GE ESS22 Series Technical Service Manual Download

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Summary of Contents for ESS22 Series

Page 1: ...PUB 31 9071 02 01 MODEL SERIES TECHNICAL SERVICE GUIDE GE Consumer Home ServicesTraining General Electric Side by Side Knob Control Metal Liner Refrigerator GSS20 GSS22 GSS25 ESS22 ESS25 HSS22 HSS25 SSS25 ...

Page 2: ...personal injury disconnect power before servicing this product If electrical power is required for diagnosis or test purposes disconnect the power immediately after performing the necessary checks RECONNECT ALL GROUNDING DEVICES If grounding wires screws straps clips nuts or washers used to complete a path to ground are removed for service they must be returned to their original position and prope...

Page 3: ...rating Characteristics Operating Characteristics 7 7 7 7 7 General Locator Views General Locator Views General Locator Views General Locator Views General Locator Views 13 13 13 13 13 Mechanical Disassembly Mechanical Disassembly Mechanical Disassembly Mechanical Disassembly Mechanical Disassembly 15 15 15 15 15 Diagnostics Diagnostics Diagnostics Diagnostics Diagnostics 32 32 32 32 32 Component a...

Page 4: ... The freezer fresh food controls are temperature setpoint type and have settings of 0 9 with 9 being the coldest temperature possible The new NO CLEAN condenser is serviceable from the rear and is designed to prevent the customer from having to clean the condenser in normal usage conditions Sealed system operation and compressor are functionally the same as previous models with some minor changes ...

Page 5: ...grounded When disconnecting the power cord from the adapter always hold the adapter with one hand If this is not done the adapter ground terminal is very likely to break with repeated use Should this happen DO NOT USE the appliance until a proper ground has again been established USAGE SITUATIONS WHERE THE APPLIANCE S POWER CORD WILL BE DISCONNECTED FREQUENTLY Do not use an adapter plug in these s...

Page 6: ... 4 Specifications ...

Page 7: ...INTERIOR SHELVES B NON DISPENSER ICE MAKER READY D CUBED ICE WATER E CUBED CRUSHED ICE WATER F 6 MO FILTER CUBED CRUSHED ICE G 1 YR FILTER CUBED CRUSHED ICE I IN LINE FILTER INDICATOR C C W ICEMAKER EXTERIOR WW WHITE WHITE AA ALMOND ALMOND BB BLACK BLACK CC BISQUE BISQUE WH WHITE BLACK AD ALMOND BLACK EXTERIOR COLOR S SIDE BY SIDE REF CONFIGURATION 20 22 25 CU FT VOLUME M 2001 MODELYEAR A INIITIAL...

Page 8: ... Centers or an authorized Customer Care technician r e v o C t o N l l i W E G t a h W f O d o i r e P e h T r o F e c a l p e R l l i W E G r a e Y e n O l a n i g i r o e h t f o e t a d e h t m o r F e s a h c r u p t r a p y n A n i t c e f e d a o t e u d s l i a f h c i h w r o t a r e g i r f e r e h t f o s i h t g n i r u D p i h s n a m k r o w r o s l a i r e t a m y t n a r r a w r a e...

Page 9: ...efrost 8 Cooling Operation Adaptive Defrost 8 Pre Chill Operation Adaptive Defrost 8 Defrost Heater Operation Adaptive Defrost 9 Dwell Period Adaptive Defrost 9 Post Dwell Adaptive Defrost 9 Liner Protection Mode 9 Dispensing Functions 9 Dispenser Light 9 Dispenser Lock 10 Filters 10 Hinge System and Door Closure 10 Airflow Cabinet Interior 11 Jelly Roll Condenser 11 Main Control Board 12 ...

Page 10: ...sary In order to accomplish the correct defrost cycle time the main control board monitors the following refrigerator operations Length of time the refrigerator doors were open since the last defrost cycle Length of time the compressor has run since the last defrost cycle Amount of time the defrost heaters were on in the last defrost cycle Adaptive Defrost is divided into 5 separate cycles Those o...

Page 11: ... minutes on these models Liner Protection Mode The liner protection mode will activate if either of the doors have been open for 3 minutes This mode will start the evaporator fan and close the damper This mode is controlled by 2 timers Timer 1 monitors door open time A 3 minute door open count begins when the door is opened If 3 minutes elapse before the door is closed the liner protection mode wi...

Page 12: ...ed with a water filter located in the upper right hand corner of the fresh food compartment The filter is designed to be used for up to 8 hours of open valve time or 1 year of calendar time When 90 of filter time dependant on model has elapsed open valve time or calendar time whichever comes first the main control board will illuminate the filter reminder LED amber When 100 of the filter time has ...

Page 13: ... and rear left and exits out front right side of refrigerator Airflow Cabinet Interior The freezer compartment is designed so that when the evaporator fan is operating air is drawn into the bottom of the air tunnel and through the evaporator The cold air is then pushed out into the top of the freezer The fresh food compartment receives chilled air via an electronic damper positioned at the top rea...

Page 14: ...1 J6 K7 PAN HTR K6 WATER AUGER K1 C CR K2 K4 COMP J4 1 8 J7 DEFROST COOLING PRE CHILL DEFROST HEATER ON TIME MINUTES COMPRESSOR RUN TIME MINUTES ACCUMULATED FF AND FRZ DOOR OPENINGS MINUTES THERMISTOR INPUTS ENCODER INPUTS MODEL SELECT COMMUNICATION INPUT OUTPUT DAMPER COILS FAN OUTPUTS DOOR SWITCH INPUTS COMPRESSOR DEFROST OUTPUTS AND INPUTS OUTPUTS PROCESSING UNIT ...

Page 15: ...tion Tech Data Sheet Location Temperature Controls Temperature Controls Damper Damper Fresh Food Thermistor Fresh Food Thermistor Freezer Light Switch Freezer Light Switch Evaporator Fan Evaporator Fan Evaporator Thermistor Evaporator Thermistor Evaporator Evaporator Freezer Thermistor Freezer Thermistor ...

Page 16: ...n Control Board Jelly Roll Condenser Jelly Roll Condenser Compressor Compressor Capacitor Capacitor Overload Overload and Relay under cover Overload and Relay under cover Condenser Fan Condenser Fan Water Water Solenoids Water Solenoids ...

Page 17: ...oor Adjustment 18 Control Panel 18 Fresh Food Light 19 Freezer Door Light Switch 19 Water Filter Cartridge 19 Shelves 20 Drawers and Bins 20 Door Shelf Extenders 21 Freezer Light 21 Icemaker 21 Ice Dispenser Drive 22 Evaporator Fan 22 Defrost Heater and Freezer Thermistor 23 Overtemperature Thermostat and Evaporator Thermistor 24 ...

Page 18: ...ontrol Panel 24 Door Dispenser Target Switch 24 Ice Crusher 25 Ice Dispenser Drive Motor 25 Ice Cube Solenoid 26 Evaporator 26 Condenser Fan 27 Dispenser Heater 27 Main Control Board 28 Roller Assembly 28 Water Solenoid 28 Fresh Food Air Damper 29 ...

Page 19: ...x screws from the upper and lower ends of the handle 3 Remove the handle Doors and Door Hinges IMPORTANT The freezer door is not adjustable The fresh food door can be adjusted up and down to match the height of the freezer door Adjust the fresh food door up or down using the hinge adjustment pin located on the fresh food lower door hinge The fresh food and freezer lower door hinges are equipped wi...

Page 20: ... riser from the lower hinge 11 Freezer Door Only Remove the cam riser and washer from the lower hinge 12 Remove 2 screws and lower hinge from cabinet Fresh Food Door Adjustment IMPORTANT The refrigerator rollers must be adjusted correctly to ensure proper door closure Refer to the Roller Assembly section in this chapter for more information The freezer door is not adjustable The fresh food door ca...

Page 21: ...er light cover removal is covered in the previous procedure 1 Remove the lower light cover by lifting it off the dowels 2 Remove 2 40 watt appliance light bulbs Freezer Door Light Switch The freezer door light switch is located on the left of the freezer compartment 1 Slide a small flat blade screwdriver under the switch and push the locking tab Pull out the switch 2 Disconnect the harness connect...

Page 22: ...ter Cartridge Cartridge Water Filter Cartridge Shelves The slide out and Spillproof shelves allow access to items stored behind other items Spillproof shelves have special edges to help prevent spills from dripping onto lower shelves The QuickSpace shelf splits in half and slides under itself to allow for storage of tall items on the shelf below To adjust this shelf 1 Tilt the shelf up until the t...

Page 23: ...m the locking device 2 Pull out the shelf extender GEA00876 Freezer Light The freezer light is attached to the evaporator fan housing 1 Remove the light cover by lifting it off the tabs 2 Replace the appliance light bulb Icemaker The icemaker is located in the rear of the freezer compartment The icemaker must be replaced as a complete unit 1 Slide out the upper icemaker dispenser tray and drawer 2...

Page 24: ...rews 3 Screws Ice Dispenser Drive The ice dispenser drive turns the ice dispenser auger in either crushed or cube mode 1 Remove 2 Phillips screws from the ice dispenser drive 2 Slide the dispenser out until the cable connector is visible 3 Disconnect the cable and remove the dispenser drive GEA00882 2 Screws 2 Screws Evaporator Fan The evaporator fan located in the upper portion of the freezer com...

Page 25: ...an GEA00885 Heater Wiring Harness Heater Wiring Harness Heater Wiring Harness Defrost Heater and FreezerThermistor The defrost heater warms the evaporator during the defrost mode of operation The freezer thermistor located at the bottom left side of the freezer compartment senses the temperature in the freezer 1 Complete steps 4 and 5 in the previous procedure 2 Remove 2 Phillips screws from the d...

Page 26: ...e top left senses the compartment temperature 1 Disengage the plastic track by sliding upward and remove the housing 2 Remove the thermistor from the housing GEA00976 Thermistor Thermistor Track Cover Thermistor Track Cover Slide upward to remove to remove Slide upward to remove Door Dispenser Control Panel The door dispenser control panel allows the consumer to select water crushed ice or ice cub...

Page 27: ...ispenser cover GEA00920 Screws Screws 8 Slide the back cover off the auger The back cover must be replaced because of tabs broken off for disassembly 9 With a flat head screwdriver remove the C clip from the end of the auger 10 Remove the auger and ice crusher blade assembly Ice Dispenser Drive Motor The ice dispenser drive motor turns the auger in the crushed or cube mode 1 Remove the ice dispens...

Page 28: ...dispenser tray and assembly see page 21 2 Remove 2 Phillips mounting screws 3 Pull out the motor 4 Disconnect the wire connectors 5 Remove the ground wire to the ice cube solenoid 6 Disconnect the wire connectors GEA00695 Solenoid Solenoid Solenoid Motor Motor Motor Ground Ground Wire Wire Ground Wire 7 Remove 2 solenoid mounting screws 8 Slide the solenoid out of the housing Evaporator Air is dri...

Page 29: ...or the condenser coil 1 Remove the machine compartment access cover 2 Remove 1 screw from the condenser fan mounting bracket GEA00895 Screw Screw 3 Entire fan motor bracket and shroud assembly can be pulled out 4 Remove 2 screws from the condenser fan cover 5 Pull out the fan until the electrical connector is exposed 6 Disconnect the electrical connector GEA00725 Electrical Connector Electrical Co...

Page 30: ...table and replaceable 1 Unsnap the base grille from the bottom of the unit 2 Remove the guide pin with a flat head screwdriver IMPORTANT To ensure proper door closure the refrigerator rollers must be adjusted to level the refrigerator This is different from previous models GEA00898 Adjusting Screw Adjusting Screw Guide Pin Guide Pin Guide Pin Roller Roller 3 Turn the adjusting screw counterclockwi...

Page 31: ...ted in the upper left corner of the fresh food compartment The damper opens to allow cold air to circulate from the freezer to the fresh food compartment 1 Remove 2 damper cover screws 2 Remove the damper cover 3 Using a flat head screwdriver remove the damper assembly from the mullion divider until the wire connector is exposed 4 Disconnect the motor wire connectors 5 Damper will be replaced as a...

Page 32: ... 30 Notes ...

Page 33: ... 31 Notes ...

Page 34: ...stic Chart 41 Fresh Food Too Cold Freezer Normal Diagnostic Chart 42 Refrigerator Dead No Sound No Cooling Diagnostic Chart 43 Evaporator Fan Not Running Diagnostic Chart 44 Condenser Fan Not Running Diagnostic Chart 45 Damper Door Not Operating Diagnostic Chart 46 Compressor Not Running Diagnostic Chart 47 Heavy Frost On Evaporator Diagnostic Chart 48 Thermistor Values Table 2 49 Efficient Use of...

Page 35: ... i s e r h g i H r o t s i m r e h t t n e m t r a p m o c d e s o l c r e p m a D e r u l i a f n a f r o t a r o p a v E e r u l i a f h c t i w s r o o D y t l u a f d r a o b l o r t n o c n i a M y t l u a f s s e n r a H k a e l t e k s a g r o o D n e p o r o o D l a m r o N e l c y C t i e h n e r h a F 4 1 d n a 4 1 n e e w t e b l a m r o N e l c y C t i e h n e r h a F 3 3 d n a 9 4 n e...

Page 36: ...NINGS MINUTES THERMISTOR INPUTS ENCODER INPUTS MODEL SELECT COMMUNICATION INPUT OUTPUT DAMPER COILS FAN OUTPUTS INPUTS PROCESSING UNIT 1 Tan 2 13VDC Red 3 Blk DC Common 4 Violet 5 Wht 1 Blu Yel 2 Wht Brn 3 Red Blk 4 Yel 1 Not Used 2 Yel Blu Band 3 Wht Blu Band 4 Brn PERSONALITY PIN NONE 20 Cu Ft Pin 8 22 Cu Ft Pin 9 25 Cu Ft 5 5VDC Blu Wht J4 J2 J3 J1 8 Red 13VDC 7 Not Used 6 Not Used 5 Yel 4 Yel ...

Page 37: ... Used 6 Violet 7 Red 8 Blk 9 Orn GEA00905 PAN_HTR AUGER N DFZ DFF OCH COMMON WATER CRUSHER QC K5 DEFROST K3 L1 COMP DEFR LINE 2 1 J6 K7 PAN HTR K6 WATER AUGER K1 C CR K2 K4 COMP J7 DEFROST COOLING PRE CHILL DOOR SWITCH INPUTS COMPRESSOR DEFROST OUTPUTS AND OUTPUTS PROCESSING UNIT ...

Page 38: ... C D V 5 y l p p u s r o t s i m r e h T C D V 5 e g a t l o v C D V 5 3 n i p 4 J o t 5 n i p 1 J 2 J 1 e u l B n a f r o t a r o p a v E r e t e m o h c a t C D V 3 6 3 n i p o t 1 n i p 2 J 2 J 2 d e s u t o N d e s u t o N d e s u t o N 2 J 3 n o m m o c C D e t i h W n o m m o c n a F C D V 2 1 8 n i p o t 3 n i p 2 J 2 J 4 k c a l B w o l l e Y n a f r o t a r o p a v E C D V 4 2 1 3 n i p o...

Page 39: ...n i p 4 J o t 3 n i p 3 J C D V 0 6 e g a t l o V g n i l e v a r T 3 J 4 w o l l e Y r e p m a D 3 n i p 4 J o t 4 n i p 3 J C D V 0 6 e g a t l o V g n i l e v a r T 4 J 1 n a T d r a o b r e s n e p s i D n o m m o c e v i e c e r t i m s n a r t c i t a m e h c s e e S 4 J 2 d e R d r a o b r e s n e p s i D n o m m o c C D V 3 1 c i t a m e h c s e e S 4 J 3 n o m m o c C D k c a l B d r a o ...

Page 40: ...t a W 0 2 1 9 n i p 7 J o t 3 n i p 7 J C A V 7 J 4 y a r G k c o l r e t n i r o t o m r e g u A C A V 0 2 1 9 n i p 7 J o t 4 n i p 7 J t u h s r o o d r e z e e r f 7 J 5 d e s u t o N d e s u t o N d e s u t o N 7 J 6 t e l o i V t h g i l r o o d d o o f h s e r F k c a b d e e f h c t i w s C A V 0 2 1 9 n i p 7 J o t 6 n i p 7 J n e p o r o o d d o o f h s e r f 7 J 7 d e R h c t i w s t h ...

Page 41: ...ck sealed system Does system check okay Unit tests OK Run checks again Reset electronics by unplugging Reset electronics by unplugging Reset electronics by unplugging Reset electronics by unplugging refrigerator for 15 seconds refrigerator for 15 seconds refrigerator for 15 seconds refrigerator for 15 seconds Look for usage problem Repair sealed system No No Yes Yes Yes Yes Yes Yes Look for blocka...

Page 42: ...he freezer normal Yes Look for blockage at vents or heavy frost on evaporator cover No Blockage Go to Heavy Frost on Evaporator Flowchart page 48 Check sealed system Does system check ok Yes Repair sealed system Remove blockage from evaporator cover vent area No Yes Unit tests OK Run checks again Reset electronics by unplugging Reset electronics by unplugging Reset electronics by unplugging Reset ...

Page 43: ...evaporator cover No Blockage Go to Heavy Frost on Evaporator Flowchart page 48 Check sealed system Does system check ok Yes Repair sealed system Remove blockage from evaporator cover vent area No Yes Unit tests OK Run checks again Reset electronics by unplugging Reset electronics by unplugging Reset electronics by unplugging Reset electronics by unplugging refrigerator for 15 seconds refrigerator ...

Page 44: ...art Go to Damper Not Operating Flowchart Go to Damper Not Operating Flowchart Go to Damper Not Operating Flowchart page 46 Damper should be closed when FF temperatures are too cold No Verify thermistors are within proper range using temperature resistance chart on page 49 Is the resistance within range Yes Check wiring connections If wiring is OK replace thermistor No Unit tests OK Run checks agai...

Page 45: ...ontrol board Check for 12 VDC at control board pins J2 3 to J2 8 Do you have voltage Yes Check wiring connections If wiring is OK replace thermistor Unplug encoder temperature control harness Does the refrigerator start once the harness is unplugged Yes Replace encoder board temperature control Yes No Unplug J4 connector from main control board Check for 12 VDC at control board pins J4 2 to J4 3 D...

Page 46: ...r both No No Yes Yes Unplug refrigerator to reset main control board Warm freezer thermistor to 70 F and set temperature controls to 5 and 5 Reconnect power Replace evaporator fan motor Repair wiring between main control board and evaporator fan motor Replace main control board NOTE NOTE NOTE NOTE When no voltage at main control board make certain to check for shorted fan motor less than 1K ohm be...

Page 47: ...or both No No Yes Yes Unplug refrigerator to reset main control board Warm freezer thermistor to 70 F and set temperature controls to 5 and 5 Reconnect power Replace condenser fan motor Repair wiring between main control board and condenser fan motor Replace main control board NOTE NOTE NOTE NOTE When no voltage at main control board make certain to check for shorted fan motor less than 1K ohm bet...

Page 48: ...ave 6VDC between pins J4 3 common and each of the pins J3 1 J3 2 J3 3 and J3 4 you have 10 seconds to check Unplug harness connector at damper Measure resistance between the yellow and red black wires and between the white brown and blue yellow wires Do you measure approximately 420 ohms for both readings Replace main control board Replace damper Yes Verify thermistors are within proper range usin...

Page 49: ...ls to 5 and 5 Is the compressor running Adjust settings and allow 24 hours to stabilize Yes Check for 120VAC at connector J7 9 orange wire to TERMINAL J8 black wire Do you have 120VAC Replace compressor Yes No Check wiring to compressor overload relay Yes Replace main board No No Direct test the compressor Did it start ...

Page 50: ...9 Is there approximately 22Ω Verify thermistors are within proper range using temperature resistance chart on page 49 Is the resistance within range No Yes No Replace main board Check wiring connections If wiring is OK replace thermistor Check wiring harness Check defrost heater Check defros safety thermostat First always check door ajar customer usage numerous door openings etc Yes ...

Page 51: ...t a r e p m e T F s e e r g e D o l i K n i e c n a t s i s e R s m h O 0 4 0 4 k 8 6 6 1 Ω 5 3 1 3 k 5 0 2 1 Ω 0 3 2 2 k 8 8 Ω 5 2 3 1 k 5 6 Ω 0 2 4 k 4 8 4 Ω 5 1 5 k 4 6 3 Ω 0 1 4 1 k 6 7 2 Ω 5 3 2 k 1 2 Ω 0 2 3 k 3 6 1 Ω 5 1 4 k 7 2 1 Ω 0 1 0 5 k 0 1 Ω 5 1 9 5 k 8 7 Ω 0 2 8 6 k 2 6 Ω 5 2 7 7 k 5 Ω 0 3 6 8 k 4 Ω 5 3 5 9 k 2 3 Ω 0 4 4 0 1 k 6 2 Ω 5 4 3 1 1 k 2 2 Ω 0 5 2 2 1 k 8 1 Ω 5 5 1 3 1 k 5 ...

Page 52: ...16 Evaporator Fan Evaporator Fan Defrost Thermostat Thermostat Defrost Thermostat Light Light Evaporator Thermistor Thermistor Evaporator Thermistor Evaporator Evaporator Defrost Heater Defrost Heater Freezer Thermistor Thermistor Freezer Thermistor ...

Page 53: ... 51 GEA00913 Fresh Food Light Switch Fresh Food Light Switch Fresh Food Thermistor Fresh Food Thermistor Damper Damper Fresh Food Lights Fresh Food Lights ...

Page 54: ...n Control Board Jelly Roll Condenser Jelly Roll Condenser Compressor Compressor Capacitor Capacitor Overload Overload and Relay under cover Overload and Relay under cover Condenser Fan Condenser Fan Water Water Solenoids Water Solenoids ...

Page 55: ... CRUSHER QC K5 DEFROST K3 L1 COMP DEFR LINE 2 1 J6 K7 PAN HTR K6 WATER AUGER K1 C CR K2 K4 COMP J7 DEFROST COOLING PRE CHILL DOOR SWITCH INPUTS COMPRESSOR DEFROST OUTPUTS AND OUTPUTS PROCESSING UNIT NOTE Refer to the Main Control Board Locator Tables in the Diagnostics chapter for more information Main Control Board 120 VAC Side ...

Page 56: ...VAP THERMISTOR FZ THERMISTOR FF DC AC BROWN BROWN BROWN BROWN BROWN ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE ORANGE BROWN OVERLOAD COMPRESSOR RELAY WHITE CAPACITOR BLACK VIOLET VIOLET ORANGE VIOLET VIOLET FF SWITCH FRESH FOOD LIGHT TOP FRESH FOOD LIGHT S MID FREEZER LIGHT FREEZER DOOR INTERLOCK GRAY AUGER INPUT WHITE WHITE WHITE RED R...

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Page 58: ...Personality Input 2 Pin 7 Personality Input 3 Pin 8 Personality Input 4 Pin 9 Damper Blue J3 Pin 1 Damper White Pin 2 Damper Red Pin 3 Damper Yellow Pin 4 FF Encoder Select Pin 5 Comm Tx Rx J4 Pin 1 Comm 12V Pin 2 Comm Common Pin 3 Discrete Disp Input 1 Pin 4 Discrete Disp Input 2 Pin 5 FZ Encoder Select Pin 6 Encoder Signal Pin 7 Encoder Signal Pin 8 Encoder Signal Pin 9 Encoder Signal Pin 10 Pin...

Page 59: ... 57 Notes ...

Page 60: ... 58 Illustrated Parts Catalog ...

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GE ESS22 Series, Technical Service Manual

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