cartridge 1 4 turn coun terclockwise so the ears on the car tridge are able to disengage from the filter head 3 Carefully remove the replacement filter from its packaging 4 Apply the sticker to the cartridge to remind you to replace the filter within 6 months 5 Reinstall the new cartridge in reverse order of removal 6 Dispense 8 to10 glasses of water through the dispenser to purge any air from the system 7 Carefully check
15. if the bimetal 2 thermostat is open or closed L1 side of line Short with an insulated piece of wire 14 gauge to run the motor If the NOTE ead this section completely be motor doesn t run replace the module fore doing any testing or adjusting Refer assembly If the motor runs replace the to the tech sheet for complete testing in bimetal thermostat formation f you leave the jumper in for half of a The test holes are identified as N M and revolution you can feel the heater in the V etc mold heat up if it is good Remove the jumper and the water valve will be energized in the last half of the revolution Make sure the freezer tem perature is cold enough to close the bi metal NOTE not short any contacts other than those specified Damage to the ice maker can result Ice Maker Unplugged Test points L amp H will check the resistance of the heater 72 ohms Replace the mold and heater assembly if not near this value 10 ohms Ejector blades should be at the end of the cycle position SERVICE PROCEDURES Cover Pull water adjustment knob first and snap off cover Index knob and reinstall in same position for same water fill Some units may not have index knobs Shut off arm Screw adjustment Mold attachment Screw access ports Module Motor and Support Assembly Insert Phillips screwdriver in access ports of modu
16. in reverse order of removal 3 7 Fountain Heater A fountain heater is used on all dispenser models The fountain heater is used to evaporate any moisture that might accumulate from condensation It is bonded to self adhesive aluminum foil which is shaped to fit the out side of the fountain housing 1 Disconnect the unit from the power source 2 Remove the ice and water fountain bracket assembly as discussed earlier 3 Disconnect the electrical quick disconnect 4 Check for resistance between the red wire with the black tracer and the white wire on the fountain housing quick dis connect electrical connector 5 Ifthe fountain heater reads open go to step 5 6 Remove the door from the unit and dis assemble liner and the gasket 7 Carefully remove the foam seals and disconnect the heater wire terminals 8 Pull the foil heater backing from the fountain 9 Reassemble the parts in reverse order of removal PC BOARD CHECKS PIN 1 WHITE WIRE TO GROUND PIN 2 WHITE WIRE TO DOOR SOLENOID PIN 3 RED WIRE TO LOCK OUT SWITCH IPIN 4 PINK WIRE TO AUGER MOTOR PIN 5 BLACK WIRE TO WATER DISPENSER VALVE PIN 6 BLACK WIRE TO SELECTOR SWITCH PIN 7 BROWN WIRE TO DOOR SOLENOID The following checks should only be made by a Qualified Service Technician 1 Disconnect unit from the power source 2 For easy access of the PC board per form steps 1 through
17. in the fresh food compartment Defrost Timer The timer control shaft is designed for screwdriver advancement When manually setting the timer to initiate defrosting turn the control shaft clockwise until you estab lish the approximate location of the defrost cycle Then turn the shaft slowly and stop immediately when the first click is heard The schematic illustrates the timer circuits in sequence To advance defrost timer turn clockwise Defrost timer mounting screws LINE BLUE DEFROST HEATER _ C Ty DEFROST THERMOSTAT O COMPRESSOR ORN FIRST CLICK DEFROST OPERATION LINE BLUE DEFROST HEATER DEFROST THERMOSTAT SECOND CLICK NORMAL OPERATION 1st Click The timer turns off the compres sor and freezer fan circuit for approximately 23 minutes and it energizes the defrost heater Once the temperature of the defrost termination thermostat reaches the cut out point the termination thermostat will open the circuit to the radiant heater However the compressor circuit remains open for the duration of the defrost interval 2nd Click The timer switches off the de frost circuit and starts the compressor freezer fan and the condenser fan motor The compressor and fan motors are now governed by the temperature control for a period of approximately 8 hours of the com pressor run time after which a new defrost cycle begins 3 Checking the Defrost Timer Disconnect
18. is 70 degrees cylin der pressure should be 100 p s i g Start the recovery system and open the valve at the process adapter attached to yoder loop Open the valve from the charging cylinder and allow 4 ounces of R134A to flow through the condenser and into the recovery sys tem This process should take about two minutes Keep the process adapters and hoses attached at this time TE VIE COMOENSEF n Pis TI EPISC TA RECEAT ES FIGURE 1 Flush into discharge line through hi side and out the yoder loop at drier inlet 2 Replace the Drier Score and break either one of the two inlet lines on the new drier the other line will remain sealed until the sweep charge at which time it will be the process tube Pre pare the drier outlet side for connection to the capillary tube The capillary tube should be inserted about 3 4 inch into the drier to prevent solder alloy from plugging the cap illary tube or the capillary tube extending too far into the drier and contacting the screen To facilitate the installation place a slight bend in the capillary tube about 3 4 inch from the end and insert into the drier Remove the process tube adapter from the yoder outlet and prepare the tube for con nection to the drier inlet The drier inlet joint will be the only copper to steel connection which will require the silver solder and flux To help prevent flux from entering
19. legs or rollers REMOVING amp REPLACING FILL CUP To remove fill cup you must separate mold The appropriate break out plug needs to be and blade from module housing Remove removed from the fill cup for your model blade from fill cup Check old ice maker Pull cup up and out of slot requires considerable force INFORMATION Motor connectors can be damaged if leads are removed The motor is available only as part of the complete module assembly One revolution of the blade takes three minutes plus stall time on ice Bench test cord can be made from cabi net socket Tan and white wires on socket plug are water valve leads SPECIFICATIONS Mold Heater Thermostat Bimetal Water Fill Module Close 17 3 Open 32 3 140cc 7 5 seconds 1 5 watts 8 450 ohms Stamped circuit Plug in connectors One revolution ejects and water fill 4 8 SECTION 5 TROUBLESHOOTING DISCONNECT THE UNIT FROM THE POWER SOURCE CONDITION Unit does not run No light in refrigerator No power at AC distribution panel of house AC outlet Defective outlet Open circuit to AC outlet Defective service cord plug Open service cord or open machine compartment wiring harness Two simultaneous prob lems light bulb out and open AC circuit to compressor Unit does not run light in refrigerator works Temperature control Defective
20. low side pressure a temporary access valve can be installed on the compressor process tube To remove the valve after repair a pinch off tool may be used to seal the tube while the valve is removed and the hole brazed shut To check high side pressure a temporary access valve should be installed on the dis charge line When the high side valve is in 1 10 stalled the technician is committed to re placement of the drier and a sealed system repair Once again this valve must be re moved upon completion of repair sure the gauges which are used to check the operating pressures are accurately cali brated When not connected to a system the gauge pointer should indicate zero pres sure If necessary turn the calibrating screw until the pointer is at 0 NOTE 7he following situations are typi cal however other factors such as gauge placement line voltage and ambient tem perature must also be considered The following symptoms use high and low side pressures plus wattage measurements to diagnose sealed system problems Nor mal low side pressure will range from be low zero to about six pounds of pressure depending on several factors such as refrig erator model ambient temperature load and customer usage Normal high side pressure is also dependent on external fac tors but will range in the 100 to 125 p s i g range Wattage and pressure figures will vary based on the model and age of the re frigerator Ref
21. off the shaft Remove the screws that secure the rear bracket to the front bracket Remove the motor from the rear mounting bracket Install the new motor to the rear mount ing bracket Mount the rear bracket to the front mounting bracket Install the slinger disc and fan blade on the replacement in the same position as on the original motor shaft RETAINER SLINGER FAN SHROUD NOTE Make sure the slinger disc does not drag on the fan bushing 7 Install the motor and bracket assembly onto the evaporator cover 8 Connect the wire leads and the ground wire to the motor 9 Reassemble those parts previously re moved and test the unit The fan blade is provided with a stop on the face of the hub It is properly installed when the blade is positioned so the stop rests against the end of the shaft SECTION 3 CABINET amp RELATED COMPONENTS ADJUSTABLE CANTILEVER SHELVES Type 1 Two support hook frame design Glass or wire cantilever shelves may be available with your refrigerator To remove a shelf tilt front up and lift the rear up a frac tion of an inch and pull straight out To lock the shelf into another position tilt the shelf with the front up Insert hooks into desired shelf openings and let the shelf settle into place Check that the shelf is securely locked into position before loading it with food Type 2 Three support hook frame design To remove the shelf grasp the shelf at the fr
22. power of any capaci tor and has an automatic means of discharg ing the capacitor through resistance is pre ferred Alternate Method Using Ohmmeter 1 Disconnect the unit from the power source 2 Disconnect the capacitor lead wires 3 Short across the terminals using a re sistor with a minimum resistance of 1 000 ohms This ensures that no charge remains to damage the ohmme ter 4 Set the ohmmeter selector switch to the 10 000 ohm scale R x 10K 5 Connect the ohmmeter leads to the ca pacitor terminals and observe the meter point lower end a If the pointer deflects to the lower end and remains there the capacit or is shorted and must be replaced b If there is no deflection of the pointer the capacitor is open and must be replaced TEMPERATURE CONTROL c the pointer deflects toward the high end of the scale and then slowly returns to the low end the capacitor is good MID 5 COLDEST 9 ALLOW 24 HOURS BETWEEN ADJUSTMENTS 4 5 6 3 7 2 8 1 OFF 9 The refrigerator has two temperature controls 1 Fresh Food Compartment The fresh food temperature control senses the temperature of its compartment and governs the compressor operation accordingly 2 Freezer Compartment The freezer compartment control adjusts the damper door which regulates the amount of air allowed to enter the fresh food compartment Turning the freezer tempe
23. the cooled air throughout the fresh food and freezer com partment The fan blade is made of poly ethylene and is pushed onto the shaft It is important when replacing the fan blade that the hub of the fan blade faces out toward the back of the evaporator fan cover If the fan fails or operates erratically the reduced air circulation will result in poor cooling char acteristics Loosen the screw Loosen the screw Remove the screw Remove the screw Freezer Fan Motor Diagnosis 1 Disconnect unit from the source power Remove the freezer shelving Loosen the two top screws and remove the two bottom evaporator cover mounting screws Grasp the bottom of the cover Care fully pull the cover forward and down to clear the upper flange Disconnect the evaporator fan motor leads The wire leads are self locking and it is important to squeeze the clip before pulling the leads off the terminals Remove the evaporator fan motor as sembly and place it on a work surface Connect the motor terminals to a ser vice cord and plug the cord into the power source If the motor fails to operate it is defec tive and must be replaced FAN MOTOR EVAPORATOR FAN BLADE Freezer Fan Motor Replacement 1 Follow steps 1 through 5 Freezer Fan Motor Diagnosis Remove the screws that secure the mo tor bracket assembly to the fan shroud Remove the fan blade by pulling it
24. the door liner and transfer the seal to the replacement liner Make sure the lip of the seal will sandwich be tween the inner and outer door panel 4 Position the replacement door liner and loosely install all the screws around the door flange 5 Openandclose the door several times to check the seal for proper alignment 6 Carefully open the door by pulling on the middle of the door panel NOTE Do not pull the door by the handle or the panel will shift out of alignment 7 Tighten all corner screws 8 Openandclose the door several times Recheck the door seal for proper align ment If alignment is correct tighten remaining screws Tighten the screws until they are just snug then turn clockwise another one half turn NOTE Do not attempt to twist the door panel after all the screws have been tightened 9 Transfer the shelves and the trim to the replacement liner Outer Door Panel Replacement NOTE Remove all food from the freezer door 1 Turn the control to the Off position 2 Remove door handle and trim 3 2 3 Use a soft lead pencil to trace around the upper hinge This will aid in replac ing the hinge 4 Remove the upper hinge and place it on top of the unit with newspaper or cloth underneath to prevent scratching Do not misplace the spacers Place the door on a padded work surface 5 Transfer the handle trim plug button bushings gaskets and liner to replace ment panel
25. the sys tem first insert the line from the yoder loop into the drier inlet then apply the flux Braze both the inlet and the outlet joints of the re placement drier m CUNEATE an marma ISTO UME mr 3 FIGURE 2 Flush the entire system less compressor out the suction line 3 Isolate and flush the remainder of the system Score and break the suction line close enough to the old compressor to be able to reconnect it to the replacement com pressor later Attach a process tube adapter to the evaporator side of the suction line Connect the hand valve and hose from the recovery equipment to this adapter figure 2 Be certain that the pressure in the charg ing cylinder is about 30 p s i g above ambi ent temperature Start the recovery unit and open the hand valve to the suction line Release four 4 ounces of R134a from the charging cylinder into the system It will take about 15 minutes for the refrigerant to pass through the condenser yoder loop drier capillary tube evaporator suction line and into the recovery system This 15 minutes time can be utilized to remove the old com pressor figure 3 and prepare the new com pressor by mounting into place and wiring electrically Remember to leave the plugs in place until brazing refer to figure 4 LooF naria INTE ISCARE LIME LIMIEASEA b FIGURE 3 YEOTA LIM
26. 0 Electrolux Electrolux Muggenhofer Stra e 135 D 90429 N rnberg Germany Fax 49 0 911 323 1022 Spares Operation Edition 03 02 SERVICE MANUAL REFRIGERATOR Side by Side Publ Nr 599 513 874 685 EN SAFETY PRECAUTIONS THIS MANUAL IS TO BE USED ONLY BY A MAYTAG AUTHORIZED SERVICE TECHNICIAN FAMILIAR WITH AND KNOWLEDGEABLE OF PROPER SAFETY AND SERVICING PROCE DURES AND POSSESSING HIGH QUALITY TESTING EQUIPMENT ASSOCIATED WITH MICROWAVE GAS AND ELECTRICAL APPLIANCE REPAIR ALL INDIVIDUALS WHO ATTEMPT REPAIRS BY IMPROPER MEANS OR ADJ USTMENTS SUBJ ECT THEMSELVES AND OTHERS TO THE RISK OF SERIOUS OR FATAL INJ URY USE ONLY GENUINE MAYTAG APPROVED FACTORY REPLACEMENT COMPONENTS 599 513 874 EN INTRODUCTION This refrigeration service manual provides the information necessary to service Side by Side model refrigerators NOTE ALL MODELS COVERED IN THIS SERVICE MANUAL USE R134A REFRIGER ANT The manual is printed in loose leaf format Each part of this manual is divided into sec tions relating to a general group of components and each section is subdivided into various parts describing a particular component or service procedure The subdividing of the subject matter plus the loose leaf form will facilitate the updating of the manual as new models and new or revised components of service procedures are introduced Each page of this manual will be identified in the lower right hand corner As new o
27. 5 of Ice and Wa ter Fountain Bracket Removal 3 Make sure everything is clear Apply power to the refrigerator and perform the following checks with a volt ohmmeter IF DOOR FAILS TO OPEN Note 7he following checks will be at terminal board connector 1 Check for 115 volts AC from PIN to PIN 1 Lock out switch must be closed 2 Check for 115 volts AC from PIN 4 to PIN 1 when selector is set to crushed or cubed and actuator is depressed If not there check selector switches actuator switch and associated wiring 3 8 3 During activation check for approxi mately 100 volts AC from PIN 7 to PIN2 If 100 volts AC is not present replace the board If voltage is present check the solenoid and associated wiring IF THE DOOR FAILS TO CLOSE 1 Disconnect the unit from the power source if the door still stays open Check the solenoid door hinge and spring assembly If the door closes go to step 2 2 Plug the unit in check for 0 volts AC from PIN 1 to PIN 4 If you read 115 volts AC check switches and wiring If voltage reads 0 go to step 3 3 Disconnect the unit from the power source and remove the circuit board Check continuity from PIN 7 to PIN 2 If shorted replace the circuit board Fountain Door Delay Normal door delay will be approximately 2 seconds Excessive Door Delay Check for mechnical obstruction if none replace PC board Short Door Delay 1 Checkfor 115 volts AC betw
28. 6 Install the top hinge using the tracing to align the hinge FRONT WHEEL ASSEMBLY The front wheel assembly is securely fas tened by two screws to the face plate of the cabinet Depending on the model you will encoun ter adjustable or non adjustable front wheel assemblies To lock the cabinet in place lower the front leveling legs CABINET LEVELING To enhance its appearance and maintain ef ficient performance the refrigerator should be level The front wheels were adjusted at the factory so the doors were properly aligned and the cabinet level However jar ring in transit or standing the refrigerator on uneven floors may cause the doors to shift out of alignment If front alignment is necessary adjust the wheel with a hex head driver Clockwise raises the cabinet counter clockwise lowers the cabinet If front wheels are not adjustable use level ing legs to level DOOR SEAL The drawing shows a view of the magnetic door seal used on all models mentioned in this manual The magnetic strips are at tracted to the metal cabinet front provid ing an excellent seal around the entire door A visual inspection of the door seal while opening and closing will reveal any areas of poor seal You will notice a slight expan sion and compression of the seal bellows as the door is opened and closed Balloon Magnetic Seal Strips Door Seal And Magnetic Strips TOE IN amp TOE OUT ADJUSTMENTS To seal evenly around th
29. ATER PROBLEMS e asakas den 4 5 TEMPERATURE PROBLEMS nennen 4 5 THERMOSTAT e er c m 4 5 INSTALLATION Re 4 6 HARNES na P 4 6 LEVELING lEEMARER k d s 4 7 REMOVING amp REPLACING FILL CUP nen Rasa 4 7 OTHER INFORMATION anna ern 4 8 SECTION 5 TROUBLESHOOTING una exin ed Ea KoA KEAREN ENEE 5 1 SECTION 6 SPECIFICATIONS ans 6 1 INDER 6 1 21 DISPENSER INON DISPENSER rss ara be a ehe a 6 2 23 25 DISPENSER NON DISPENSER eu 6 3 21 NON DISPENSER MAY TAG dosimies 6 4 23 25 DISPENSER NON DISPENSER MAY PA sesijas 6 5 23 25 DISPENSER NON DISPENSER MAYTAG PREMIUM 6 6 SECTION 7 SCHEMATICS aan ee 7 1 INDEX 7 1 599 513 874 vi 599 513 874 vii SECTION 1 GENERAL INSTRUCTIONS ELECTRICAL REQUIREMENTS It is the personal responsibility and obliga tion of the appliance owner to provide ad equate electrical service for this appliance Observe all electrical and local codes and ordinaces A 120 volt 60 Hz 15 ampere fused electri cal supply is required An individual branch or separate circuit serving only this appli ance is recommended Do not use an extension cord Befo
30. CORD FOUNTAIN HEATER WH RD BLK X 4 FOUNTAIN LIGHT RD RD BLK BLK WH LIGHT SWITCH RP WATER DISPENSER SCHEMATIC WIRING DIAGRAM LOCK OUT 1 SWITCH ACTUATOR SWITCH LIGHT SWITCH REERIG LIGHT S Bex NE ON CERTAIN MODELS ONLY ete O I ML CRISPER LIGHT WH FREEZER LIGHT WH ON CERTAIN MODELS ONLY DEFROST FOR DIAGNOSTIC CONTINUITY TIMER CHECK 240K OHMS OR OR ii p gt N zb OVERLOAD COMPRESSOR Y CAPACITOR ON CERTAIN MODELS ONLY 7 3 FOUNTAIN HEATER FOUNTAIN HEATER LIGHT SWITCH WATER DISPENSER INTERLOCK LIGHT SWITCH SWITCH m WATER DISPENSER INTERLOCK SWITCH LIGHT SWITCH WATER DISPENSER LOCK OUT N O SWITCH ACTUATOR SWITCH ACTUATOR SWITCH 1 1 SELECTOR SELECTOR SWITCH 1 SWITCH 2 ACTUATOR SWITCH CRUSHER CUBE WATER LIGHT CUBE WATER LIGHT LOCK CUBE WATER LIGHT FOUNTAIN HEATER gt E 5 FOUNTAIN HEATER LLI T O SWITCH O a gt LLI oc ACTUATOR me Q E D SWITCH oc uro 1 2 N 22 lt FOUNTAIN DELAY 7 LL CARD T A CUBE LIGHT CUBE O o 7 4 SCHEMATIC RWD4 DISCONNECT THE UNIT FROM THE POWER SOURCE PICTORIAL WIRING DIAGRAM ALLOW 10 PERCENTTOLERANCE ON ALL RESISTANCES d GR EI er Sk il M ON gt
31. DOOR eier 3 4 WATER ICE DISPENSER FREEZER DOOR REMOVAL 3 4 FOUNTAIN ASSEMBLY Manual Slide Control aa 3 6 Ice and Water Fountain Bracket Assembly Removal eee 3 6 Checking and Replacing the Crusher and Water Cube Switch 3 6 Checking and Replacing the Actuaring 3 7 Fountain Heater ea ee OO 3 7 PC BOARD nenne een 3 8 FO EIMBGO Mh Mm TT 3 7 Excessive Door Delay Rte 3 7 short Door Delay ass u 3 7 FOUNTAIN ASSEMBLY Electronic CONG nun sen ee ee 3 8 Ice and Water Fountain Bracket 3 8 Fountain Bracket Assembly an essen 3 9 Checking and Replacing the Actuator Switch iue hn trn ens 3 9 Electronic Control Beard Troubleshooting ua s ses 3 9 ICE CRUSHER BIN AND SHELF ASSEMBLY au 3 10 ICE CRUSHER BIN SHELF ENCLOSURE ASSEMBLY act dta nein cu se 3 11 599 513 874 EN SECTION 4 ICEMARKER ln 4 1 SERVICING 4 1 TEST PROCEDURES XX B 9 4 1 SERVICE PROCEDURES une 4 2 ACCESSING THE CONTROL BOX issue sans asiana duc eimi 4 2 MODULE COM PONEN mier 4 3 WATER FILL AD USTMENT t dos 4 4 W
32. E 3 6 4 Place slide selector in center position 5 Remove the three fountain bracket mounting screws See drawing in the lower left column 6 Carefully pull the assembly out of the fountain housing You now have full ac cess to the solenoid dispenser mecha nism PC delay board lock switch light socket and the light switch 7 To repair the assembly disconnect electrical quick disconnect Checking and Replacing the Crusher and Water Cube Switch 1 Disconnect the unit from the power source 2 Perform steps 1 through 3 of Ice amp Wa ter Fountain Bracket Assembly Removal 3 Remove the two slide selector mount ing screws See drawing in the lower left column 4 Remove the slide selector 5 Check the continuity of the switch If defective go to step 6 6 Remove the switch mounting screw 7 Remove the switch 8 Remove the wire leads 9 Install new switch in reverse order of removal WATER CUBE SWITCH CRUSHER SWITCH LOCK SWITCH LIGHT SWITCH Checking and Replacing the Actua tor Switch 1 Disconnect the unit from the power source 2 Perform steps 1 through 6 of To Re move and Water Fountain Bracket Assembly 3 Check the continuity of the switch if defective go to step 4 4 Remove the mounting screw b Remove the switch 6 Remove the wire leads 7 Install new switch
33. IEASEA lb narum INTE 215 LIME FIGURE 4 During final flush remove old compressor and install replacement compressor leave plugs in place until brazing 4 Complete compressor replacement Close valves to the recovery system Re move process tube adapters from both the suction and discharge lines CAUTION In order to prevent sealed system contamination the time of atmo spheric exposure must be limited to 15 minutes do not pull the plugs from the new compressor until you are ready to make the connections Connect and braze suction and discharge lines to the replacement compressor fig ure 5 You are now ready to add the tem porary piercing valve to the drier process line and proceed with the sweep and final charging of the system aa TO RIDER LEGE ren PROSERR TUBE FIGURE 5 Flush complete ready for sweep charge SWEEP AND FINAL CHARGE The sweep charge is a method of purging the sealed system of moisture air and po tential contaminants Also during this pro cedure the system may be checked for leaks before the final charge If this proce dure is followed as outlined it will allow for the capture of 90 95 percent of the available refrigerant thereby ensuring that the sys tem will operate as designed The sweep procedure for R134a refrigerant systems is made after the system has been repaired and or flushed Three
34. ITION POSSIBLE CAUSE CORRECTION High usage of refrigerator Advise customer especially in high ambient Unit runs excessively The refrig Setting of temperature Reset control erator compartment and freezer control too high for prevail compartment both too cold ling environmental and normal wattage readings usage conditions Defective temperature Replace control Door seals may be leaking Adjust door or replace door gasket Unit runs excessively but temp Problem is one of customer Advise customer erature appears to be normal in usage and education with refrigerator severe environmental conditions after confirmation by a temperature recording Frequent door openings Check light switch and Light may stay on constantly replace if needed Check in refrigerator door adjustment Replace nefficient compressor e See below Short running cycle Refrig Temperature control erator and freezer compart ments are cooling but are not cold enough Replace Defective control normal wattage readings Reset control Improper setting of temper ature control for prevailing environmental and usage conditions e See below Air circulation Check and advise customer Ventilation around conden ser is blocked Replace Condenser fan is defective Advise customer that it may Dirty or restricted condenser require cleaning periodically due to particularly greasy in
35. NECT THE UNIT FROM THE POWER SOURCE PICTORIAL WIRING DIAGRAM ALLOW 10 PERCENT TOLERANCE ALL RESISTANCES p CR ICE MAKER ER em RECEPTACLES TEMPERATURE S WH RD FOUNTAIN T CUBE SWITCH ET TT HEATER SELECTOR SWITCH 1 p 1 SELECTOR SWITCH 2 BRN REF LIGHT 2 INTERLOCK 4 L9 sorENoID switcH _LIGHT SWITCH D RD N LOCK OUT SWITCH WHITE T1 Au ACTIVATOR SWITCH LINE CORD jew veiow y D Brown CRISPER LIGHT ORANGE CERTAIN MODELS GRN YEL GR ONLY DEFROST HEATER EN NER 77 WHITE BLUEIWH BLU uem WHITE RED WH RD WH OR S t RUN 1 CAPACITOR ESSOREM CERTAIN MODELS ONLY L Su N E RUN K CAPACITOR ses condenser fan motor grasp the connector with your thumb inserted between the connector and the locking lever as shown and pull the connector SCHEMATIC WIRING DIAGRAM C FREEZER LIGHT WH ON CERTAIN MODELS ONLY FOUNTAIN HEATER TAAAAAA 1 WH RD INTERLOCK WATER eran eel DISPENSER VALVES LOCK OUT SWITCH ACTUATOR SWITCH 1 4 1 SELECTOR SELECTOR SWITCH 1 SWITCH 2 DOOR SOLENOID FOUNTAIN DELAY CARD wu p Suee sorod ICE MAKER VALVES WH BLU RD ICE MAKER
36. OAD Y FEN N 4 is Pd J ICE MAKER Ta 2 OVERLOAD COMPRESSOR 2 RELAY ON CERTAIN MODELS ONLY connector and the locking lever as shown and pull the connector 7 2 SCHEMATIC RWD2 DISCONNECT THE UNIT FROM THE POWER SOURCE PICTORIAL WIRING DIAGRAM ALLOW 10 PERCENTTOLERANCE ON ALLRESISTANCES p we N PRESS nr r T ICE MAKER m 7 RD RECEPTACLES Ser To PS 0 CONTROL REF LIGHT CERTAIN VESS Sec FOUNTAIN HEATER SELECTOR SWITCH 1 N 1 SELECTOR SWITCH 2 g CT sor ENoID 7 A Mpeg pam LIGHT SWITCH FOUNTAIN LIGHT WIRE CODE L ACTIVATOR LER w SWITCH RED WHITE B BLACK Bam mu YELLOW wi lov BROWN CRISPER LIGHT ORANGE CERTAIN MODELS C GRN YEL PINK DEFROST oh TAN HEATER h N VIOLET 5 BLAR m ES IRED BLACK RD BLK AV CAPACITOR NZ tad CERTAIN MODELS N SJ s ONLY 1497 BS Le 2 f 1 E N 7 n COMPRESSOR M gt LA e m b S FAN 2 zl WATER 2 NDISPENSER VALVE S ICE VALVE N N condenser fan motor grasp the connector with your thumb inserted between the connector and the locking lever as shown and pull the connector REFRIGERATOR Tc UU a Done ATG NONE SETA POWER
37. STEM IDENTIFY REFRIGERANT 134 RECOVER REPAIR LOW SIDE LEAK PLUGGED CAPILLARY TUBE COMPRESSOR REPLACEMENT REPAIR FINAL CHARGE FINAL CHARGE FLUSH INCLUDES COMPRESSOR REPLACEMENT Remember before entering the sealed sys tem all other systems must be tested and properly repaired These include the elec trical system defrost system control op eration and air flow systems evaporator and condenser motors Before turning screwdriver many checks can be made simply by using your senses LISTEN What is the customer complaint Are the fans operating s the compressor operating LOOK Are ice cubes present s the light on off when the switch is operated Are the controls set properly Do door gaskets seal properly s there an ice buildup on the evaporator cover Are the return air ducts free of ice TOUCH s the evaporator cover warm Is air felt exhausting from the kick plate s air circulating in the freezer and fresh food compartments s the quarter inch discharge line from the compressor hot s the condenser warm SEALED SYSTEM DIAGNOSIS Once it has been determined that the other refrigerator systems are working properly a probable sealed system problem can be confirmed through the use of a wattmeter and checks of low and high side pressures Access valves are not to be left on a sealed system after service To measure
38. Since the PTC device is temperature sensitive a variance in its tem perature causes a change in its resistance When current is first applied to the com pressor the PTC device s low resistance shorts out the run capacitor thus produc ing adequate motor starting torque As the compressor motor approaches run ning speed the current through the PTC device causes the temperature and resis tance of the PTC device to increase to where it appears to be an open circuit The com pressor continues to operate on the run winding in parallel with the series combina tion of the run capacitor and start winding 2 6 Over load Pro tector Capacitor Checking the PTC Device 1 Disconnect the unit from the power source 2 Discharge the capacitor NOTE See Testing The Capacitor on page 2 7 3 Remove the wires from the PTC de vice terminals 4 Allow the PTC to cool to room temperature 5 Remove the PTC device 6 Using an ohmmeter check the resis tance between the PTC device termi nals The ohmmeter should register between 3 and 20 ohms An extreme variance between 3 and 20 ohms indicates a defective PTC device which must be replaced NOTE We discourage using a voltmeter to check performance of the device because test results are influenced by several factors such as its dependence on line voltage to the compressor the re sponse characteristic of the voltmeter and the PTC device temperature a
39. ain PC control board Black wire from Green Coil Light Inter Lock Switch White Wire Neutral WATER FILTER Wh Blu Wire DUAL VALVES 77182 4 Green Coils 250 Ohms 6 Red Coil 275 Ohms 6 Note Water Filter Valve Body is Yellow Ice Water Valve Body is Blue 3 16 WATER LINE ROUTING FOR PURI CLEAN WATER FILTER SYSTEM WATER FOUNTAIN ICEMAKER sili 5 16 O D Tubing 1 4 O D tubing Water Tank Assembly Icemaker Valve 1 4 O D tubing T M Puri Clean Water and Ice Filter Assembly WATER FILTER AND ICEMAKER WATER TUBE ROUTING ON THE BACK OF THE REFRIGERATOR _ Water Filter Outlet Water Filter Inlet Icemaker Inlet Water lcemaker Valves Filter Valves SECTION 4 ICEMAKER SERVICING The design of this ice maker allows all of the components to be tested without re moving the ice maker or moving the refrig erator away from the wall to access the water valve TEST PROCEDURES Ice maker plugged into power Shut off arm down Freezercold Remove the cover and you will see the test Test points L amp N will verify 120 volts to points identified on this module ice maker module Neutral side of line Make sure your test probes go into M connection test points 1 2 Heater connector Test points T amp H will verify
40. ain control board FOUNTAIN LIGHT WILL NOT LIGHT 1 Check bulb and mechanical connec tions 2 Doesfountain light illuminate during a dispense Yes a Replace LED Switch board No b Replace fountain control board WILL NOT DISPENSE ICE OR WATER 1 Press lock button 3 times If another LED lights replace LED Switch PC Board 2 When actuator pad is pressed does fountain light come on Note Make sure fountain light bulb is good No a Check actuator switch and mechanical connections b Replace PC control board Yes a If nothing works ice door sole noid auger cube solenoid water valve replace PC control board No b If some functions work check for 115 VAC at ice door solenoid auger cube solenoid water valve terminals during dispense 1 If 115 VAC output exists replace component 2 If 115 VAC output is not present replace control board ICE CRUSHER BIN AND SHELF ASSEMBLY 1 Toservice the ice crusher related com ponents turn the ice maker off by lift ing the shut off arm Remove the bin assembly 2 Remove the four bin front mounting screws BIN FRONT BIN FRONT MOUNTING SCREWS BIN FRONT MOUNTING SCREWS CRUSHER HOUSING MOUNTING SCREWS 3 Place the bin assembly on the crusher housing CRUSHER HOUSING MOUNTING SCREWS 4 Care should be taken when removing the control rod spring to ensure it does not snap back on yo
41. all wires from the timer and at tach ohmmeter probes to the terminals specified in the accompanying chart If no continuity is indicated the timer is defec tive To Test Turn Timer Check Between Knob To Terminals 1st Click 182 2nd Click 184 See Maytag Monthly Bulletin June 1993 volume 03 Issue 40 Page 1 Low watt Timers This test works on all low watt timers Timer Replacement 1 Disconnect the unit from the power source 2 Open the fresh food door and remove any items on the top shelf 3 Remove the light shield cover by pull ing down on the back corners of the cover and sliding the cover forward 2 14 4 Remove the fascia radiant shield mounting screws Remove the control housing mounting screw at the back of the control housing Slide the control housing to the right and lower it from the control housing supports 5 Disconnect the temperature control housing electrical quick disconnects 6 Remove the temperature control hous ing from the refrigerator and place on a flat work surface 7 Remove the two timer mounting screws 8 Disconnect the electrical connector from the timer 9 Install the replacement timer in reverse order of removal ADAPTIVE DEFROST CONTROL The adaptive defrost control assembly is a microprocesser controlled defrost timer This new control allows defrost to occur only when needed compared to mechani cal timers which defrost at a preset interval whether it is n
42. and wattages shown were taken a during a normal running cycle b with freezer temperature near 0 F refrigerator temperature if applicable near 37 F no sooner than 5 minutes after compressor start up In the home measurements will vary depending upon environmental and usage conditions Ambient Ambient Ambient 6 5 SECTION 7 SCHEMATICS ELECTRONIC FOUNTAIN ADAPTIVE DEFROST MAYTAG amp JENN AIR RWD 5 ELECTRONIC FOUNTAIN DEFROST TIMER MAYTAG amp JENN AIR RWDIF 6 WATER FILTER MODELS ELECTRONIC FOUNTAIN ADAPTIVE DEFROST MAYTAG amp JENN RWDIF 7 AIR WATER FILTER MODELS REFRIGERANT FLOW 7 1 DISCONNECT THE UNIT FROM THE POWER SOURCE SCHEMATIC RWD1 PICTORIAL WIRING DIAGRAM ALLOW 10 PERCENT TOLERANCE ON ALL RESISTANCES SCHEMATIC WIRING DIAGRAM ON PROVISIONAL ORICE MAKER ON PROVISIONAL OR ICE MAKER MODELS ONLY a ICE MAKER DEFROST TIMER REFRIG w SWITCH LIGHT i CRISPER LIGHT E RD LIGHT SWITCH GY WHITE BLACK FREEZER LIGHT m TEMPERATURE ON CERTAIN MODELS ONLY CONTROL ELA GRN YEL DEFROST ES GRAY MIS PINK TIMER CRISPER LIGHT gt GY VIOLET CERTAIN MODELS gt IRED BLACK RD BLK M N 7 lt lt ET FOR DIAGNOSTIC CONTINUITY N Be SE an CHECK 240K OHMS f RN r t ayy 7 N em Y as COMPRESSORN SVERL
43. aper to clean the capillary tube 3 inches from the original joint Also clean the input tubing to the drier of 3 inches from the original joint Use steel wool or fine emery paper to clean both ends of the new drier Use a knife or file to score the capillary tube 1 inch from the original joint Use your finger to break the connection Make an offset 1 2 from the end of the cap tube to prevent it from penetrating too far into the drier e Cut the inlet tube of the replacement drier and use pliers to snap off the scored end f Install the new drier using silver solder with the proper flux at the Yoder tube to drier joint Use silfos at the drier to capillary tube joint 10 Evacuate recharge and leak test the system 11 Test run the unit to check operation 12 Replace the machine compartment cover CONDENSER REPLACEMENT The following general information explains how to successfully replace the condenser for any model covered in this manual 1 Disconnect the unit from the power source 2 Remove all loose items from the refrig erator interior 3 Working at the back of the cabinet re move the cover from the machine com partment It is necessary to reinstall this cover after the job is completed 4 Using a sponge remove any drain wa ter from the defrost pan 5 With assistance tilt the cabinet back and remove the front condenser mounting SCrew Shroud Condenser Mounting Screw 6 Wit
44. ation tools needed ALL HOSES AND EQUIPMENT MUST MEET STANDARDS FOR HANDLING R134A RE FRIGERANTS e APPROVED AND CERTIFIED RECOVERY EQUIP MENT AND RECOVERY CYLINDER see local sup plier for variety of equipment e MANIFOLD GAUGE SET HOSES MUST HAVE LOW LOSS FITTINGS Robinair 41365 e HEATED CHARGING CYLINDER WITH R134A SCALE Robinair 43134B e TEMPORARY ACCESS VALVES 2 Robinair 40288 1 4 FLARE TEE MFL X MFL X FFL Robinair 40399 1 4 QUICK COUPLER VALVE Robinair 40380 e PROCESS TUBE ADAPTER SET Robinair 12458 Other tools required but not necessarily dedicated to R134A Service e TUBING CUTTER Robinair 14987A e BRAZING TORCH Robinair 12587 e SWAGGING TOOLS Robinair 14313 e VOLT WATT METER MAYTAG CUSTOMER SERVICE 20000019 LEAK DETECTION EQUIPMENT FOR CFC HCFC AND HFC OR EQUIVALENT e PINCH OFF TOOLS Robinair 12294 or 12396 NOTE ob nair equipment is listed as a reference only equivalent substitutes may be used Additional tools may be required for special situations LEAK DETECTOR Leak detectors compat ible with R134A should be used Due to the possibility of contaminating the sealed sys tem with moisture using soap bubbles can cause problems especially if drawn into a low side leak To minimize the possibility of moisture entering the system the use of wet rags or towels to cool a brazed joint should be avoided DRIERS FILTERS Any time a sealed sy
45. auger motor attach an ohmmeter probe to the auger motor terminals The meter should show re sistance If the meter does not show resistance the motor should be re placed 7 replace the motor hold the auger motor armature and turn the yoke clockwise releasing yoke from the mo tor shaft Remove the yoke and washer 8 Remove the four mounting screws that fasten the motor enclosure Remove the motor from the enclosure 9 Install the replacement part in reverse order of removal 10 To check the solenoid yoke assembly attach an ohmmeter to the solenoid ter minals The meter should show resis tance does not show resistance replace the solenoid yoke assembly 11 Remove the four screws that fasten the solenoid yoke assembly to the enclo sure Remove the assembly from the enclosure 12 Install the replacement part in reverse order of removal 3 14 Operation The water valve assembly is mounted on the inside of the machine compart ment The assembly consists of a dual filter valve and a dual water ice valve The water supply copper tubing is connected to the inlet of the dual filter valve Plastic Y tubing is connected from the outlet of the dual water filter valve to the inlet of the water filter as sembly From the filter a plastic tube feeds the dual water ice valves The dual valve controls the flow of filtered water to the icemaker and to the water dispenser When dispensing water the
46. cket Screws 3 The condenser fan motor is connected in parallel with the compressor If the com pressor runs but the motor doesn t the motor is either defective or disconnected If neither operates check the cold control defrost timer and the cabinet wiring To Check The Condenser Motor Direct 1 Disconnect the unit from the power source 2 Remove the insulated cover from the rear of the cabinet 3 Disconnect the condenser fan motor lead connector on the motor terminals Remove Ground Wire Screw To remove the lead connector from the condenser fan motor grasp the connec tor with your thumb inserted between the connector and the locking lever as shown Pull the connector away from the motor 4 Attach a 115v test cord to condenser motor and plug into a power source If the motor fails to operate it is defec tive and must be replaced Condenser Fan Motor Replacement 1 Disconnect the unit from the power source 2 Remove the insulated cover from the rear of cabinet 3 Disconnect the condenser fan motor lead connector on the motor terminals 4 Remove the screws that mount the fan motor to the brackets 5 Transfer the fan blade to the replace ment motor making sure it is installed in the same manner as the original 6 Install the fan motor leads and ground wire 7 Install those parts previously removed Test run the unit FREEZER FAN MOTOR The freezer fan circulates
47. conds To de termine the free movement of the auger motor place the selector switch in either cube or crushed position slide selector models On electronic models push the cube or crushed selector pad Open the freezer door push and hold the cabinet in terlock switch in the closed position while pushing the dispenser actuator pad The solenoid is energized only when the selector switch is in the cube position This will pull back the actuated blades To deter mine the free movement of the solenoid yoke assembly place the selector switch slide selector models in the cube position On electronic models push the cube selec tor pad Open the freezer door While push ing the dispenser actuator pad push and hold the cabinet interlock switch in the closed position Observe the control rod yoke for vertical movement The auger motor and the solenoid control rod yoke assembly are easily removed 1 Disconnect the unit from the power source 2 Remove the ice crusher bin assembly 3 Remove the retainer screw at the bot tom left side of the ice crusher bin shelf enclosure 4 Pull the shelf forward and disconnect the quick disconnect 3 13 e p SOLENOID YOKE ASSEMBLY AUGER MOTOR 5 Remove assembly from the freezer and place on a flat work surface 6 To check the
48. cover by loos ening the top two screws on each cor ner of the cover and removing the bot tom screws on each corner Tilt the top of the evaporator cover for ward and disconnect the wire harness connector Remove the evaporator cover and fan motor assembly It is very important that this part be reinstalled in the same manner as it was originally Disconnect the defrost heater wire leads Using long nose pliers remove the defrost heater retainer clips One on the right side of the heater and one on the left side Install the replacement heater in the re verse order of removal THERMOSTAT REPLACEMENT The defrost termination thermostat is lo cated on the top right side of the evaporator 1 Follow the first five steps in replacing the defrost heater Disconnect the leads from the thermostat 3 4 Remove the defrost thermostat and mounting clip by releasing the mount ing clip that is snapped around the evaporator tubing Install the new defrost thermostat in the reverse order of removal Make sure the thermostat is located per the draw ing below Defrost Thermostat 1 5 Away From Back of the Freezer Wall Foam Block e 2 P 52522 S Defrost Heater Clip CONDENSER FAN MOTOR Remove Motor Wire Harness Lock Lever Remove Fan Motor Bra
49. e con trol housing Changes in air temperature cause the damper door to open and close A control rod and gear connect the fresh food control knob to the damper control Turning the fresh food control knob to the COLDEST position increases the flow of freezer air into the fresh food section The freezer compartment temperature control warms at a faster rate and cools at a slower rate increasing the compressor run time necessary to maintain a satisfied freezer temperature control Turning the fresh food control knob to a WARMER setting decreases the flow of chilled air into the fresh food section The freezer compartment temperature control warms at a slower rate and cools at a faster rate decreasing the compressor run time necessary to maintain a satisfied freezer temperature control 1 2 11 cking the Auto Damper Disconnect the unit from the power source Open the fresh food door and remove any items on the top shelf Set the fresh food control to the cold est position Remove the light shield cover by pull ing down on the back corners of the cover and sliding the cover forward Remove the fascia radiant shield mounting screws Remove the control housing mounting screw at the back bottom center of the control housing Slide the control housing to the right Lower the control housing Disconnect the temperature control housing electric quick disconnect Remove the temperature control hous ing
50. e entire door the seal must make contact at the top and bot tom at the same time For this reason the door when ajar should not toe n or toe out To correct a toe n or toe out condition first check that the hinge side of the door is par allel with the cabinet then proceed as follows 3 3 1 Checkthe cabinet levelers and adjust able wheels Raising the handle side may correct a toe out lowering may correct a toe in 2 Loosen all inner panel mounting screws along the top bottom and handle side of the door Do not loosen the screws along the hinge side 3 Hold the corner that toes in stationary and push in on the toe out corner until the door is lined parallel with the cabinet 4 Openandclose the door several times to ensure a proper fit If necessary re peat steps 2 and 3 5 Tighten all loosened screws HINGE ADJUSTMENTS Hinge adjustments are necessary when 1 Thesealis not sealed sufficiently along the hinge side of the door 2 The seal is compressed more than 1 16 on the hinge side causing a poor seal elsewhere around the top 3 The distance between the door and cabinet is greater at the top than it is at the bottom or vice versa 4 Thehinge side of the door is not 1 16 out past the side of the cabinet when measured from the side of the cabi net or when the door panel top is not 7 64 above the cabinet top 5 If one or more of these conditions ex ist adjust one or both hinge
51. e freezer compart ment If a leak is present in the evaporator it is not repairable and must be replaced On R134A systems whenever the evapo rator is replaced the heat exchanger must also be replaced as well as the compres sor The replacement evaporator will come with the heat exchanger attached Leave the caps in place on the opposite end of the heat exchanger Again whenever the evapora tor and heat exchanger are replaced on R134A units the compressor must also be replaced and the sealed system flushed Do not connect the suction line to the replace ment compressor until the system has been flushed see System Flush Procedure After mounting the evaporator in place con nect the capillary tube of the heat exchanger to the replacement drier Heat Exchanger The heat exchanger is composed of the cap illary tube and suction line soldered to gether The heat exchanger should be re placed if there is a non repairable leak plugged capillary more than 3 inches have been removed from the capillary or the cap illary tube separates from the suction line If the heat exchanger is replaced the evapo rator must also be replaced as well as the compressor Compressor The compressor is the heart of the refrig erator consisting of an electrical motor and a pump sealed inside a steel case The compressor used on R134A refrigerant sys tems is virtually the same in external ap pearance as the compressor used with R12 ref
52. eads together and place the toggle switch in the OFF position There should not be any bare leads touching the cabinet Plug in the tester and flip the switch to the start position When the compres sor starts release the switch to the run po sition If the compressor is operative it will continue operating on the run windings If the compressor fails to run the compres sor is defective and must be replaced Overload Protector The overload protector prevents the com pressor from burning out its electrical wind ings in the event the compressor becomes overheated or draws too much current The overload trips opening the circuit to the compressor If it does this repeatedly the compressor is said to be cycling on the overload Cycling on the overload may be caused by 1 Insufficient air circulation around the compressor and condenser 2 Pull down on the compressor caused by a large quantity of warm food placed in the refrigerator 3 Compressor stalling due to lack of pres sure unloading 4 Low line voltage 5 Defective start relay 6 Defective winding in the compressor or shorted windings Testing the Overload Protector Disconnect the unit from the source power To test the overload protector remove the compressor terminal cover Examine the bottom of the overload for signs of arcing If signs of arcing are present either check for continuity or connect a jumper wire across the terminals If us
53. ecessary or not The new control will continually adjust defrost inter vals based on the amount of time the de frost heater is energized This allows the defrost intervals to be adjusted closer to the optimum defrost interval based on use thus saving energy Checking the Adaptive Defrost Control 1 Disconnect the unit from the power source 2 Open the fresh food door and remove any items on the top shelf 3 Remove the light shield and the tem perature control housing see steps 3 and 4 replacing the timer 4 Connect the refrigerator to a wattme ter 5 Make sure compressor is running cold control closed 6 Using an insulated number 22 jumper wire short between L1 and Test this will put the refrigerator into a defrost for approximately 23 minutes 7 The watt meter should read between 500 to 600 watts depending on the model Note f the temperature control is open unit not running and you jumper 17 and Test the unit will cycle through the test mode in two seconds and there will be no watt draw YELLOW ORANGE WHITE HITE WITH BLACK TRACER RED These models use a metal sheath heater to remove accumulated frost from the freezer evaporator and drain trough during a de frost cycle The defrost timer models energizes the defrost heater every 8 hours of accumu lated compressor run time When the tem perature in the thermostat area reaches ap proximately 43 F the thermostat
54. eck the cut in cut out temperatures attach the bulb of thermistor temperature tester to the control feeler tube and set con trols at midposition Allow the compressor to complete two or three complete cycles If the temperature readings are not within two degrees of the requirements the control is defective and must be replaced Do not attempt to recalibrate A defective control may cause the compres sor to run continuously or not at all If ei ther of these conditions exist check as follows Compressor Won t Run 1 Remove the control enough to expose its terminals 2 Short across the control terminals If the compressor starts install a new control If the compressor fails to start check the defrost timer compressor receptacle and unit wiring for defects 2 9 Temperature 1 Thermal Mass Retainer Front of Cabinet Compressor Runs Continuously Turn the control knob to OFF If the com pressor continues to run proceed to step 2 If the compressor stops check that the feeder tube is positioned prop erly and that the air flow through the con trol housing is not restricted If the feeler tube is positioned properly and there is no air restriction check the con trol operating temperatures Remove the control far enough to re move one of the wires from its termi nal If the compressor continues to run there is a short in the unit wiring Control Replacement Disconnect the unit from t
55. ed This should be determined by either locating the actual leak or by isolat ing the component from the rest of the sys tem and determining if it holds pressuriza tion or a vacuum whichever method is chosen COMPONENTS Drier Whenever the sealed system is entered the drier must be replaced For R134A refrig erant systems use a 13900 1 drier This drier has the proper desiccant suitable for the refrigerant The drier is stamped with an arrow which indicates the direction of re frigerant flow The drier inlet has two lines one connects to the yoder loop and the other will be used as a process tube through which the system sweep and final charge will be made The drier outlet will be con nected to the capillary tube Care should be taken to ensure that the capillary is not inserted too far into the drier to make con tact with its internal screen yet in far enough to prevent restricting the small diameter capillary tube opening with the solder alloy Condenser The condenser is a long folded tube which receives the hot high pressure vapor from the compressor While the most common problem is keeping the condenser clean from lint and dirt buildup which prevents proper airflow and the required transfer of the heat to the surroundings it is possible that due to an unrepairable leak or a non removable restriction the condenser could require replacement As with any R134A sealed system repair the key to success is the li
56. een PIN 3 and PIN 1 This ensures proper wiring and good connection Low voltage may represent a problem in wiring con nections or at outlet 2 Check for 115 AC between PIN 1 and Pin 4 when dispenser switch is engaged The PC board uses this line to charge the holding circuit A low voltage condition here may represent poor switch contacts Low voltage may cause short delays low voltage conditions do not exist replace the PC board FOUNTAIN ASSEMBLY Electronic Control E LJ D ESCUTCHEON MOUNTING SCREWS Jii Li x HN Ice amp Water Fountain Bracket Removal GRILL 1 Disconnect the unit from the power source 2 To remove the grill from the fountain sump pull straight out 3 Remove the two escutcheon mounting screws 4 Carefully raise the escutcheon up and off the fountain assembly 5 Disconnect the quick disconnect edge connector from the PC fountain switch board 6 Remove the three fountain bracket mounting screws Quick disconnect edge connector from the PC fountain control board Pull up to remove PC FOUNTAIN SWITCH BOARD MOUNTING SCREWS REAR VIEW FOUNTAIN ESCUTCHEON 7 Carefully pull the assembly out of the fountain housing You now have full ac cess to solenoid dispenser mecha nism PC fountain control board a
57. er to the performance data table s at the end of the manual Symptoms High Side Near normal pressure Low Side Slightly lower pressure Wattage Lower than normal Diagnosis Low side restriction The evaporator suction line or other low side tubing is probably restricted kinked or blocked with a foreign article such as mois ture or contaminant This condition is usu ally accompanied with a frost build up on the low side of the restriction High side pressure will take longer to balance with the low side pressure when the compressor is stopped Symptoms High Side Lower than normal Low Side Slightly lower than normal Wattage Lower than normal Diagnosis High side leak Both high and low side pressures will drop as more refrig erant escapes Symptoms High Side Higher than normal Low Side Slightly lower thannormal Wattage Higher than normal Diagnosis Low side leak High side pres sure will continually increase since air is being drawn into the system through the leak and becomes trapped in the high side tubing The low side may show a slight in crease in pressure because of the air being drawn in through the leak Symptoms High Side Lower than normal Low Side In a vacuum Wattage Lower than normal Diagnosis Capillary tube restriction High side pressure will take much longer or not at all to equalize with the low side pressure when the compressor is stopped Symptoms High Side
58. evaporate into a vapor state and be drawn into the compressor The compressor pressurizes the vapor and pumps it into the condenser The hot va por in the condenser gives off the heat into the room As the vapor cools it condenses back into a liquid and returns to the evapo rator to start the process over again The system continually soaks up the heat inside the refrigerator and deposits the heat back into the room The compressor of the refrigeration sys tem serves two purposes it ensures movement of the refrigerant throughout the system and it increases the pressure and temperature of the vapor received from the suction line and pumps the re frigerant into the discharge line The condenser receives this high tempera ture high pressure refrigerant and al lows the heat to be released into the cooler surroundings This heat removal condenses the refrigerant vapor into a liquid The yoder loop is the last pass of the condenser routed around the cabinet of the freezer to help prevent moisture for mation The drier is installed at the end of the condenser or yoder loop to capture moisture which may be present in the system The capillary tube meters the flow of refrigerant and creates a pressure drop Size and length of the capillary is critical to the efficiency of the system As the refrigerant leaves the capillary tube and enters the larger tubing of the evaporator the sudden increase in tub ing diameter
59. f holding charge when you center the lines or remove the plugs return it NOTE A new drier must be installed each time any component of the system is opened or replaced REPLACING THE COMPRESSOR 1 Disconnect the unit from the power source 2 Locate defective compressor and evacuate the sealed system See Sweep Charging and Refrigerant Recovery 3 Clean and cut the refrigerant lines as close as possible to the compressor stubs leaving enough length to install the replacement compressor Disconnect lead wires from compres sor terminals Remove the retaining clips from the compressor mounts Remove defec tive compressor from cabinet and in stall rubber grommets on replacement compressor Clean the compressor stubs with an abrasive cloth such as grit cloth No 23 Do not open the compressor stubs Install the replacement compressor us ing the mounting clips previously re moved Connect the compressor leads Solder a short piece of tubing to the pro cess tube approximately 6 inches long Connect the refrigerant tubing to the compressor stubs using silfos on copper to copper joints and silver sol der and flux on steel to copper joints Locate and remove old drier Install new drier The new driver is installed in the fol lowing manner 2 2 Carefully bend the old drier and tubing away from electrical parts Use steel wool or fine emery p
60. for leaks MOLDED IN LINE ON HOUSING LINES UP WITH INDICATORS ON LABEL Checking the water valve coils 1 Disconnect the unit from the power supply 2 Remove the machine compartment cover 3 Remove the valve s bracket assembly mounting screw Carefully pull the bracket assembly out of the machine compartment 4 Remove the valve s terminals and attach ohmeter probes should show continuity Replacing the Water Valve s 1 Shut off water and disconnect the unit from the power supply 2 Remove the machine compartment cover 3 Locate the water valve s assembly and remove the mounting screw 4 Disconnect the water inlet fitting from the water valve and drain the water into a container 5 Disconnect water valve outlet lines Drain water into a container 6 Remove the wire leads from the defec tive water valve s 7 Remove and replace the defective valve assembly from the main bracket assembly 3 15 8 Install in the reverse order of removal those parts previously removed Turn on the water and check all connection for leaks Filter Valve s Bottom Icemaker water Valve s Top WIRING PICTORIAL WATER FILTER MODEL REFRIGERATORS FOUNTAIN ICEMAKER ICEMAKER amp FOUNTAIN DUAL VALVES 77182 1 Red Fountain pin 7 fount
61. from the refrigerator and place on a flat work surface Remove the auto damper control rod retainer control rod and the slide con trol gear from the auto damper control Turn the control housing over Remove the two auto damper mount ing screws then remove the auto damper from the control housing Mark the auto damper rod approxi mately 1 4 away from the housing Uncoil the auto damper capillary tube approximately four inches 13 14 15 Auto Damper 1 Submerge into a glass of ice no water Watch for door to move to the closed position Remove from ice and warm capillary tube use your hand Watch door for opposite reaction If no movement is detected replace the control Control Replacement Complete steps 1 through 10 checking auto damper Reinstall new auto damper Reinstall control housing in reverse or der of removal AUTO DAMPER CONTROL Exploded View CONTROL ROD RETAINER TEMPERATURE CONTROL AUTO DAMPER CONTROL ROD R DEFROST TEMPERATURE MER CONTROL N HOUSING AUTO DAMPER ROD SEAL d SLIDE CONTROL HOUSING TEMPERATURE CONTROL CONTROL ROD CONTROL ROD END CAPS CABINET LIGHT SLIDE CONTROL FASCIA FRESH FOOD AIR TUNNEL FRESH FOOD AIR DEFLECTOR DEFROST TIMER The freezer evaporator defrosting system is actuated by an electric timer The timer is mounted in the control housing located
62. greater part of chilled air is directed into the freezer compartment to maintain freezer temperature Forced air models use fan cooled condenser De pending on the model the evaporator is automatically defrosted every eight hours of compressor run time Defrosting is ac complished by a defrost heater activated by a timer The accumulated moisture is drained into a defrost pan located in the compressor area of the cabinet FRONT VIEW m FREEZER SIDE VIEW AIR FLOW FORCED AIR SYSTEMS The airflow balance between the fresh food and freezer compartments is an important factor in maintaining proper compartment temperatures in a forced air refrigeration system A baffle is used to regulate the amount of chilled air directed into the fresh food compartment If a colder freezer com partment temperature is desired the baffle is adjusted so that less air is directed into the fresh food compartment This causes the compressor to run longer since the ther mostat sensing element is located in the fresh food compartment Cold air is drawn across the evaporator and into the fan A portion of the air is deflected into the fresh food compartment where it absorbs heat and returns to the fin and tube evaporator 1 2 through the return opening in the divider However most of the air moving across the evaporator is blown through the freezer air tunnel and circulated throughout the freezer compartment It then circulates back acr
63. h assistance return cabinet to up right position Remove the back con denser mounting screw 7 Disconnect the fan motor wire lead connector 8 Use steel wool or fine emery paper to clean both the inlet and outlet end of the new condenser 2 3 10 11 12 13 17 18 19 20 21 Evacuate the sealed system See Sweep Charging and Refrigerant Re covery Clean and then cut the inlet and the out let tube of the old condenser Remove the condenser assembly from the compressor mounting pan and place it on a workable surface Remove the shroud condenser screws which secure the fan motor shroud to the condenser Transfer all clips to the replacement con denser Make sure the condenser tub ing goes through the rubber sleeve on the fan motor shroud Install the mount ing screws Set the replacement condenser on the compressor mounting pan and install both front and rear condenser mount ing screws Clean then connect the discharge line to the inner tubing Clean again and connect the Yoder loop to the outer tubing of the condenser Solder all joints Silver solder and proper flux should be used on copper to steel or steel to steel joints Excess flux should be wiped off all tubing Remove and replace the old drier Do not allow more than 1 2 of the cap tube to penetrate the drier Install the new drier using silver solder with the proper flux Visually check the joi
64. he power source Open the fresh food door and remove any loose items on the top shelf Remove the light shield cover by pull ing down on the back corners of the cover and sliding the cover forward 10 11 Remove the control housing mounting screw at the back of the control hous ing Slide the control housing to the right and lower from control housing supports Disconnect the temperature control housing electrical quick disconnect Remove the temperature control hous ing from the refrigerator and place on a flat work surface Remove the control knob by pulling it away from the temperature control Remove the electrical and ground leads from the temperature control terminals Remove the control by pushing on the tab with right thumb to release the lock With the left hand rotate the control out of its locking tabs To remove the thermal mass insert a flat bladed screwdriver between the thermal mass and the control housing area Turn the screwdriver to release the mass from its locking tab Install the replacement control in the re verse order of removal AUTO DAMPER CONTROL MODELS The Auto Damper model refrigerator has two controls and both have capillary sens ing The Auto Damper controls the fresh food temperature and the Freezer Tempera ture Control guides the freezer temperature The fresh food compartment temperature is maintained by a damper assembly lo cated at the back of the temperatur
65. humidity and large number of freezer and refrigerator door openings Sealed system See below Overcharge high wattage Evacuate and recharge with readings proper amount of refrigerant Undercharged low wattage Check and see Checking readings Operating Pressure Partial restriction Check and see Checking Operating Pressure e Compressor motor defective Replace Inefficient compressor low wattage readings Condenser fan See below AC circuit to fan open high Refer to wiring diagrams and wattage reading check circuit Defective fan high wattage Replace reading e Dirty or restricted condenser Advise customer that it may due to particularly greasy require cleaning periodically in dusty or significant pet traffic this environment in the home Too much warm food placed Advise customer in refrigerator at one time e Air no leak in sealed system Replace drier and evacuate sys tem thoroughly recharge with proper amount of refrigerant Unit runs excessively Refrigera Partial restriction in air duct Check and remove what is tor compartment eventually from freezer to refrigerator causing the restriction See Air gets cold enough but freezer Flow Diagram compartment is too cold Freezer cold control setting Adjust control for proper adjust too cold ment see Freezer Cold Control DISCONNECT THE UNIT FROM THE POWER SOURCE COND
66. illary tube increasing the pres sure ahead of it warming and decreasing the pressure beyond it cooling To con firm the existence of a restriction in the low side tubing perform operational pressure checks 3 Slow Leak In System On forced air models long run time will be noticed during the early stages of a leak As the refrigerant continues to escape both compartments will gradually warm up and the compressor will run continuously The freezer will probably warm up first 4 Incorrect Refrigerant Charge The sealed unit may have too much refrig erant overcharged system or too little re frigerant undercharged system The para graphs below will inform you on how to recognize a system with these defects An overcharged system may have a frost back condition appearing on the suction line When the compressor stops the frost melts and drips on the floor heat ex changer separation will also cause this symptom An undercharged system depending on the degree of undercharge will operate with temperatures above normal and the com pressor run time will be increased The greater the undercharge the higher the tem perature will be and the longer the run time An undercharged system must be purged evacuated and recharged with the proper amount of refrigerant Before recharging test for refrigerant leaks TOOLS NEEDED FOR R134A SEALED SYSTEM REPAIR The following list may help identify basic refriger
67. ing a jumper wire plug in the line cord and set the tempera ture control to a cold setting If the com 2 5 pressor starts the over load is defective and must be replaced If the compressor fails to start check for a defective start re lay or compressor 1 Remove the PTC and overload from the compressor 2 Connect one ohmmeter probe to the compressor shell Make sure the probe makes good contact with bare metal One at a time connect the other ohm meter probe to each of the three com pressor terminals 3 f the meter shows no continuity to ground install PTC and overload pro tector to the compressor s terminals If the meter indicates the compressor ter minals are grounded replace the compressor 4 Attach a jumper wire across the over load terminals 5 Make sure the jumper wire does not short to ground 6 Reconnect the unit to power source If the compressor starts the overload protector is defective and must be re placed STARTING DEVICE AND CAPACITOR RUN Run Capacitor The PTC solid state starting device is a push on component mounted to the start and run terminals of the compressor This device is connected in parallel with the run capaci tor and is in series with the compressor start windings This will produce a short circuit across the run capacitor during the com pressor starting sequence and full current is applied to the start windings as well as the main winding
68. ing lever as shown and pull the connector SCHEMATIC WIRING DIAGRAM FREEZER LIGHT ON CERTAIN MODELS ONLY FOUNTAIN HEATER INTERLOCK SWITCH WHITE T1 ulm BR SOLENOID of SWITCH RED BLK BOARD VIOLET BLACK BLACK y WATER DISPENSER VALVES WH ON CERTAIN MODELS ONLY LIGHT O kit INTERLOCK CRISPER LIGHT SWITCH TEMPERATURE CONTROL ADAPTIVE DEFROST FOR DIAGNOSTIC CONTINUITY CHECK 240K OHMS OVERLOAD comPRESSOR CAPACITOR RELAY ON CERTAIN MODELS ONLY 7 8 REFRIGERANT FLOW RD1 N Lp YODER CONDENSER LOO SUCTION V EVAPORATO Y M la Hear 22 25 COMPRESSOR gt DRYER a t T Y DISCHARGE TUBE CAPILLARY SS TUBE Ss L CONDENSER
69. le Loosen both screws Discon nect shut off arm Pull mold from support assembly To remove module only remove 3 Phillips screws and pull module out of housing Shut Off Arm Pull out from white bush ing Reinsert to full depth See page 5 15 for detailed position Mold amp Heater port assembly heater assembly Remove module and sup Install on new mold and Bimetal Remove module and support as sembly Pull out retaining ring clips with bimetal Fill Cup Remove module and support as sembly Remove ejector blades and shut off arm Pull fill cup up from mold Ejector Blades or Stripper Remove mod ule and support assembly When reinstall ing ejector blades realign D coupling with module cam ACCESSING THE CONTROL BOX To remove motor and contact assembly from control box take out three screws see arrows and pull free after disconnect ing the shut off arm MODULE COMPONENTS Shut off arm linkage Follower WARNING Warning Never rotate the blade or the drive gear will ruin the main assembly E There are several switches which will jam if manually turned counterclockwise Also the gears will be destroyed if turned clock wise If you need to advance the ice maker into the cycle use a jumper to bridge H to T Unless the motor is defective it will run The shut off arm must be in the ON position Ground slightly longer than other 3 terminals so that grou
70. lly occurs at the outlet end of the capillary tube Normally frost buildup can be detected in this area NOTE When using a heat gun or hair dryer use low heat Never use a torch At the discharge end of the capillary apply heat If there is enough head pressure and if the restriction is caused by moisture freeze up you will be able to hear a gurgling noise as the heat releases the refrigerant through the tubing It is possible that this moisture will be ab sorbed by the drier and remedy the trouble However if the freeze up reoccurs you must replace the drier A kink in the capillary tube will reveal the same symptom as a moisture freeze up except for the accumulation of frost Where possible check the capillary tube and straighten any kinks to relieve the restric tions Check the unit operation If the con dition persists replace the defective part If the freeze up condition does not exist and there is not a kink you can assume that a foreign particle is causing the restrictions The only remedy in this case is to replace the restricted part 2 Partial Restriction In Low Side Tubing Bent tubing foreign matter or moisture in the system may cause a partial restriction in the low side tubing This is usually indi cated by frost free tubing between the re 1 3 striction and the capillary tube and by frost covered tubing between the restriction and the suction line The restriction acts like a second cap
71. miting of the time of atmospheric ex posure Do not remove the plugs on the condenser inlet and outlet tubes until the new condenser is mounted in place and made ready for brazing The inlet side will connect to the compressor discharge line and the outlet to the yoder loop EVAPOR SUCTION LINE 4 YODER CONDENSER LOOP EXCHANGER 4 C OMPRESSOR Yoder Loop The yoder loop is a non replaceable component of the sealed system routed within the walls of the cabinet To diagnose the yoder loop the tubing must be isolated from the sealed system This procedure is shown below If the loop fails to hold the vacuum heater repair assembly is to be installed and the loop bypassed by connecting the con denser outlet tube directly to the inlet of the drier Condenser Loop YODER LOOP DIAGNOSTIC TEST 1 Isolate yoder loop from remainder of sealed system 2 Cap or seal one end of the loop braze or use process adaptor and cap 3 Attach process adaptor to open end of loop 4 Attach compound gauge and vacuum pump to the loop 5 Pull a vacuum and close valve to test for leak in the loop 6 If unit holds a vacuum no leak is indicated Reconnect the yoder loop to the system replace the drier and recharge the system to specifications A VACUUM WILL BE MAINTAINED IF THE SYSTEM IS GOOD Evaporator The evaporator is a long aluminum tube folded or coiled within th
72. nal plastic parts are also re placeable A failed mold heater requires complete re placement of the mold and mold heater assembly THERMOSTAT If the thermostat is diagnosed as defective it can be removed and replaced easily Re move the module from the mold by taking out two Phillips screws Pull Front of module Pull the module free of the mold and you will see the thermostat on the mold side Thermostat Retaining Clips Using needle nose pliers grasp one of the thermostat clips and pull out Press in new thermostat making sure that pins are prop erly indexed Using this procedure it is not necessary to remove the electrical assem bly If you are replacing the module trans fer the clips to the new mold support Use new thermal bonding material 4 5 INSTALLATION Installation Procedure 1 Start with arm in down position 2 Follow steps 1 2 and 3 Into bushing 1 Push arm into center slot in white bushing bottom out Flange Fill cup 2 Push arm 3 Arm should be inside through fill cup edge of housing Shut off arm Down flange hole past position notch HARNESS To remove the wiring harness depress the retaining tab and pull the plug free Depress 4 6 LEVELING ICE MAKER Ensures uniform ice crescents 1 4 Screw Loosen Level by sliding left or right in slot of bracket Tighten Make sure the refrigerator is level front to back adjust
73. nd light socket 8 To repair the assembly disconnect electrical quick disconnect PC FOUNTAIN CONTROL BOARD FOUNTAIN ASSEMBLY ESCUTCHEON REMOVED Fountain Bracket Assembly ICE DOOR SOLENOID FOUNTAIN LIGHT SOCKET CONNECTOR ACTUATOR SWITCH Checking and Replacing the Actua tor Switch 1 Disconnect the unit from the power source 2 Perform Steps 1 through 6 of Ice amp Wa ter Foutain Bracket Removal 3 Continuity check the switch If defective go to step 4 4 Remove the mounting screw b Remove the switch 6 Remove the wire leads 7 Install the new switch in reverse order of removal 3 10 Electronic Control Board Troubleshooting The following checks should only be made by a Qualified Service Technician NO LED S ILLUMINATED ON THE FOUN TAIN TOUCH PAD 1 Check ribbon cable wire connection between the two PC boards Mechani cally Tight 2 Checking the AC line in fountain veri fies operation closure of door interlock switch TRACE SIDE OF PC FOUNTAIN CONTROL BROWN JF1 BLUE ui WHITE TI BROWN IUF2 3 Check fountain heater continuity Un plug the unit Check heater resistance neutral to heater connection it should read approximately 4800 ohms 4 Replace LED Switch board 5 Replace fountain control board SOME LED S WILL NOT LIGHT 1 Replace LED Switch board 2 Replace fount
74. nd makes first and breaks last when dis connected or plugged in NOTE 7 ere are several slotted shafts on the motor assembly board Do not under any circumstances insert a screwdriver and attempt to turn these shafts These slots are to permit assembly only NOTE There are no repairable or replace able components in the module Unless replacing the module there should be no need to remove it when diagnosing or re pairing the ice maker 4 3 WATER FILL ADJUSTMENT Turning the water level adjustment screw will move the contact in its relationship with the contact ring segment This causes the contact to vary the time that the water valve is energized since the contact ring is tapered at the end of the fill time Turning the knob or screw clockwise decreases fill counterclockwise in creases the fill amount Only one revolution is possible with the cover on due to a stop molded on cover Water valve energized 7 5 secs 140 fill NU Viewed from front Module Side WHAT HAPPENS DUR ING BLADE ROTATION Do Not Test if blades are past rest position Thermostat opens in this range of rotation 360 will affect fill by 40cc 180 varies the fill by 20cc Further adjustment could damage module If water valve adjustment screw falls out put it back in and align the hole in the hole as shown Water adjustment When small hole is centered in larger hole the water fill adjustment is fo
75. nd step can take about 15 minutes in order to circu late the refrigerant through the condenser the drier the capillary tube the evaporator and out the suction line into the recovery equipment During this 15 minutes the old compressor can be removed and the re placement set into place mounted and pre pared electrically The compressor is to tally installed except for the final brazing of the suction and discharge lines R134A SEALED SYSTEM SERVICE PROCEDURE Any sealed system failure in the upper area indicated below requires the replacement of the evaporator heat exchanger drier and compressor Perform system flush sweep and add final charge according to procedure shown Leaks at joints 1 or 2 will require Pan the replacement of the compressor Suction Line jo E 3 and drier Perform system flush connection at sweep and final charge the compressor Eee 2 oo Leaks or repairs to joints or components in the ower area require repair or replace ment of the component and drier Perform system sweep and add final charge accord ing to normal procedure 1 7 REFRIGERATION SYSTEM All refrigerators cool by removing heat from the cabinet rather than pumping in cool air In a conventional refrigerator liquid re frigerant enters the evaporator and vapor izes boils due to the low pressure creat ing a very cold surface which removes heat from inside the cabinet This causes the re frigerant to boil
76. nt 115 VAC 60 HZ Temp Control Normal Setting Operating Amps Cut Out 2 F 10 Max 7 2 Cut In 22 F 22 Refrigerant Charge lex Fan_Cooled 4 25 i R134A oz Capillary Tube ER Compressor Oil Bi 103 inches Charge oz 350 cc Diameter 0 028 inches I D Compressor Defrost thermostat BTU hr Cut Out 32 F 43 Cabinet Liner High Impact Cut In IT F 15 F Defrost Timer Door Liners High Impact Defrost Cycle Cabinet amp Divider Defrost Heater Watts Watts NA PERFORMANCE TEST DATA The laboratory test data in this chart was obtained under the following conditions 1 power source of 115V 60 Hz 2 no door openings 3 no load 4 customer control s set at mid point The pres sures and wattages shown were taken a during a normal running cycle b with freezer temperature near 0 F refrigerator temperature if applicable near 37 F c no sooner than 5 minutes after compressor start up In the home measurements will vary depending upon environmental and usage conditions Ambient Ambient Ambient 6 3 23 25 Dispenser Non Dispenser Maytag Temp Control Normal Setting Operating Amps Cut Out 2 F 10 Refrigerant Charge Compressor Oil Length 103 inches Diameter 0 028 inches 1 0 Compressor Defrost thermostat Cabinet Liner High Impact Cut In 11 F Door Liners High Impact Defrost Cycle Cabinet amp Divider Defrost Heater Fountain Hea
77. ntrol is defective short contacts or not adjusted Freezer control not adjusted properly Air duct from freezer to refrigerator is blocked normal wattage reading Freezer fan Defective fan motor See Checking Operating Pressure Check light switch and replace if needed Check door adjustment Advise customer that it may require cleaning periodically in this environment Repair or replace Repair or replace Replace Locate and repair leak before recharging Replace defective part or parts Repair or replace Replace or adjust as required See Freezer Cold Control for proper adjustment Remove what is blocking the air duct See Air Flow Diagram See below Replace DISCONNECT THE UNIT FROM THE POWER SOURCE CONDITION POSSIBLE CAUSE CORRECTION AC circuit to fan open lower Refer to wiring diagrams and wattage readings check circuit Not defrosting lower wat See below tage readings than normal and frost buildup or evapor ator Defective defrost timer defrost heater or defrost Replace defective part or parts terminal thermostat AC circuit to defrost system Refer to wiring diagrams and open check circuit Temperature control See below High setting of temperature Check and adjust for proper control may result in these setting conditions under very severe environmental and usage conditions high
78. nts for leaks Connect the fan motor wire connector Evacuate and recharge the system 22 Test for leaks 23 Install the machine compartment cover 24 Test run the refrigerator to make sure it is operating properly ELECTRICAL SYSTEM e wiring diagram is located in the con trol housing area e electrical components are grounded to the cabinet e The green yellow center conductor in the power cord is attached to the cabi net to provide a ground circuit when the cord is plugged into properly grounded outlet e After replacing an electrical component always reconnect the ground wire e The electrical outlet should be checked to make sure it is properly wired Check the outlet with a circuit tester COMPRESSOR TESTER SWITCH Off Run Start Capacitor Testing the Compressor Direct Testing the compressor with no other wir ing in the circuit is called the direct test method Remove all electrical components from the compressor in order to perform this test It is recommended that a com illustrated be used to pressor tester as make this test The tester leads are marked RUN START and COMMON Connect the common lead to the common terminal of the compres sor the start lead to the start terminal and the run lead to the run terminal The com pressor terminal arrangements are illus trated above The other two leads are for a start capacitor if used When not in use attach the two l
79. oltage Must be at least 100V with all other load on the line DISCONNECT THE UNIT FROM THE POWER SOURCE CONDITION POSSIBLE CAUSE CORRECTION Unit runs excessively or continuously Unit does not run for period of time after defrost Unit runs continuously but there is no cooling in refrigera tor and freezer compartments Unit runs continuously The refrigerator and freezer com partment are both too cold normal wattage reading Unit runs continuously The refrigerator compartment not cold enough but freezer compartment is colder than normal Unit runs excessively or contin uously The refrigerator and freezer compartments are cool ing but are not cold enough Complete or possible partial restriction under high ambi ent cycles on overload pro tector after unit stops and tries to restart Check to ensure light does not stay on continuously Dirty or restricted condenser due to particularly greasy dusty or significant pet traffic in the home Defective cold control Condenser fan not running Defrost timer is defective does not advance advance to cool cycle Substantial loss of sealed system charge low wattage readings Restricted capillary or drier on high side low wattage readings while running Will cycle on overload when unit tries to start after defrost cycle or after having been shut off and restriction is still present Defective compressor Temperature co
80. ont with one hand and push up under the shelf back with the other hand and pull out To lock shelf into another position keep the shelf horizontal guiding the support hooks into the slots in the shelf support at the rear of the cabinet Lower the shelf until the hooks lock into position Check that the shelf is securely locked into position before loading with food CANTILEVER SHELF TRIM The cantilever shelf trims are easily re moved by placing the shelf on a flat work surface Raise the front of the shelf grasp the right underside of the front trim and pull toward you Next remove the glass from the rear trim and remove trim 3 1 Install the new rear trim on the glass Place the shelf in a vertical position shelf front up Install the glass and rear trim by applying a downward force on the rear metal shelf cross brace until it snaps securely in place Next install the front trim on the glass and the front metal shelf cross brace pou Front Trim CABINET DOORS AND ASSOCIATED PARTS Inner Door Liner Replacement The polystyrene inner door liner and the door seal are mounted to the outer panel by screws placed around the door flange The inner door liner can be replaced with out removing the door from the cabinet If it is necessary to remove the door liner proceed as follows 1 Turn the control to the Off position 2 Open the freezer door and remove the screws from around the door flange 3 Remove
81. or adjusted incorrectly AC circuit open to control Defrost timer Defective contacts com pleting compressor circuit are open AC circuits open to timer motor winding or contacts May be defrosting Overload protector AC circuit open to overload Defective overload Starting relay AC circuit open to coil over load does not click Defective relay Compressor motor AC circuit open to compressor Defective compressor over load may or may not click depending upon what is wrong with compressor Low line voltage overload will click on and off as unit tries to start POSSIBLE CAUSE CORRECTION Check and advise customer to call an electrician Advise customer to have defective outlet replaced Replace fuse If problem not corrected advise customer to call electrician Replace Repair or replace if necessary Refer to wiring diagrams and check circuit Replace light bulb Refer to wiring diagrams and check circuit See below Replace or adjust if necessary Refer to wiring diagrams and check circuit See below Replace Refer to wiring diagrams and check circuit Repair or replace See below Refer to wiring diagrams and check circuit Replace See below Refer to wiring diagrams and check circuit Replace See below Refer to wiring diagrams an check circuit Replace Check v
82. oss the fin and tube evaporator where it begins another cycle CHECKING OPERATION The following general information explains several methods for checking operation of the refrigeration system This information applies to all systems covered in this manual The correct operation of a refrig eration system is dependent upon the proper function of each of the parts com prising the system If the system does not operate properly long run periods warmer than normal tem peratures the trouble may be caused by one of the following conditions 1 Restricted Capillary Tube The opening of a capillary tube is about the same diameter as the period at the end of this sentence Because of this it is easy to restrict the tube Extra precautions should be taken when any service procedure in volves moving or touching the capillary tube The slightest kink can cause a com plete tube restriction Restrictions of the capillary tube may be caused by 1 moisture freeze up 2 for eign particles lodged in the tube or 3 a bend or kink If the capillary tube is restricted there will be a noticeable lack of frost on all cooling surfaces the compressor may operate for a short period of time and cycle on the overload Because some models can hold the entire charge in the condenser the com pressor may run continuously and a defi nite vacuum will be noticed in the low side When moisture freeze up causes a restric tion it usua
83. r revised pages are published it will be easy to keep the manual up to date This serivce manual is a valuable service tool and care should be taken to keep it up to date by prompt and proper filing of subsequent pages as they are issued The following models are covered in this manual ALL E MODELS ARE ENERGY MODELS AND HAVE A PREMIUM SOUND PACKAGE NOTE WHEN SERVICING E MODELS USE ONLY PARTS SHOWN FOR THAT MODEL IN THE PARTS LIST 599 513 874 EN ii 599 513 874 CONTENTS GENERAL SAFETY PRECAUTIONS ved i INTRODUCTION M lieliem n gua ii CONTENT S rcc iv SECTION 1 GENERAL INFORMATION eene nnne nennen nennen nn nnn 1 1 ELECTRICAL REQUIREMENTS 22 2 0222 nel 1 1 SAFETY zs c gie M ee ee no han 1 1 anne en 1 1 FORCED AIR SYSTEM S nen are 1 2 FLOW FORCED AIR SYSTEMS ida hant ME ti eben ae 1 2 CHECKING OPERATION zehn ne 1 3 TOOLS NEEDED FOR R134A SEALED SYSTEM REPAIR nasse 1 4 ADDITIONAL SYSTEM INFORMATION za mes 1 5 R134A SEALED SYSTEM SERVICE PROCEDURE ee 1 7 REFRIGERATION SYSTEM ee M 1 8 REFRIGERATION nee 1 9 Biel Pom 1 10 SEALED SYSTEM DIAGNOSIS xir aie aito ttt sd
84. r 7 5 seconds fill time normal Ejector blade stop position about 1 30 o clock Ejector stalls on ice 1 2 minute to 5 minutes 6 o clock position 4 4 WATER PROBLEMS Water quality can cause ice makers to fail or produce unacceptable cubes mineral content or sand is a problem the screen in the fill valve can restrict A particle of sand can keep the valve from seating properly Results will be small crescents or no ice or flooding of the ice container if the water valve does not close Mineral content can also lime up the mold causing wicking of water over the mold and poor cube release Silicone is applied at the upper edges around the fill cup and stripper TEMPERATURE PROBLEMS Temperatures in the freezer section which average above the normal 0 5 will slow the production of ice Complaints of inad equate crescent production may be cor rected by setting the freezer to a colder tem perature in this one revolution ice maker is 17 3 Obviously the ice will be well frozen when these temperatures achieved but cycling time will be slowed if the freezer temperature is not cold enough to achieve these mold temperatures easily NOTE Only the thermostat mold with heater and wiring harness are replaceable Any other failure including the motor re quires replacement of the module assem bly If you are replacing the mold assem bly it comes with a new mold heater in stalled Exter
85. r is on the outside of the cabinet Disconnect the door water line tubing Remove the top hinge cover Disconnect the door wire harness by pulling apart the two halves of the con nector DO NOT PULL THE WIRES Mark the position of the top hinge with a lead pencil Remove the ground wire screw with a 1 4 socket amp rachet Hold door with one hand and finish removing screws Leave the hinge in the door Replace the door in reverse order of removal WATER ICE FREEZER DOOR REMOVAL Lift the door up enough to allow another adult to guide the water line through the hinge pin Rest door on a non scratching surface Connector Water Line Door A To Cabinet Water Line Push collet against connector to release the door water line Mark the location of the bottom hinge with a pencil Use a 5 16 socket amp ratchet to remove the 3 screws from the bottom hinge Pull Apart Remove 3 Screws Ground Hinge Wire Screws Screw 3 5 FOUNTAIN ASSEMBLIES Manual Slide Control CRUSHED CUBE WATER ESCUTCHEON MOUNTING SCREWS Ice and Water Fountain Bracket Assembly Removal 1 Pull straight out to remove the grill from the fountain sump 2 Remove the two escutcheon mounting screws 3 Raise the escutcheon up and off the fountain assembly SLIDE SELECTOR CENTERED
86. rature control to the coldest settings reduces the flow of chilled air to the fresh food compartment The fresh food temperature control uses a sensing element that must be cooled suffi ciently before stopping the compressor The reduced air flow causes longer com pressor run time and colder freezer tem peratures while maintaining the required fresh food compartment temperatures 2 8 Conversely by turning the freezer tempera ture control to the warmest setting you in crease the flow of air into the fresh food compartment and decrease the flow to the freezer This cools the fresh food tempera ture control sensing element faster result ing in shorter compressor run times and warmer freezer compartment tempera tures The fresh food compartment will stay near the recommended fresh food tem perature unless the freezer temperature is turned to an extreme temperature The dif ferential between cut in cut out tempera ture will vary approximately 10 F Checking Operating Temperatures The temperature control feeler tube is lo cated in the fresh food compartment The feeler tube is wrapped around a thermal mass located in the back left corner of the control housing A small amount of air passes over the thermal mass which gives consistent run time during ambient changes Lead Rear of Cabinet Tape thermocouple lead at the 12 00 position on the last wrap of the capillary tube To ch
87. re plugging in power cord operating or testing follow grounding instructions in Grounding Section Electrical Service Grounding 120 VOLTS 60Hz Only IMPORTANT SAFETY PRECAUTIONS WARNING Personal Injury Hazard To prevent unnecessary risk of fire elec trical shock or personal injury all wiring and grounding must be done in accor dance with National Electrical Code and local codes and ordinances INFORMATION amp WARNING Warning Electrical 4 ground is required on this appliance Grounding Instructions This appliance is equipped with a power supply cord having a 3 prong grounding plug For your safety this cord must be plugged into a mating 3 prong type wall re ceptacle which is properly wired grounded and polarized mating wall receptacle is not available contact a qualified electrician to have the wall receptacle replaced Do not use an AC adapter plug f there is any question local building officials or electrical utility should be consulted ES Warning Do not under any circumstances re 4 move the grounding prong from the power supply cord FORCED AIR SYSTEMS On all forced air models an air circulating fan draws air from across the evaporator and directs it to the fresh food and freezer com partments A carefully measured amount of chilled air is directed into the fresh food compartment through a baffle to maintain the desired fresh food compartment tem perature The
88. rigerants However due to changes in lubricants and other internal differences the compressors are not to be interchanged otherwise system failure will result Diag nostic procedures will be the same as with the R12 refrigerant systems except that the high side pressure will be slightly higher and the low side pressure will be slightly lower If a new compressor is to be installed pull one of the plugs to ensure that it is prop erly pressurized If no pressure is observed do not use the compressor If unit is pres surized reinstall the plug and keep the com pressor sealed until it is installed and ready for solder connections Whenever the com pressor is replaced on a R134A refrigera tor the sealed system must be flushed see System Flush Procedure SYSTEM FLUSH Before accessing the sealed system it is necessary to determine that the problem is actually a sealed system problem by utilizing a wattmeter thermometer visual and touch indicators Once it has been determined that the problem is in the sealed system and diagnosis indicates a low side leak plugged capillary tube or a defective compressor in addition to the normal repair the system must be flushed and the compressor must be replaced SEALED SYSTEM REPAIR SUMMARY A Recover the refrigerant in the system if any B Repair the low side leak or replace the evaporator and heat exchanger whichever applies If the complete low side is replaced do not bra
89. s ACCESS VALVE TO CHARGING CYLINDER TO RECOVERY SYSTEM Step 3 Leave valve A closed and valve C open System compressor still running open valve B to allow refrigerant to flow into the recovery system After vacuum has been held turn off system compressor ACCESS VALVE CHARGING 1 RECOVERY CYLINDER A E B SYSTEM F X f e Step 4 Close valve B Liquid refrigerant still present to valve A and charging cylinder pressure is 30 p s i g above room ambient Open valve A to slowly allow the proper refrigerant charge into the system Close valve A If needed valve C can be closed and valves A and B opened to recover refrigerant in the hoses and charging cylinder ACCESS VALVE TO bh CHARGING CB RECOVERY CYLINDER 19 d eStep 5 Use pinch off tool to seal the process tube between the drier and the access valve Remove the access valve and braze the opening After the required five minute equalization time start the system compressor SECTION 2 COMPONENTS COMPRESSOR REPLACEMENT The following general information explains how to successfully replace compressors for any model covered in this manual All replacement compressors are charged with the correct amount of oil and a holding charge of dry nitrogen The holding charge is your assurance that the compressor is dry and ready to install If you receive a replacement compressor that shows no evidence o
90. s tem repair is made the drier must be re placed The drier on R134A systems is dif ferent using a new desiccant which pro vides system compatibility and proper moisture absorption Use of the old type drier on new R134A systems would result in a repeat sealed system failure Part num ber 13900 1 is the drier which must be used on R134A systems This drier may also be used on R12 systems and will supersede the 13900 drier but be sure that the older 13900 is WOT used on the R134A system Additionally unsoldering a joint rather than the score and break method is not ac ceptable due to the possibility of chemical and moisture contamination Always cut the drier out of the system never apply heat ADDITIONAL INFORMATION SYSTEM CAUTION Always wear eye protection and protective clothing when handling any refrigerants LIMIT TIME EXPOSURE TO THE ATMOSPHERE Whenever a sealed sys tem is repaired do not expose an open line to the atmosphere for more than 15 min utes Replacement components will come sealed by either brazing drier or plugs compressor Do not open the new drier to the atmosphere until you are ready to braze it into place Before installing a new compressor pull a plug to be sure the unit is still pressurized If no pressure exists do not use the compressor If pressure exists reinstall the plug to ensure non contamina tion during the service procedure LOW SIDE LEAKS In the event of
91. s to correct the trouble Raising the hinge side may correct a door sag DOOR ALIGNMENT The cabinet door on all models is in correct alignment when 1 The hinge side of the door is an equal distance from the cabinet flange at the top and bottom 2 Thegasketseals smoothly and is com pressed no more than 1 16 along the hinge side with the door closed 3 The door lines up with the side of the cabinet viewed from the front The door panel is parallel with the cabinet top In many cases leveling the refrigerator will eliminate the need for cabinet door adjust ments Ensure that the refrigerator is plumb by checking all edges as well as both sides of the cabinet with a carpenter s level DOOR SWITCH Disconnect the unit from the power source The door switches can be easily removed by using a flat blade screw driver or putty knife Pry from the liner and disconnect wires WATER ICE DISPENSER FREEZER DOOR REMOVAL Before attempting to remove the door hinge look at your refrigerator and note the exact number and position of all protective shims on the door hinge Later when you replace the hinge these must be positioned correctly 3 4 Disconnect the unit from the power source Open the door completely Remove the bottom hinge cover by squeezing on the bottom and top while pulling it toward you Locate the water line tubing coming out of the cabinet Carefully pull on the tub ing until the connecto
92. t the time the compressor is energized Device Replacement 1 Disconnect the unit from the power source 2 Disconnect the PTC from the compres sor terminals 3 Remove the lead wires from the PTC terminals 4 Replace the PTC and reconnect the wires to the proper terminals RUN CAPACITOR The run capacitor is mounted adjacent to the compressor It is electrically connected to the compressor circuit to provide the required phase difference between the start and run windings for running the compressor Capacitor Failures May Be Caused By 1 A Short Circuit Will cause the start windings to be energized continuously in the start mode The compressor could start but the overload protector will trip and eventually trip continu ously 2 An Open Circuit Should under normal conditions allow the compressor to start Under a heavy running load how ever the compressor will trip on the overload 3 Capacitor Low in Capacitance capacitor may lose capacitance by a loss of its electrolytic properties The com pressor would run under a light load but would trip on the overload in high ambient conditions 2 1 Testing the Capacitor EX Warning Discharge ca pacitor before handling Short across its terminals resistor with a resistance of 4 using minimum 1 000 Ohms We recommend using a capacitor analyzer when testing A solid state unit that mea sures capacitance and
93. ter Watts 550 Ohms Defrost Amps Max IET Watts PERFORMANCE TEST DATA The laboratory test data in this chart was obtained under the following conditions 1 power source of 115V 60 Hz 2 no door openings 3 no load 4 customer control s set at mid point The pres sures and wattages shown were taken during a normal running cycle b with freezer temperature near 0 F refrigerator temperature if applicable near 37 F c no sooner than 5 minutes after compressor start up In the home measurements will vary depending upon environmental and usage conditions Ambient Ambient Ambient Running Watts 145 165 6 4 23 25 Dispenser 23 Non Dispenser Maytag Premium Power Requirement Temp Contre Normal Setting Operating Amps Cut Out 2 F 10 F Max 7 2 Cut In 2 F 22 F Refrigerant Charge Fan Cooled R134A oz Capillary Tube Compressor Oil Length 103 inches Charge oz Diameter 0 028inches 1 0 Compressor Defrost thermostat BTU hr Cabinet Liner Cut 11 F Laminated Polystyrene Defrost Timer Door Liners High Impact Cycle Adaptive Defrost Cabinet amp Divider 3 Defrost Heater Insulation Foam Ohms 7 Watts ms Watts 2 75 PERFORMANCE TEST DATA The laboratory test data in this chart was obtained under the following conditions 1 power source of 115V AC 60 Hz 2 no door openings 3 no load 4 customer control s set at mid point The pres sures
94. this environment dusty or significant pet traffic in the home Refer to wiring diagrams and AC circuit to condenser fan check circuit is defective high wattage readings unit may be cycling on the overload protector Replace Compressor motor defective high wattage readings Unit may be cycling on the Replace overload protector DISCONNECT THE UNIT FROM THE POWER SOURCE CONDITION POSSIBLE CAUSE CORRECTION High resistance contacts or Check and replace broken part too many broken wire Refer to wiring diagrams and strands in compressor motor check circuit AC circuit high wattage readings unit may be cycling on the overload protector Overload protector defective normal wattage readings Replace Too much warm food placed in the unit at one time May Advise customer be cycling on overload Poor freezer door seal Adjust door or replace if Unit runs and cycles necessary Refrigerator is normal but freezer is not cold enough normal wattage readings Freezer air baffle control Reset control For proper setting too warm setting see Freezer Cold Control Room temperature too cold Advise customer Excessive freezer door Advise customer openings Too much warm food placed Advise customer in freezer at one time Few refrigerator door open Advise customer ings low usage in low ambient temperature Check for refrigerant leaks Repair or replace
95. tube could be moisture on the floor behind the refrigerator The heat from the capillary tube is utilized by the suction line to ensure that vapor rather than liquid refrigerant is re turned to the compressor If liquid is present in the suction line frost or moisture forms on the outside of the line and even tually drips to the floor LEAK TESTING Once it has been determined through proper diagnosis that a leak is present in the sealed system attempt to find the leak be fore opening the system if possible To check the high side for leaks be sure that the compressor is running During run time the high side pressure is greater To increase the pressure slightly stop the condenser fan blade or block the air flow through the condenser To check the low side for leaks stop the compressor During off times the low side pressure will increase to equalize with the high side By warming the evapo rator this pressure will increase If too much refrigerant has leaked out to create enough pressure to locate the leak add 4 ounces of the proper refrigerant to the system and proceed with the test procedure The presence of oil around a tubing joint usually indicates a leak Care must still be taken to pinpoint the exact location Re member that a leak detector compatible with R134A refrigerant must be used A sealed system component such as the evaporator or yoder loop should not be condemned unless a non repairable leak is confirm
96. ur finger CONTROL ROD SCREW DRIVER 7 CRUSHER CONTROL ROD 5 When removing the control bracket hold the clip this will prevent it from being thrown off 3 12 When removing the crusher housing position the snap ring 1 as shown in the above drawing then remove it and the retainer washer 2 Push the auger assembly away from the crusher housing using your thumb 3 To remove the auger nut turn it clockwise DISPENSER MANDIPLATE IMPELLER MANDIBALE PIN CRUSHER CONTROL ROD ACTUATED BLADES 9 Replace the parts as required The number on the blades should face the back of the auger nut Blade number 4 should be nearest to the auger nut 10 Make sure the ice diverter is aligned to the boss on the dispenser mandiplate 11 Reinstall all other components in the re verse order of removal ICE CRUSHER BIN SHELF ENCLO SURE ASSEMBLY TURN CLOCKWISE TO REMOVE DRIVE YOKE AUGER MOTOR MOUNTING SCREWS SOLENOID YOKE ASSEMBLY MOUNTING SCREWS The auger motor and solenoid are located behind the storage bin The yoke fastened to the motor engages the drive ring and turns auger in a clockwise direction Both the yoke and drive ring are designed to pre vent a loosening of the yoke by exerting counter pressure while in operation The auger motor makes one revolution ap proximately every three se
97. vidually NOTE When using the meter avoid touching the probes as this could result in a false reading and misdiagnosis To test the defrost heater and thermostat when the evaporator temperature is 15 F or below proceed as follows 1 Disconnect the unit from the power source and plug it into a watt meter 2 Plug the watt meter into power source and manually advance the defrost timer to the defrost cycle See the defrost timer section for information on manu ally advancing the timer DEFROST THERMOSTAT FOR DIAGNOSTIC CONTINUITY CHECK 240K OHMS DEFROST HEATER 3 The watt meter should read between 345 and 475 watts depending on the model total wattage of the timer mo tor and defrost heater Should the reading be 0 to 4 5 watts the defrost heater or thermostat is defective further isolate the defective part pro ceed to step 4 4 Disconnect the unit from the watt meter 5 Follow steps 2 and 3 of testing the heater and thermostat when the evapo rator temperature is 15 F or higher 6 If the meter reads approximately 240K ohms the defrost thermostat is defec tive To use an ohmmeter set the meter to R x 1K scale If the reading is approximately 20 to 40 ohms the defrost heater and thermo stat are operative WHITE ORANGE DEFROST 1 DEFROST HEATER REPLACEMENT Disconnect the unit from the power source Remove the ice maker if equipped Remove the evaporator
98. ze the suction line to the replacement compressor until the completion of Step 3 of System Flush Procedure C Proceed with the following flush procedure which includes the compressor replacement D After flushing procedure is com pleted continue with the normal sweep and final charging procedure SYSTEM FLUSH PROCEDURE 1 Isolate and flush the Condenser Score and break the discharge line at a con venient location to which the replacement compressor tubing can be connected later Attach a process tube adapter to the con denser side of this break Connect a quick coupler hand valve to the process adapter Connect the hose from the charging cylin der to this valve refer to figure 1 This con nection will remain in place throughout the flush procedure in Step 3 NOTE Due to the extra flushing and sweep charge procedures about 12 ounces of R134A refrigerant should be added to the original charge specified on the model serial plate and loaded into the charging cylinder initially Next score and break the tube at the yoder loop to the input side of the drier Attach a process tube adapter to the condenser side of this break Connect a quick coupler hand valve to this process adapter Connect the hose from the recovery equipment to this valve figure 1 Use the heater on the charg ing cylinder to ensure the cylinder pressure to be approximately 30 pounds above room ambient temperature For example if room temperature

SERVICE MANUAL REFRIGERATOR - Genuine McCulloch Spares

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