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CONSUMER SERVICES TECHNICAL

EDUCATION GROUP PRESENTS

R-101

JOB AID

Part No. 8178501A

FAST FILL

DISPENSER

SYSTEM

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Summary of Contents for 8178501A

Page 1: ...CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R 101 JOB AID Part No 8178501A FAST FILL DISPENSER SYSTEM ...

Page 2: ...s used in this Job Aid are typical and should be used for training purposes only Always use the Wiring Diagram supplied with the product when servicing the unit GOALS AND OBJECTIVES The goal of this Job Aid is to provide information that will enable the service technician to properly diagnose malfunctions and repair the Fast Fill Dispenser System The objectives of this Job Aid are to Understand an...

Page 3: ...r System Overview 2 1 COMPONENT ACCESS 3 1 Component Locations 3 1 Removing The Water And Ice Dispenser Components 3 2 Removing The Freezer Door Dispenser Supply Harness And Water Tube 3 8 Removing The Smart Valve 3 10 Removing The Freezer Door 3 11 COMPONENT TESTING 4 1 Ice Door Motor 4 1 Water Ice Pad Switches 4 1 IDI Motor 4 2 Smart Valve Coils 4 2 DIAGNOSTICS TROUBLESHOOTING 5 1 Diagnostics 5 ...

Page 4: ... iv NOTES ...

Page 5: ...hat can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING These words mean All safety messages will tell you what the potential hazard is tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed You can be killed or seriously injured if you don t immediately follow instructi...

Page 6: ...OOR CAPACITY CUBIC FOOT SIZE 6 26 MODEL SERIES N FAST FILL MODEL FEATURES MODEL CODE E ENERGY STAR DOOR SWING X SxS YEAR OF INTRODUCTION R 2005 COLOR CODE B BLACK Q WHITE ON WHITE S STAINLESS STEEL Y GREY STAINLESS STEEL ENGINEERING CHANGE DIGITS 00 01 02 03 ETC SERIAL NUMBER S S 21 12345 MANUFACTURING SITE S Fort Smith AR YEAR OF PRODUCTION S 2005 WEEK OF PRODUCTION 21ST WEEK PRODUCT SEQUENCE NUM...

Page 7: ...SCHEME SERIES T CONTOURED DOORS F FORMED DOORS N FLAT DOORS CAPACITY CUBIC FOOT SIZE MODEL FEATURES YEAR OF INTRODUCTION R 2005 COLOR CODE BL BLACK WH WHITE SS STAINLESS STEEL ENGINEERING CHANGE DIGITS 00 01 02 03 ETC SERIAL NUMBER S S 21 12345 MANUFACTURING SITE S Fort Smith AR YEAR OF PRODUCTION S 2005 WEEK OF PRODUCTION 21ST WEEK PRODUCT SEQUENCE NUMBER ...

Page 8: ...1 4 MODEL SERIAL NUMBER LABEL LOCATIONS WHIRLPOOL MODEL KITCHENAID MODEL Model Serial Number Label Refrigerator Compartment Model Serial Number Label Refrigerator Compartment ...

Page 9: ...ded by a Whirlpool designated service company Whirlpool Corporation or Whirlpool Canada LP will not pay for 1 Service calls to correct the installation of your refrigerator to instruct you how to use your refrigerator to replace house fuses or correct house wiring or plumbing to replace light bulbs or replacement water ﬁlters other than as noted above 2 Repairs when your refrigerator is used in ot...

Page 10: ...ement parts to correct defects in materials or workmanship in the sealed refrigeration system These parts are compressor evaporator condenser dryer and connecting tubing KitchenAid or KitchenAid Canada will not pay for 1 Service calls to correct the installation of your refrigerator to instruct you how to use your refrigerator to replace house fuses or correct house wiring or plumbing to replace l...

Page 11: ... Area The core control is attached to the dispenser housing and controls the dispenser motor ice door motor dispenser housing and ice door heaters The core control also monitors the condition of the freezer door switch and provides the 14 volt DC power supply for the user interface and smart valve Water and ice can not be dispensed while the freezer door is open The user interface provides custome...

Page 12: ...rily jammed open the door this will ensure it does not stay open indeﬁnitely A re quest to fully open and then close the door is also made immediately when power is applied or restored to the refrigerator Ice Door And Housing Heaters The housing heater is a 120 volt AC 2 25 watt heater Service doors for refrigerators with stainless steel door skins will have additional zone heaters to reduce moist...

Page 13: ...f measure are selected 2 The volume of water requested is en tered 3 The water keypad is pressed or the water dispenser activation pad is held closed 4 The user interface receives the signal 5 The user interface signals the smart valve 6 The smart valve then energizes the water valve solenoid with 120 volts AC and us ing the ﬂowmeter sends a signal for the amount of water as it is dispensed to the...

Page 14: ...nals the core control on P1 2 which direction to run the auger 4 The core control outputs the square wave to the ice door motor for approximately 1 second and at the same time the IDI motor is energized on P2 1 and P2 2 with 120 volts DC 5 When dispensing has stopped the ice door will remain open for 10 seconds and then power is applied for approximately 1 second to close the door Operation Defaul...

Page 15: ...y Side Refrigerator The components and their locations are shown below COMPONENT ACCESS User Interface Board Dispenser Light Assembly Ice Pad Switch Water Pad Switch Ice Door Motor Water Nozzle IDI Motor Core Board Smart Valve Dispenser Cover Assembly Dispenser Unit Compartment Dispenser Supply Harness Water Tube ...

Page 16: ...gerator or disconnect power 2 Pull the dispenser drip tray out as far as it will go then press down to release the catch pull the tray out all the way and remove it from the dispenser 3 Removethetwoscrewsfromthedispenser cover assembly 5 Disconnect the dispenser cover 3 wire connector from the user interface board and the ground wire connector from the ground wire harness 4 Pull out at the bottom ...

Page 17: ...m the ﬁtting see the top right photo d Release the two clips and pull the nozzle ice guide out just far enough to remove the motor wires and connec tor then remove the ice door assembly from the dispenser e Remove the two screws from the motor and remove the motor from the ice door assembly housing Ice Door Motor Screws Ice Door Motor Continued on the next page Motor P5 Ice Door Assembly Ice Door ...

Page 18: ...release button and slide the pad switch clips off the dispenser cover assembly Back Of Dispenser Cover Assembly Water Ice Pad Switch Connectors 8 To remove an ice or water pad switch a With the back of the dispenser cover assembly facing up press the release tabinonthewireconnector andpullthe connector off the user interface board pins c Remove the pad switch assembly Slide Pad Switch Up To Diseng...

Page 19: ... penser cover assembly User Interface Dispenser Light Assembly Connector Back Of Dispenser Cover Assembly With Board Removed Continued on the next page Push Out Tab Pull Out Dispenser Light Assembly Lift Locking Tabs Lift Ribbon Cable 9 To remove the user interface board a With the back of the dispenser cover assembly facing up disconnect the ice and water pad switch connectors b Disconnect the us...

Page 20: ...the IDI motor housing h Remove the three screws from the IDI motor housing and remove the motor and housing from the dispenser c Remove the two screws from the hex drive shaft coupling holder and remove the coupling assembly d Lift the spring and hex drive shaft up and out of the door i Remove the four screws from the IDI motor and remove the motor from the housing IDI Motor Screw 1 of 4 Connector...

Page 21: ... from the ﬁtting b Pull out on the locking clip and remove it from around the quick disconnect c Removethecoverfromthewaternozzle housing d Unclip the water nozzle and remove it from the housing Water Nozzle Housing Cover Water Nozzle Water Nozzle Housing Cover Housing Water Tube Locking Clip Quick Disconnect Housing Clip ...

Page 22: ...orsP1and P7 from the core board d Disconnect the ground wire screw Harness Connector e Grasp the ends of the harness wires ﬁrmly and pull the harness up and out of the channel opening in the freezer door Harness Channel Opening 4 To remove the dispenser water tube a Turn off the water supply to the refrig erator b Place a towel or a small container to catch any water when you disconnect the water ...

Page 23: ...o drain into the container or onto the towel d Push down on the blue quick discon nect locking ring and pull the water tube from the ﬁtting Dispenser Water Tube e Pull the water tube out of the freezer door channel and remove the tube Quick Disconnect Water Tube Nozzle Quick Disconnect Pull Water Tube Out Through Opening ...

Page 24: ...Cover 6 Place a towel or a small container to catch any water when you disconnect the water supply tubing 7 Pushdownonthequick disconnectlocking rings and pull the water inlet ice maker and dispenser outlet water tubes from the ﬁttings 8 Disconnect the smart valve wire connec tors from the smart valve and remove the smart valve assembly Smart Valve Screws Water Inlet Tube Smart Valve Wire Connecto...

Page 25: ...lves 6 Close the freezer door Harness Tubing Disconnects Door Water Tube Quick Disconnect 7 Usingascrewdriver pryoutontheharness connector locking tab and disconnect the harness connector from the unit 8 Place a towel or a small container under the freezer door hinge to catch any water in the tubing when it is disconnected 9 Push down on the blue quick disconnect locking ring and pull the door wat...

Page 26: ...d re move the hinge IMPORTANT DO NOT remove the tap plate retainer screw inside the center hinge cutout 12 Partially open the freezer door and lift it off the bottom hinge pin Guide the wires andtubingthroughthehingeopening and remove the door Remove 3 Hinge Screws Do Not Remove Tap Plate Retainer Screw Lift Door Off Bottom Hinge Pin Remove Wires Tubing ...

Page 27: ...r 2 Disconnect the water and ice pad switch connector from the user interface board 3 Set the ohmmeter to the R x 1 scale 4 Touch the ohmmeter test leads to the pad switch connector pins and press the pad The meter should indicate less than 175 Ω Before testing any of the components perform the following checks The most common cause for control failure is corrosion on connectors Therefore dis conn...

Page 28: ...ILS Refer to page 3 10 for the procedure for ac cessing the smart valve 1 Unplug refrigerator or disconnect power 2 Unsnap and remove the cover from the smart valve housing 3 Set the ohmmeter to the R x 10 scale 4 Touch the ohmmeter test leads to either coil connector The meter should indicate between 240 and 280 Ω Ice Maker Coil Red Dispenser Coil Green Cover 5 4 3 2 1 Electrical Shock Hazard Dis...

Page 29: ...the previous step by pressing the FILTER RESET button 5 All buttons and pads are inoperative ex cept for those described in the actions for each step 6 The diagnostics charts shown on the fol lowing pages describe each component that is tested 7 If communication is lost with the dispenser core control board steps 10 14 will display on digits 1 3 8 If communication is lost with the smart valve cont...

Page 30: ...5 2 WHIRLPOOL MODELS ...

Page 31: ...5 3 KITCHENAID MODELS ...

Page 32: ...5 4 MODULAR ICE MAKER ICE LEVEL DETECTOR MODELS ...

Page 33: ... Ice Water Dispenser Is Operating Normally Page 5 8 4 Ice Maker Does Not Produce Enough Ice Page 5 8 5 Water Cannot Be Dispensed Ice Maker Is Operating Normally Page 5 9 6 Measured Fill Is Not Accurate Page 5 10 7 Water Dispenser Fill Is Too Slow Page 5 10 8 Dispenser Lighting Does Not Operate Page 5 11 9 Dispenser Lighting Does Not Operate Correctly In The Auto Mode Page 5 11 10 Dispenser Lightin...

Page 34: ... diagnostics Check for normal operation Part Passes Replace user interface board Go to diagnostics on page 5 1 then to step 5 on page 5 2 or 5 3 and press the ice pad Go to diagnostics on page 5 1 then to step 5 on page 5 2 or 5 3 and press the ice pad Part Fails Replace ice pad Door does not open Status is not correct Go to diagnostic step 14 Replace core control board Replace ice door motor B In...

Page 35: ...BK YL wire between smart valve and core control board Replace core control board Replace filter Repair water supply YES NO YES NO Check for correct water supply to refrigerator Is supply correct Check the grill filter Does water dispense with filter removed Check smart valve for 14 vdc across RD YL BK YL wires Is reading correct Check core control board across RD YL BK YL wires Is reading correct ...

Page 36: ...s Repair or replace ice maker 3 ICE MAKER DOES NOT PRODUCE ICE WATER DISPENSER IS OPERATING NORMALLY Verify freezer temperature is 5 F or colder Ice production will be slow from 10 F to 15 F and will stop at around 18 F Ice maker should be in the park 2 00 position Voltage will be present on the tan wire of the ice maker for 7 to 8 seconds during harvest just before it reaches the park position Th...

Page 37: ...is pressed Digits 2 3 do not display 34 when water button is pressed Digits 1 2 3 display decimal number for software version Digits 1 2 3 display decimal number for software version Check ribbon cable connections P4 and P5 on user interface board Tighten connections Digits 2 3 display 34 when water button is pressed Digits 2 3 do not display 34 when water button is pressed Digits 1 2 3 display Di...

Page 38: ...essure or water plumbing leaks Make sure that no leaks occur in the following locations Door Spigot Door Elbow Joint Water Tank Smart Valve Water Dispenser Outlet Smart Valve Ice Maker Fill Outlet Smart Valve Inlet Customer Connection Filter Inlet Outlet If no leaks are found replace the smart valve 7 WATER DISPENSER FILL IS TOO SLOW Verify proper refrigerator water supply Water filter is blocked ...

Page 39: ...Press the light button to exit diagnostics Go to diagnostics step 7 Replace user interface touchpad 8 DISPENSER LIGHTING DOES NOT OPERATE Use this diagnostics procedure in the event that the dispenser night light never turns on 9 DISPENSER LIGHTING DOES NOT OPERATE CORRECTLY IN THE AUTO MODE Use this diagnostics procedure in the event that the dispenser lighting does not operate correctly when set...

Page 40: ...lace user interface board Reseat connectors retest Replace user interface touchpad Unit operates properly 12 USER INTERFACE DISPLAY INDICATORS DO NOT OPERATE CORRECTLY Includes fragmented digits on display or LED indicators that do not operate If the user interface display is completely blank make sure that power is applied to the refrigerator Disconnect user interface connector P1 and measure the...

Page 41: ...condensation will be normal during high humidity conditions especially on the ice door Replace core control board Replace freezer door assembly Unit operates Press Ice Mode Cubed button until digit 3 displays 1 Digit 3 displays 0 heater is off YES NO Remove connector at core control board P3 and measure resistance across heater leads Is resistance present 120 vac is present on core control board P...

Page 42: ...5 14 NOTES ...

Page 43: ...6 1 WHIRLPOOL MODELS WIRING DIAGRAM 1 Color Code See A On Wiring Diagram 2 See B On Wiring Diagram 2 WIRING DIAGRAMS ...

Page 44: ...6 2 WIRING DIAGRAM 2 A B ...

Page 45: ...6 3 SCHEMATIC DIAGRAM 1 Color Code ...

Page 46: ...6 4 SCHEMATIC DIAGRAM 2 ...

Page 47: ...6 5 KITCHENAID MODELS WIRING DIAGRAM 1 See A On Wiring Diagram 2 See B On Wiring Diagram 2 Color Code ...

Page 48: ...6 6 WIRING DIAGRAM 2 A B ...

Page 49: ...6 7 SCHEMATIC DIAGRAM 1 Color Code ...

Page 50: ...6 8 SCHEMATIC DIAGRAM 2 ...

Page 51: ...RIZED SERVICER IN CANADA FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL 1 800 461 5681 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL THE TECHNICALASSISTANCE 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 KITCHENAID PRODUCTS 1 800 422 1230 FOR ROPER PRODUCTS 1 800 447 6737 FOR LITERATURE ORD...

Page 52: ...CORPORATION ...

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