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5-12

CHECKING THE MOTOR

To check voltages* at the motor for crushed
or cubed ice operation:

1.

Open the freezer door and remove the ice
bucket from the door.

2.

Tape the door switch closed.

NOTE: When you are instructed to make a
reading at the motor connector, press the tips
of the red and black test leads into the indi-
cated harness connector slots so they touch
the bare metal wire connectors. Reach around
the front of the door and press the ice dispenser
lever to activate the dispenser switch.

* Voltage readings may vary, depending on the supply

voltage, and the type of test equipment being used.

Press The Ice
Dispenser Lever

Door Switch
Taped Closed

Pin 1

Press Tips Into
Connector Slots
Against Bare Wire
Terminals To Check
Voltages

Motor Harness
Connector

Test Leads

Electrical Shock Hazard

Voltage is present during these tests.

WARNING

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Summary of Contents for 4322658A

Page 1: ...CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R 92 JOB AID Part No 4322658A WHIRLPOOL KITCHENAID IN DOOR ICE SYSTEM ...

Page 2: ...e the Wiring Diagram supplied with the product when servicing the unit GOALS AND OBJECTIVES The goal of this Job Aid is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair the In Door Ice System The objectives of this Job Aid are to Understand and follow proper safety precautions Successfully troubleshoot and diagnose malfunctions Su...

Page 3: ...ostics 5 1 Optics Diagnostics Mode 5 1 Optics Diagnostics For Original Design Boards 5 2 Optics Diagnostics For 2002 Design Boards 5 4 Component Diagnostics Mode 5 5 Optics Diagnostics Mode Charts 5 6 Component Diagnostics Mode Chart 5 7 Troubleshooting Chart A Original Optics Design 5 8 Troubleshooting Chart B 2002 Optics Design 5 9 Troubleshooting Chart C Component Diagnostics Mode 5 10 Troubles...

Page 4: ... iv NOTES ...

Page 5: ...place all panels before operating Failure to do so can result in death or electrical shock GENERAL SAFETY FIRST Your safety and the safety of others is very important We have provided many important safety messages in this Job Aid and on the appliance Always read and obey all safety messages DANGER WARNING All safety messages will tell you what the potential hazard is tell you how to reduce the ch...

Page 6: ...ntistatic wrist strap Connect the wrist strap to the green ground connec tion point or to an unpainted metal sur face in the appliance OR Touch your finger repeatedly to a green ground connection point or to an un painted metal surface in the appliance Before removing the part from its pack age touch the antistatic bag to a green ground connection point or to an un painted metal surface in the app...

Page 7: ...per and ice level shutoff have all been redesigned Location Mounting The ice maker has been relocated to the top front of the freezer liner and has been rotated 90 Due to code requirements the ice maker heater area is now protected by a plastic PVC mounting bracket The bracket is attached to the ice maker with three mounting screws and is held in place by grooved tracks on either side of the freez...

Page 8: ... to the ice maker mold by means of a tube within a tube design A con duit system consisting of three separate pieces liner fitting conduit back panel fitting is foamed into place in the cabinet This conduit provides a pathway from the freezer liner to the back panel The majority of this system is routed above the refrigerator liner to prevent the water tubing from freezing The tubing that delivers...

Page 9: ...electronic ice level control system This system is located on either side of the freezer liner and utilizes infrared light technology to sense the level of ice in the door mounted ice container Amanual shutoff option is still available on the right side of the freezer liner This feature consists of a plastic slide that covers the receiver sensor and blocks the infrared beam Infrared Emitter Ejecto...

Page 10: ... Major changes have been made to the power train The motor has been redesigned and re located to the freezer door The cube crush selector solenoid and its related linkage have been eliminated and a drive shaft spring loaded coupling have been added Motor The motor is now located on the freezer door in a foamed in place enclosure under the dis penser bubble area of the inner door panel The motor is...

Page 11: ...d the motor drive shaft coupling will spring up and engage the ice container coupling The original designed units use a pin that rests on a spring located inside the drive shaft The newly designed units have only the spring which rests in a shallower opening at the top of the drive shaft and eliminates the need for the pin On newly designed models the hex drive shaft coupling has a skirt around it...

Page 12: ...2 6 NOTES ...

Page 13: ...t of the diagnostic All other system en hancements are transparent during the ice making system operation The new ice making system consists of the fol lowing an ice maker with an integrated con trol module an electronic ice level sensor an external water valve and a freezer door com partment mounted ice storage bin The ice maker control module is a stamped circuit that provides power and control ...

Page 14: ...3 2 NOTES ...

Page 15: ...ce Bin Motor Drive Coupling Ice Container Auger Coupling Hex Drive Shaft Motor Infrared Emitter Water Fill Nozzle Ice Maker Infrared Receiver Freezer Door COMPONENT ACCESS COMPONENT LOCATIONS Ice Maker Door ...

Page 16: ...he spring loaded emitter door and open the ice maker door g If you are completely removing the ice maker unplug the wiring harness connector from the ice maker c Push the ice maker door to the left so that the right pin disengages from the pivot arm then lift the pin out of the pivot and remove the left pin Emitter Door Open Emitter Door Closed d Remove the wire shield screw from the bottom of the...

Page 17: ...l nozzle out of the fitting in the top of the freezer liner then continue to pull the rest of the tube out of the liner It will require some force to remove the first foot or so of tube from the liner NOTE If the fill tube has water frozen inside it will be necessary to melt the ice before removing the tubing otherwise the tub ing will tear when it is removed Follow step 4 to melt the ice If the f...

Page 18: ... not twist the tube and nozzle assembly Pull the end of the tube at the rear of the unit to take up any slack NOTE The end of the tube may get caught on the fitting at the back of the unit If this hap pens position the tube in the center of the hole with a small screwdriver and push the tube the rest of the way through from the front Pull Tube Out Here Fitting Rear of Unit Water Nozzle c Install a...

Page 19: ...move the three screws from the mod ule 3 To remove the receiver module a Open the freezer door b Remove the three screws from the mod ule c Pull the module out and remove the connector from the board c Pull the module out and remove the connector from the board Connector Connector Emitter Module Screw 1 of 3 REMOVING THE EMITTER RECEIVER MODULES Screw 1 of 3 Electrical Shock Hazard Disconnect powe...

Page 20: ...otor terminals f Pull the hex drive shaft out of the mo tor Press To Release Screw 1 of 4 Harness Connector Motor Housing Cover REMOVING REINSTALLING THE MOTOR e Remove the four screws from the mo tor bracket and allow the motor to drop down Motor Dropped Electrical Shock Hazard Disconnect power before servicing Replace all panels before operating Failure to do so can result in death or electrical...

Page 21: ...r is designed to fit only one way on the motor termi nals e Position the motor housing cover so that the raised center faces the motor and mount it in place with the two screws you removed earlier f Make sure that the spring and pin are in the center hole of the hex drive shaft and that the bearing and seal are prop erly positioned on the coupling as shown Push Down On Coupling g Position the coup...

Page 22: ...ice container is installed They will engage as soon as the ice dis penser is activated At that time the motor will turn and the spring loaded coupling on the end of the hex drive shaft will pop up and engage the ice container coupling you will hear a snap when the coupling pops up and engages Couplings Engaged Couplings Not Aligned Motor Coupling Depressed Motor Coupling Snaps Up ...

Page 23: ...the unit from the electrical supply 2 Pull out and unclip the drip tray on the ice and water dispenser compartment Drip Tray ACCESSING THE SELECTOR SWITCH PACK DISPENSER SWITCHES Selector Switch Pack Ice Dispenser Switch Electrical Shock Hazard Disconnect power before servicing Replace all panels before operating Failure to do so can result in death or electrical shock WARNING ...

Page 24: ...4 10 NOTES ...

Page 25: ...ther the optics circuits are operating properly If the optics circuits are malfunctioning the ice maker will not operate The optics system consists of an emitter board and a receiver board The emitter board trans mits a beam of infrared light that is detected by the receiver If the beam of light is inter rupted the ice maker will not operate The optics system can have one of two types of optics bo...

Page 26: ...then to view the LED output code U Shaped Cutout Infrared Emitter Beam Ice Level Freezer Door Light Switch If you observe two LED pulses flashes per form the following steps 1 Open the freezer door and remove the ice bin from the door 2 Make sure the ice maker manual shutoff slide is in the on open position 3 Tape the spring loaded emitter door to the emitter cover in the down position 4 Close the...

Page 27: ...e 60 seconds to openthefreezerdoor and2secondsfrom then to view the LED output code If the LED still flashes twice there could be dirt or frost on the optics something could be blocking the infrared beam path or the optics may be defective Clean the optic elements and repeat the previous test If the LED does not flash the ice maker may have been in a harvest preventing the diag nostics from being ...

Page 28: ...r switch If the LED does not flash as described above the original style optics boards may be installed Perform the steps shown in Chart A on page 5 6 3 Check the ice maker manual shutoff slide and make sure that it is in the ON open position on the infrared receiver module Emitter Module 4 Close the flapper door on the emitter mod ule so that the infrared beam has a clear path to the receiver boa...

Page 29: ...er immediately after the water fill 11 With the freezer door closed reconnect the power 12 Wait for a minimum of 5 seconds and a maximum of 50 seconds then open the freezer door and view the status LED for the output codes as shown in Chart C on page 5 7 NOTE The optics must be working properly to test the ice maker If the optics test fails you will not be able to force a harvest and check the ice...

Page 30: ...nutes after the ice maker begins a harvest cycle To reset the control wait until the ice maker parks then unplug the refrigerator for 5 seconds and repeat the test While the control board is running self checks Reset the control as above 2 The ice maker control must be in the ON position 3 The ice bin must be on the door and the ice level below the notched openings STEP STATUS LED POSSIBLE CAUSES ...

Page 31: ...atch the water fill during step 8 8 Disconnect power immediately after the water fill STEADY LIGHT for 5 seconds indicates the relay and optics are okay and the receiver senses the ice maker NO LIGHT Unplug the refrigerator for 5 seconds and repeat the test 3 PULSES repeated once indicates the optics and relay are okay but the ice maker is not being sensed or will not operate If this happens COMPO...

Page 32: ...is in harvest cycle Wait 5 minutes until harvest cycle is complete and retest LED was not viewed within 2 seconds of opening freezer door Retest and view LED within 2 seconds of opening freezer door Freezer door was not closed for a minimum of 5 seconds before starting test Close freezer door wait for at least 5 seconds and retest Incorrect wiring at emitter or receiver board Correct wiring and re...

Page 33: ... Replace emitter and receiver boards and retest No LED pulses Ice maker is in 5 minute harvest cycle To verify press in on door switch Status LED should flash at 1 second intervals Incorrect wiring at emitter or receiver board Correct wiring and retest Optics performing self tests will not perform diagnostic tests during this time Make sure ice maker is parked Unplug refrigerator for 5 seconds to ...

Page 34: ...etest Optics check not run before testing ice maker Run optics test and recheck ice maker Freezer door not closed after Optics test Close freezer door to start harvest Optics path not clear Clear optics path Optics test failure Replace emitter and receiver boards and retest Ice maker is unplugged Plug ice maker in Thermal fuse in ice maker harness is open Replace ice maker harness Wiring harness o...

Page 35: ...ear inside motor as sembly 3 Motor starts but heats rapidly a 2 3 5 4 Motor runs too hot after extended opera tion a 3 4 6 9 5 Reduction in power motor overheats a 2 5 6 6 High no load speed 30 RPM is nominal a 2 7 Excessive noise mechanical a 2 7 8 8 Jerky operation severe vibration a 2 1 Open circuit in connection to line e g house fuse is blown or motor is defective 2 Defective motor 3 Overload...

Page 36: ...ted harness connector slots so they touch the bare metal wire connectors Reach around the front of the door and press the ice dispenser lever to activate the dispenser switch Voltage readings may vary depending on the supply voltage and the type of test equipment being used Press The Ice Dispenser Lever Door Switch Taped Closed Pin 1 Press Tips Into Connector Slots Against Bare Wire Terminals To C...

Page 37: ...eter s black test lead to wire harness pin 6 and the red test lead to pin 7 then press the ice dispenser lever The meter should read 115 VDC 10 6 Press the Crushed ice button on the ice and water dispenser front panel 7 Touch the DC meter s black test lead to wire harness pin 1 and the red test lead to pin 2 then press the ice dispenser lever The meter should read 115 VDC 10 8 Press the Cube ice b...

Page 38: ...t should turn on If the light does not turn on a Check switch pack pins BU BK and YL BK using an AC voltmeter The meter should read 115 VAC if the switch is open or 0 VAC if the switch is closed b Disconnect the BU BK and YL BK wires from the Light switch terminals Check the switch continuity with an ohmme ter The continuity should change when the Light switch is pressed on and off 2 The Locked Un...

Page 39: ... dis penser switch pack continuity tests All of the tests are performed with power disconnected from the unit and the wires disconnected from the terminals of the switch under test d Touch the DC voltmeter s black test lead to RD WH and the red test lead to BR WH then press the ice dispenser lever The meter should read 115 VDC 10 Electrical Shock Hazard Disconnect power before servicing Replace al...

Page 40: ...in place SERVICING THE HARNESS MOTOR CONNECTOR Both the motor connector and the wire harness are serviceable To remove a wire from the motor connector 1 Use a small screwdriver or knife and lift the wire retainer tab far enough to slide the wire terminal out of the connector Electrical Shock Hazard Disconnect power before servicing Replace all panels before operating Failure to do so can result in...

Page 41: ...cked position 2 The dispenser has a built in inverter board which converts the 115 VAC to 115 VDC The OR BU wire is the positive side of the DC signal and the PK BK wire is the negative side The BR WH and RD WH wires switch polarity depending on the crushed cubed switch position see the following table BR WH RD WH Crushed Cubed WIRING DIAGRAMS STRIP CIRCUITS ...

Page 42: ... The dispenser has a built in inverter board which converts the 115 VAC to 115 VDC The OR BU wire is the positive side of the DC signal and the PK BK wire is the negative side The BR WH and RD WH wires switch polarity depending on the crushed cubed switch position see the following table BR WH RD WH Crushed Cubed ICE DISPENSER MOTOR SEE NOTE 2 ...

Page 43: ...Light Interlock Switch Dispenser Lock Switch Crushed Ice Selection Ice Lever Switch BK BU BK GY BU OR BU PK BK BR WH RD WH Voltage Rectifier Bridge Converts 115 VAC to 115 VDC Motor CCW Rotation L1 N Light Interlock Switch Dispenser Lock Switch Cubed Ice Selection Ice Lever Switch BK BU BK GY BU OR BU PK BK BR WH RD WH ...

Page 44: ...6 4 NOTES ...

Page 45: ...ction in Cubed mode and dispenser lock switch in Locked position 2 The dispenser has a built in inverter board which converts the 115 VAC to 115 VDC The OR BU wire is the positive side of the DC signal and the PK BK wire is the negative side The BR WH and RD WH wires switch polarity depending on the crushed cubed switch position see the following table BR WH RD WH Crushed Cubed ICE DISPENSER MOTOR...

Page 46: ...re is the positive side of the DC signal and the PK BK wire is the negative side The BR WH and RD WH wires switch polarity depending on the crushed cubed switch position see the following table 2 Trace the circuit for the cubed ice operation by closing the necessary switches Refer to the Wiring Diagram NOTES at the bottom of the page BR WH RD WH Crushed Cubed ICE DISPENSER MOTOR SEE NOTE 2 L1 To L...

Page 47: ...R READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR LITERATURE ORDERS PHONE 1 800 851 4605 IN CANADA FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL 1 800 461 5681 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL THE TECHNICAL ASSISTANCE LINE 1 800 488 4791 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR WHIRLPOOL PRODUCTS 1 800 253 1301 FOR KITCHENA...

Page 48: ...CORPORATION ...

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