UD-19 SERVICE UPDATE FIRST HALF 2001 Home Appliances Prepared by: WHIRLPOOL CONSUMER LOYALTY PART NO. 8178023
foreword The following service update information is provided to make you more knowledgeable about Whirlpool, Roper, and KitchenAid major appliances. Service update information is designed for the experienced service specialist. It keeps you advised of the most recent improvements and product changes, and allows you to service these products more efficiently. Table Of Contents PRODUCT INTRODUCTIONS... Page 1 Laundry... Page 1 Calypso-Match Dryer Model GE/GW9200K... Page 1 Long Vent Dryer Model LE/GV4634J... Page 9 Refrigeration... Page 10 Whirlpool 2001 ACQ Model Electronic Control Air Conditioners All QL Serial Codes... Page 10 2001 Electronic Control Dehumidifier Models AD40LBK, AD50LBK, AD60LBK, & AD65LBK0... Page 14 Genie Replenishment Management System... Page 16 PRODUCT UPDATES... Page 17 Refrigeration... Page 17 Whirlpool In-Door Ice Refrigerator Revised Diagnostics... Page 17 All Remanufactured Warranty Products... Page 19 KitchenAid Built-In (KABI) Refrigerators With Electronic Controls & Variable Capacity Compressor... Page 19 Side-By-Side Refrigerator With Adaptive Defrost Control & Water Filter Indicator (ADC/WFI)... Page 20 Servicing The Adaptive Defrost Control... Page 21 Compactors... Page 22 Gear Adjustment When Replacing The Motor/Gear... Page 22 SERVICE POINTER INDEX... Page 23 WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE OTHER THAN WHIRLPOOL AUTHORIZED SERVICE SPECIALISTS. Copyright 2001 Whirlpool Corporation, Benton Harbor, MI
PRODUCT INTRODUCTIONS LAUNDRY Calypso-Match Dryer Model GE/GW9200K THEORY OF OPERATION The Calypso-Match Dryer is based on the 27 platform. For additional information on the Whirlpool 27 design, refer to Job Aid #4322260. Control Panel CYCLE DESCRIPTIONS Automatic Cycles The automatic cycles use a moisture sensor to detect the surface conductivity of the clothes. There are five dryness levels that can be selected. Refer to the Default Settings table for the valid default settings for each. Drying temperatures are determined by the automatic cycle selected and cannot be changed. For any of the automatic cycles, the total time of the cycle is dependent upon the load size and moisture content. The maximum allowable cycle time for any of the automatic cycles is 150 minutes. This time includes the add-on time and COOL DOWN, but does not include WRINKLE SHIELD, which is up to an additional 120 minutes. A cycle must be selected before any automatic cycle can be modified. The automatic cycle keys are not valid once the cycle has been started. During an automatic cycle, the 7-segment display will show an estimated time until the add-on portion of the cycle. At that point, the Estimated Time LED will turn off, and the actual time will be displayed. Add-On-Time Add-On-Time is an additional timed portion added to the automatic cycle when the sensor can no longer detect the small levels of moisture remaining in the clothes load. The Add-On-Time is necessary to complete the drying cycle to the dryness level selected. The Add-On-Time is variable and is based on the overall drying time and moisture reduction performance during the cycle. Soft Heat Soft heat is the Extra Low temperature setting used in the last five minutes of a timed cycle. Soft heat is not used in the automatic cycles. 1
Cool Down The time-based cool down time for automatic cycles varies from two to ten minutes, depending on the load size, moisture content, and dryness level selected. For timed cycles, the cool down time depends on the total drying time the user selects. Wrinkle Shield The WRINKLE SHIELD action tumbles the load without heat for 10 seconds of every 5 minutes after the drying cycle is complete. WRINKLE SHIELD will continue for a maximum of 120 minutes (2 hours). If the door is opened and the PAUSE/CANCEL key is pressed once, the control will enter the pause mode and pressing the START key with the door closed will restart the WRINKLE SHIELD operation. If the 120 minute time limit expires, the WRINKLE SHIELD action terminates, the CYCLE SIGNAL is then sounded, (if selected), and the control removes power from the motor and LEDs. Pressing the WRINKLE SHIELD key while in WRINKLE SHIELD mode also terminates WRINKLE SHIELD. In essence, deselecting WRINKLE SHIELD after the main cycle has completed simply turns the dryer off. SALES DEMONSTRATION MODE The Sales Demonstration Mode allows sales personnel to quickly demonstrate the cycles and options on the sales floor. The mode consists of an embedded software routine which resides in the main dryer program which is defined as follows: 1. Open the dryer door. 2. Press the Touch Up cycle. 3. Select Air Only temperature. 4. Press Wrinkle Shield. 5. Press Start. The sequence of operation is as follows: The Sensing LED turns on for 5 seconds and then turns off. The Wet LED turns on for 5 seconds and then turns off. The Damp LED turns on for 5 seconds and then turns off. The Drying & Cool Down LED turns on for 5 seconds and then turns off. The Cycle Complete and Wrinkle Shield LEDs turn on, and the End-Of-Cycle signal sounds at the selected level. Terminate the Sales Demonstration mode by pressing the Stop/Cancel keypad. 2
DEFAULT CYCLE SETTINGS Automatic Cycles CYCLE 1, 2 EXHAUST TEMP 3 AUTO DRY TIME/ OPTIONS / MODIFIERS (LED TEMP) TRIP / RESET DRYNESS DEFAULT Heavy Duty 155 F / 145 F 39 minutes, Normal Dry (High) Auto Dry Level factory default is Towels / Cotton Normal Dry, retain the last used setting 155 F / 145 F 45 minutes, Normal Dry (High) on a per-cycle basis Normal Wrinkle Shield factory default is 150 F / 138 F 34 minutes, Normal Dry (Medium Dry) On for the Casual cycle, and Off for all Bulky Items other cycles, retain the last used setting 140 F / 128 F 60 minutes, Normal Dry (Medium) on a per-cycle basis Casual Cycle Signal factory default is 125 F / 115 F 36 minutes, Normal Dry (Low) Softer, retain the last used setting per Delicate run. 115 F / 105 F 22 minutes, Normal Dry (Extra Low) Notes: 1) Temperature is not user-adjustable in automatic cycles. 2) Some automatic cycles may start at a higher temperature and then adjust to the displayed temperature later in the cycle. 3) The default temperatures are for reference only. The actual temperature is adaptive and variable and may not fall within the ranges listed. Timed Cycles CYCLE TIME TEMPERATURE OPTIONS / MODIFIERS Timed Dry 45 minutes factory default Medium factory default, user Auto Dryness Level only available user selectable, retain last selectable, retain last setting in automatic cycles setting per run per run Wrinkle Shield factory default Off, Rack Dry 60 minutes default, user Air default, user selectable, retain last used setting on a per-cycle selectable, not retained not retained basis, not available in Rack Dry cycle Touch Up 20 minutes default, user Medium High default, user Cycle Signal factory default is Softer, selectable, not retained selectable, not retained retain last used setting per run Notes: TIMED CYCLES - Default times and temperatures are selectable. WRINKLE SHIELD - Selectable in all cycles except Rack Dry. A valid user input results in one (1) BEEP. An invalid user input results in three (3) beeps. 3
COMPONENT ACCESS CONSOLE COMPONENTS 1. Disconnect the power supply to the dryer. 2. Use a putty knife and push in on the spring clips at each corner of the console, as shown. 3. Lift the console front up and rotate it back. All components in the console are now accessible for service. Putty Knife IMPORTANT SERVICING POINTS Electrostatic Discharge (ESD) Sensitive Electronics Do not open the package containing the Electronic Printed Circuit Board until it is time to install it. ESD may damage or weaken the electronic board. Use an antistatic wrist strap. Connect the wrist strap to a green ground connection point or unpainted metal on the appliance. OR Touch your finger repeatedly to a green ground connection point or unpainted metal on the appliance. Avoid touching electronic parts or terminal contacts; handle the electronic board by the edges only. 4
Removing The Electronic Control Board The Electronic Control Board is located in the center of the console area. 1. Disconnect the two (2) wiring harness plugs and two (2) ribbon connectors from the electronic control board. Wiring Harness Connectors Ribbon Connectors 5
COMPONENT TESTING & DIAGNOSIS SERVICE DIAGNOSTIC TESTS The control must be in the STANDBY state before pressing the keypads to initiate the diagnostic tests. To start the test routine, press the following keypads, in sequence, within 5 seconds: 1. More Time 2. Less Time 3. More Time 4. Less Time Once in the diagnostics, the following events will occur: All the LEDs will turn on and 88 will appear on the display. If the model identifier diodes in the keyswitch do not match the configurations in the Model Identifiers Table, an E3 error message will appear on the display. Make sure the correct control board is installed before continuing. Pressing the corresponding keys will turn off each LED and sound a beep (volume is Loud). When opening the door, the dryer will beep and the display will show a number, followed by a capital E for electric or lower case g for gas. The first number will be 7 for Whirlpool models. Open the door. Each actuation of the door switch will sound a beep. Short the moisture strips. The dryer will beep and the display will show a 2- digit software revision code. Press the Start key. The heater and motor turn on, and the display reads a 2- digit project identification code. The code for this project is 00. Press the Stop/Cancel key to exit the diagnostics. KEYPAD MATRIX TOUCHPAD + LEAD LEAD Heavy Duty P3-14 P3-11 Towels / Cotton P3-14 P3-9 Normal P3-13 P3-11 Bulky Items P3-13 P3-10 Casual P3-12 P3-11 Delicate P3-12 P3-10 More Dry P3-14 P3-8 Less Dry P3-14 P3-7 Timed Dry P3-13 P3-9 Rack Dry P3-14 P3-10 Touch Up P3-12 P3-9 Temp P3-12 P3-8 Cycle Signal P3-12 P4-2 Wrinkle Shield P3-13 P3-8 More Time P3-13 P3-7 Less Time P3-12 P3-7 Stop / Cancel P3-13 P4-2 Start P3-14 P4-2 6
ERROR CODES DISPLAY EXPLANATION PF (Power Failure) If the household power goes off and the control was in RUN mode or PAUSE mode, the electronic control board will display a power failure error code. To resume operation from where the last cycle was interrupted, press the START keypad. To switch to STANDBY mode, press the STOP/CANCEL keypad. (Thermistor Failure) The dryer will not run if the exhaust temperature drops below 18 F or exceeds 250 F. E1 When the thermistor circuit is open (>50K Ω), the error code E1 flashes in the display. E2 When the thermistor circuit is shorted (<500 Ω), the error code E2 flashes in the display. NOTE: During a cycle, if the error condition is detected, the control delays action one (1) minute for the start of the cycle to allow temperatures to get into the allowable range. During diagnostics, the error is displayed immediately. If the START keypad is pressed, an invalid tone will sound, and the dryer will remain in PROGRAM mode. The dryer will not start until the failed thermistor is replaced. E3 (Keyswitch or Flashes when there is a keyswitch or software mismatch. NOTE: This error code Software Mismatch) is displayed only in the diagnostics mode. THERMISTOR RESISTANCE TEST TEMPERATURE RESISTANCE F K (1000) Ω 50 19.9 60 15.3 70 11.9 80 9.2 90 7.4 100 5.7 110 4.7 120 3.7 130 3.1 140 2.5 7
TECH TIPS WIRING DIAGRAMS Electric Dryer L1 Line - Black 240 Volts L2 Line - Red 120 Volts White - Neutral N BK Black DL Drum Lamp P1-1 L1 Brown DOOR NEUTRAL P1-3 P1-4 White Blue D2 Neutral Terminal Linked to Cabinet Door Switch USER INTERFACE P3 P4 MOTOR PT-1 MOIST. MOIST. RTN MODEL P1-2 Grn/Yel P2-1 SENSOR P2-2 P2-3 Blue Thermal Fuse 196 F Blue Sensor MOVS 4M Belt Switch Main 2.4-3.6 Start 2.4-3.6 Drive Motor 1/3 H.P. White 3M 5M 4M Centrifugal Switch 2M 1M N.O. COM Heater Relay MODEL RTN TEMP TEMP RTN P2-4 P2-5 P2-6 Thermistor 10K Ω ±3% ELECTRONIC CONTROL N.C. P2-7 N.C. Red Black Red/White Hi Limit Red Thermostat Thermal 250 F Heater Cutoff 7.8-11.8 Ω (TCO) 350 F or 360 F Gas Dryer L1 Line - Black Black Black USER INTERFACE Drum Lamp P1-1 N.O. COM DL L1 P3 P4 Heater Relay ELECTRONIC CONTROL Brown DOOR NEUTRAL MOTOR PT-1 MOIST. MOIST. RTN MODEL MODEL RTN TEMP TEMP RTN P1-3 P1-4 P1-2 P2-1 P2-2 P2-3 P2-4 P2-5 P2-6 N.C. P2-7 120 Volts Grn/Yel SENSOR Black Red/White Blue White Blue Thermistor 10K Ω ±3% TF1 Red Sensor MOVS Thermal Fuse 196 F TF2 Red 4M HS1 White - Neutral N Belt Switch Main 2.4-3.6 Start 2.4-3.6 Drive Motor 1/3 H.P. Valve MOV N.C. Hi Limit Thermostat HS2 205 F D2 D White D1 Door Switch 5M White L2 Line - Red 3M 6M Black 1V 1G 1GR Ignitor 50-500 Ω 2 1 1 3 Hold Assist 4 5 Main Valve #1 Valve #2 FS1 FS2 Flame Sensor 22,000 BTU/HR 8
Long Vent Dryer Model LE/GV4634J The Long Vent Dryer uses technology similar to the Easy Clean 100 Lint Storage Dryer. A pulley and belt attached to the end of the drive motor (see the photo below) steps up the speed of the blower to twice the standard speed. This increases the air pressure in the exhaust to allow for substantially longer exhaust vent lengths. The chart below shows the relation of the duct length to the number of bends. NUMBER OF 4 RIGID DUCT 90 BENDS LENGTH (FT.) 0 120 1 105 2 95 3 85 4 75 5 65 To maintain the current volume of air, (150 CFM), an air flow controller has been added to the outlet of the lint chute (see the photo). Air Flow Controller 9
REFRIGERATION Whirlpool 2001 ACQ Model Electronic Control Air Conditioners All QL Serial Codes NOTE: This does not apply to QLL serial codes. THEORY OF OPERATION Model 2001 ACQ air conditioners will have electronic controls and be shipped with an infrared remote control. The control will operate in one of the following four modes: AUTO COOL FAN ONLY ENERGY SAVER When changing modes, the LED indicator will change immediately, but there will be a 3-second delay before the new mode is activated. This will allow the user to step through the FAN ONLY mode without turning off the compressor. TEMPERATURE CONTROL The control panel (see the photo) will display temperatures from 64 F to 86 F, and can be set in 1-degree increments. To change the display from Fahrenheit to Celsius, turn the unit on while pressing both the MODE and FAN SPEED keypads at the same time. After a power failure has occurred, the control will default to Fahrenheit. 10
AUTO The Auto mode will change fan speed automatically, based on the room temperature. If the room temperature is greater than 10 degrees above the user setting, the control will use the TURBO fan speed. From 6 to 10 degrees above the user setting, the fan speed will be HIGH. When the room temperature is less than 6 degrees above the user setting, the fan speed will be LOW. COOL During the Cool mode, the fan will operate continuously, and the compressor will cycle to maintain the selected room temperature. FAN ONLY During the Fan Only mode, the fan will operate at Turbo speed, and the display will read FO. ENERGY SAVER During the Energy Saver mode, both the fan motor and the compressor will cycle on and off. When the desired room temperature is reached, the compressor will cycle off, and the fan will turn off after a 2-second delay. When cooling is needed, the fan will turn on, and the compressor will start after a 2-second delay. TIME DELAY Time delay allows the consumer to start or stop the unit at a delay of 1 to 24 hours. The delay time is set with the Up or Down keypads in 1-hour increments. To cancel the TIME DELAY mode, press and hold the timer button for 3 seconds. POWER INTERRUPTION When the unit experiences a power interruption during operation, it will return to operation in the same mode, speed, temperature, and timer setting, when power is restored. CONTROL DEFAULTS The following chart shows the operating characteristics of the unit if the thermistor is defective. When the temperature is set, as indicated in the chart, Condition 1 will occur, and be followed by Condition 2. These two conditions will repeat until the thermistor is replaced. This will apply to the AUTO, COOL, and ENERGY SAVER cycles. TEMPERATURE SETTING ( F) 64-70 71-77 78-86 CONDITION 1 Compressor On Fan On for 20 minutes Compressor On Fan On for 20 minutes Compressor On Fan On for 15 minutes CONDITION 2 Compressor Off Fan On for 5 minutes Compressor Off Fan On for 10 minutes Compressor Off Fan On for 10 minutes 11
DIAGNOSTIC MODE The Diagnostic mode will test all of the LEDs, the keypads, and the thermistor. To enter the diagnostic mode, start with the unit in the Off position, and press: UP, DOWN, TIMER ON/OFF, FAN SPEED, MODE, and POWER ON/OFF, all within 7 seconds. All of the LEDs will light indicating that all keypads are functional, and that you are in Step 1. It will not be possible to enter the Diagnostic mode if a keypad is defective. There is a 5-minute maximum time for the Diagnostic mode before the control returns to a cooling mode. To advance to the next step, always use the UP keypad. If other keypads are pressed the unit will turn Off. To return to the Diagnostic mode, repeat the 6-keypad sequence. Diagnostic Mode Chart NOTE: To Advance To The Next Step, Press The UP Keypad. Step Component Number Tested Description 1 2 3 LEDs Thermistor Compressor All LEDs will be lit, except for the display. All LEDs will turn off and the display will light to indicate the thermistor temperature reading. Warming the thermistor will change the reading. An open thermistor will read FF indicating a temperature above 140 F. A shorted thermistor will read 00 indicating a temperature below 32 F. The COOL LED will light and the compressor will run for 20 seconds, or until advanced to the next step. The display will read 88 until the end of the Diagnostic Mode. 4 Fan Motor The TURBO LED will light and the fan will run TURBO Speed on Turbo speed. 5 Fan Motor The HIGH LED will light and the fan will run on HIGH Speed High speed. 6 Fan Motor The LOW LED will light and the fan will run on LOW Speed Low speed. 7 Exit Press the UP keypad to exit the Diagnostic Mode. 12
REMOVING THE SHIPPING SCREW FROM ALL 2001 SLIDE-OUT CHASSIS AIR CONDITIONERS 1. Remove the front panel from the air conditioner. 2. Remove shipping screw (A) from the side of the cabinet. 3. Remove the ground screw and the ground wire from the front of the air conditioner base and slide the air conditioner out of the cabinet. 13
2001 Electronic Control Dehumidifier Models AD40LBK, AD50LBK, AD60LBK, & AD65LBK0 THEORY OF OPERATION Electronic controls will be introduced on 2001 model dehumidifiers (see the photo below). The electronic control, thermistor, humidistat, and bucket switch will control all operations of the dehumidifier. The control will operate in one of the following modes: Low, High, Auto Dry, or Continuous. AUTO DRY MODE The Auto Dry mode will automatically change the fan speed based on the relative humidity in the room. If the relative humidity is 7% or more above the customer settings, the unit will switch to the fan s high speed. When the relative humidity level drops below 5% above the customer setting, the unit will switch to the fan s low speed. CONTINUOUS MODE In the Continuous mode, the fan will run at high speed. The compressor will not cycle unless the unit enters a low temperature condition, or when the bucket is full, or is removed. GENERAL OPERATING CHARACTERISTICS When the unit is turned off, or if power is interrupted, the control will remember the previous mode and humidity setting, and resume at that point when operation is resumed. When the bucket is removed, or is full, the bucket switch will open, the compressor and fan will turn off, and the red Empty/Adjust Bucket LED will light. When the empty bucket is installed, the bucket switch will close, and normal operation will be resumed. 14
When the humidistat calls for operation, the fan will switch on immediately, and the compressor will start after a 6-second delay. When the humidity setting has been reached, the compressor will turn off, and the fan will continue to run for an additional 2 seconds. If the compressor is switched off by the control, or by the bucket switch, the control will not allow a compressor restart for a minimum of 3 minutes, to protect the compressor. If either the humidistat or thermistor fails, the control will default to the fail-safe condition. Until the failure is corrected, the fan will run continuously, and the compressor will cycle on for 30 minutes, and off for 10 minutes. If the thermistor registers a temperature lower than 30 F for a period of 30 minutes, the compressor will switch off for 10 minutes, and the fan will continue to run. This condition will repeat until the room temperature rises above 30 F. DIAGNOSTICS Perform the following steps to enter the diagnostic mode: 1. Disconnect the power to the dehumidifier for a minimum of 5 seconds. 2. Remove the bucket from the unit. NOTE: In the next step, you will have 5 seconds to press the three keypads after applying power. If you do not press the keypads within the allowable time, the red EMPTY/ADJUST LED will light to indicate that the unit has returned to normal operation. You will have to repeat the diagnostics if this occurs. 3. Reconnect the power to the dehumidifier and press the following three keypads in the order shown. RIGHT LEFT ON/OFF All three keypads must be operational to enter the diagnostic mode. You will have 15 minutes to complete the diagnostic routine before the unit returns to normal operation. Step 1 LED test: All LEDs should be on or flashing. Press the RIGHT arrow keypad to continue. Step 2 Control Memory, Thermistor, & Humidity Sensor test: This step uses the humidity LEDs to display the output, starting with the far left LED. If there is a failure, the appropriate LED will flash: 1st LED: Control Board Memory. 2nd LED: Humidity Control. 3rd LED: Temperature Sensor. 4th LED: Bucket Switch. The LED should be flashing to indicate an open bucket switch. Insert the bucket and press the LEFT keypad to retest the switch. The LED will go out, indicating a closed switch. Press the RIGHT arrow keypad to advance to step 3. Continued on the next page 15
Step 3 Motor Speed, Low & LOW LED: The fan should be running in the low speed mode. Press the RIGHT arrow keypad to continue. Step 4 Motor Speed, High & HIGH LED: The fan should be running in the high speed mode. Press the RIGHT arrow keypad to continue. Step 5 Compressor & CONTINUOUS LED: The compressor will start and run regardless of the temperature or humidity input until the end of the test. The fan motor will continue at high speed. To exit the diagnostic mode, press the ON/OFF keypad. Genie Replenishment Management System The Genie Replenishment System is a refrigerator-mounted management system that consists of a computer, modem, hand-held scanner, and a thermal printer. The customer can use the hand-held scanner to scan the UPC codes of any product to create one or more shopping lists. The lists can be printed with the thermal printer, or sent via the internet to a participating retail outlet. The display uses a 7.2 (diagonal) color touch-screen for information display and input. The system is mounted on the outside of the refrigerator compartment door, and is not consumer removable. The refrigerator can print out the shopping list, or the list can be e-mailed to a participating retail outlet via the internet. A standard telephone line connection is required for the system if internet service is desired. Production is expected in the second quarter of 2001. Annual volume of 25,000 units is forecast. Only Whirlpool side-by-side models are planned at this time. 16
PRODUCT UPDATES REFRIGERATION Whirlpool In-Door Ice Refrigerator Revised Diagnostics IMPORTANT NOTE: For no ice, or low ice production, always confirm that the freezer temperatures are normal before starting the diagnostic tests. Always perform the Optics Diagnostics Mode test first. OPTICS DIAGNOSTICS MODE 1. Make sure that the ice maker is in the parked mode, and not the harvest mode. 2. Set the ice maker control to the On position. 3. If not already done, install the ice bin on the door. 4. Make sure that the ice level in the bin is below the notched openings. IMPORTANT NOTE: When you are instructed to activate the door switch, shown in step 2 of the following chart, press and hold in on the switch for 1 second, then release the switch for 1 second, and repeat the procedure two more times, for a total of three times. TEST PROCEDURE DIAGNOSTICS LED INDICATION 2 Pulses Steady Light No Light 1. Open the freezer door. repeated once for 5 seconds Unplug the 2. Activate the door switch 3 times. indicates that one indicates the refrigerator for 3. Close the freezer door for a minimum of 5 or both of the optics are okay. 5 seconds, and seconds to a maximum of 50 seconds. optics boards are Continue to the repeat the test. 4. Open the freezer door and view the defective. Replace Component Diagdiagnostics LED. both boards. nostics Mode. 17
COMPONENT DIAGNOSTICS MODE IMPORTANT NOTE: Be sure to run the Optics Diagnostics Mode test before you perform the component diagnostics test. 1. Make sure that the ice maker is in mid harvest immediately after the water fill. 2. Perform steps 1 through 8 in the following chart to set the ice maker for the test. 3. Set the ice maker control to the On position. 4. If not already done, install the ice bin on the door. 5. Make sure that the ice level in the bin is below the notched openings. IMPORTANT NOTE: If the ice maker will not run with the jumper properly in place, (see step 3 in the chart), stop the test, and check the ice maker. The bail arm switch must be in the down position for the ice maker to operate. Use a screwdriver and turn it counterclockwise to activate the switch. A bail arm is not used on in-door ice systems. TEST PROCEDURE DIAGNOSTICS LED INDICATION 4 Pulses 3 Pulses 2 Pulses Steady Light No Light 1. Disconnect the power supply plug. repeated once repeated once repeated once for 5 seconds Unplug the 2. Slide the ice maker out and remove the cover. indicates that the indicates that indicates the indicates the refrigerator for 3. Jumper holes T to H to bypass the relay is defective. there is a pro- optics are optics are okay, 5 seconds, and bimetal and start a harvest. Replace the blem with the defective. and the receiver repeat the test. 4. Reconnect the power supply plug. optics boards. I/M circuit. Replace both senses the I/M 5. Close the freezer door to align the optics and Check all of the optics boards. in the circuit. a harvest cycle will begin in 5 seconds. I/M connections 6. Open the freezer door and observe the ice and components. maker. A harvest should be in progress. NOTE: If the ice maker will not operate, refer to the Important Note above the chart. 7. Remove the jumper before the fingers reach the 10 o'clock position. Reinstall the ice maker, or be prepared to catch the water that will occur in the next step. 8. Listen for the water fill and disconnect the power immediately after the fill. 9. Close the freezer door and reconnect the power supply. 10. Wait 5 seconds to a maximum of 50 seconds, open the freezer door, and watch the LED. 18
All Remanufactured Warranty Products A growing number of Trade Partners are requiring vendors to take back all consumer returns. In 1998, there were many room air conditioners and dehumidifiers that were returned as defective, or ineffective. Due to the high volume of returns, many of these products have been returned to the LaVergne Division to be remanufactured to their original factory specifications. It has become necessary to develop a process for accepting, reworking, and reselling these consumer and field returns in the most cost-efficient manner possible. Remanufactured Model & Serial Numbers: All returned products will be received and sold utilizing model numbers that identify the products as Remanufactured to avoid legal issues. These numbers will have an RM (ReManufactured) inserted after the first letter of the model number. Some examples are as follows: The current model number for a dehumidifier is AD50G. The remanufactured number would be ARMD50G. The current model number for an air conditioner is ACM052XG. The remanufactured number would be ARMCM052XG. KitchenAid Built-In (KABI) Refrigerators With Electronic Controls & Variable Capacity Compressor Beginning midyear 2001, KABI side-by-side and bottom-mount refrigerators will be built with an electronic control board that controls a variable speed compressor, variable speed evaporator fan, variable air baffle, and a condenser fan motor, which operates at a fixed 900 rpm. The DC compressor will operate at speeds from 1600 to 4500 rpm. The DC evaporator fan will operate at speeds from 1800 to 3000 rpm. The control will maintain proper temperature with input from two thermistors, one in each compartment. The control will incorporate Adaptive Defrost Control with Pulsed Defrost and Evaporator Fan Delay. For detailed theory and diagnostics, refer to Job Aid KAR-11 #4317326, available June, 2001. 19
Side-By-Side Refrigerator With Adaptive Defrost Control & Water Filter Indicator (ADC/WFI) Beginning in March, 2001, selected Whirlpool and KitchenAid model side-by-side refrigerators with built-in water filters and mechanical thermostats, will use a combination ADC/WFI control board. These controls are identified in the photos below. The standard ADC and the ADC/WFI control boards are not interchangeable. Standard ADC Control Board ADC/WFI Control Board It is expected that the new control board, or variations of the new control board, will be used in production in the following four variations: ADC-Adaptive Defrost Control Board only. ADC/WFI-Adaptive Defrost Control Board with Water Filter Indicator. ADC/FD-Adaptive Defrost Control Board with Evaporator Fan Delay. ADC/FD/WFI-Adaptive Defrost Control Board, Evaporator Fan Delay, and Water Filter Indicator. It is important to note that both the new ADC/WFI and recent production of the standard ADC have a slight change in the test mode operation. The routine to initiate the defrost has not changed. However, now the control will pause for up to 30 seconds after the defrost has been initiated, while the control looks for a closed bimetal. This 30-second delay was necessary for changes in production line testing. 20
SERVICING THE ADAPTIVE DEFROST CONTROL STATIC ELECTRICITY DISCHARGE MAY CAUSE DAMAGE TO THIS ELECTRONIC BOARD Use an anti-static wrist strap. Connect the wrist strap to the green ground connection point, or to an unpainted metal surface in the appliance. Touch your finger repeatedly to a green ground connection point, or to an unpainted metal surface in the appliance. Before removing the part from its package, touch the anti-static bag to a green ground connection point, or to an unpainted metal surface in the appliance. The refrigerator/freezer defrost system can be checked by manually initiating a defrost cycle. The following two methods will initiate the ADC test mode: Method 1: 1. Turn the thermostat off for 15 seconds. 2. Turn the thermostat on for 5 seconds. 3. Turn the thermostat off for 15 seconds. 4. Turn the thermostat on for 5 seconds. 5. Turn the thermostat off for 15 seconds. 6. Turn the thermostat on for 5 seconds. 7. Turn the thermostat off. Within 3 to 8 seconds, the ADC should turn on the defrost heater (with the bimetal closed). NOTE: The test mode will terminate when the bimetal opens. If the refrigerator/freezer is already in defrost, the test mode can be terminated by unplugging the unit from the wall outlet, and waiting 30 seconds before plugging it back in. The refrigerator/freezer should immediately go into the cooling mode if the thermostat is closed. If this first test procedure fails to make the ADC initiate a defrost cycle, use the second test method to make the ADC begin the test mode. Method 2: 1. Disconnect the refrigerator/freezer from the wall outlet for at least 30 seconds. 2. Turn the thermostat off. 3. Reconnect power to the refrigerator/freezer. Within 3 to 8 seconds, the ADC should turn on the defrost heater (with the bimetal closed). If the unit fails to go into the defrost mode during this test, the problem may not be with the ADC. A defective bimetal may be the cause of the failure. The ADC will only go into a test mode if the bimetal is closed. If the ADC senses an open bimetal, it will return to the cooling mode within 30 seconds. HELPFUL HINT: Upon entering the test mode, the relay mounted on the ADC board should turn the compressor off and the defrost heater on. Listen for the relay to click, and then listen for up to 30 seconds for a second click. If you hear one click, check the defrost heater for continuity. If you hear two clicks, check for an open bimetal. 21
COMPACTORS Gear Adjustment When Replacing The Motor/Gear For proper gear fit and performance, the gap between the drive motor gear and the driven gear should only be a few thousands of an inch. To adjust the gears, refer to the photo below, and perform the following steps: 1. Loosen the four motor mounting nuts. 2. Insert a 2 (approximate) strip of paper between the drive motor gear and the driven gear. 3. Position the drive motor so the two gears mesh tightly together with the strip of paper in between, and tighten the four motor mounting nuts securely. 4. Turn the driven gear and remove the strip of paper from between the gears. 5. The gears mesh should now have a slightly loose fit. Motor Mounting Nuts Drive Motor Gear Paper Driven Gear Motor Mounting Nuts (Located Below Gear) 22
SERVICE POINTER INDEX LAUNDRY BRAND & ID# DESCRIPTION DATE ISSUED Whirlpool L8177975 Catalyst Washer, Model GSX9885J, 10/00 Serial Code Date Prior To CK32: Bleach And Fabric Softener Dispensing Intermittently Whirlpool, KitchenAid, & Roper L8177986 Direct Drive Washers With Mechanical Pressure 11/00 Switch, Serial Code Date CK36 - CK38: Intermittent Operation After Washer Fills REFRIGERATION BRAND & ID# DESCRIPTION DATE ISSUED Whirlpool, KitchenAid, & Roper R8177979 Top-Mount Refrigerators 18 To 22 Cu. Ft.: 10/00 Warm Refrigerator Section Temperatures Whirlpool & KitchenAid R8177980 Side-By-Side Refrigerators: Dispenser Overlays 10/00 Show Discoloration Whirlpool, KitchenAid, & Roper R8177982 Freestanding Side-By-Side Refrigerators, 10/00 Serial Code Dates SJ06 Through SJ20: Change To Overload/Relay 23
KITCHEN BRAND & ID# DESCRIPTION DATE ISSUED Whirlpool & KitchenAid K8177912-A All Whirlpool And KitchenAid 27 And 30 10/00 Microwave Combination Built-In Ovens -6, -7, & -8 Models And Whirlpool Gold Series Ovens Only: Self-Clean Door Latch Assembly Melting Whirlpool & KitchenAid K8177915-A All Whirlpool And KitchenAid 24, 27, & 30 10/00 Built-In Single And Double Ovens -6, -7, & -8 Models And Whirlpool Gold Series Ovens Only: Oven Not Operating (Thermo-Disc Failure) Whirlpool K8177960 Whirlpool Gas And Electric Slide-In Ranges 10/00 Models GY395LXG, GY396LXG, RS310PXG, & GW395LEG Code Dates Prior To IMK11: Unable To Program The Time And/Or Oven KitchenAid K4317315 KitchenAid Dishwasher Model KUDS01DJ 11/00 Serial Code Date Prior To FK46: Section Of Top Console Overlay Lifted Up Whirlpool, KitchenAid, & Roper K8177989 Dishwashers With Power Clean Module 11/00 Service Part #675501 Seal Kit: Dishwasher Pump Face Seal Replacement 24
U.S.A. Have your store number ready to identify you as an authorized servicer. FOR TECHNICAL ASSISTANCE FOR ALL PRODUCTS EXCEPT KITCHENAID BUILT-IN REFRIGERATORS: Phone: 1-800-253-2870 Hours: 7:30 am to 8:00 pm (EST) FOR TECHNICAL ASSISTANCE FOR KITCHENAID BUILT-IN REFRIG- ERATORS ONLY: Phone: 1-800-223-8962 Hours: 24-Hours FOR LITERATURE ORDERS: Phone: 1-800-851-4605 CANADA Have your store number ready to identify you as an authorized servicer. FOR PRODUCT AND WARRANTY INFORMATION: Phone: 1-800-461-5681 FOR TECHNICAL ASSISTANCE: Phone: 1-800-488-4791
Whirlpool CORPORATION Benton Harbor, Michigan Printed in the U.S.A. 2001 WHIRLPOOL CORPORATION Part No. 8178023