Amana SXD520T, SR520T, SRD520T, SBDT520T, SBDX520T Service

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Service

International Side by Side 1997 “T” Model Refrigerators

Refer to Technical Sheet for values and wiring schematics.

Models and manufacturing

numbers in this manual

SR520T P1312901W

SB520T P1313001W SSD522T P1313602W SXD520T P1313701W

SBDX520T P1313202W SSD522TB P1313601W SBDT520T P1313201W

SRD520T P1313101W SRD522T P1313301W SRD526T P1313401W

SRDE520T P1312401W SBDE520T P1312301W

SRDE520TB P1312402W

SRDE528T P1312601W

SRDE528TB P1312602W

SRD325S5 P1313501W SRD327S3 P1312502W

SXD322 P1313901W

SRDE327S3 P1312501W

SX322S2 P1313801W

This manual is to be used by qualified appliance technicians only. Amana does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person.

RS5290000

Revision 0

April 1998

Important Information

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE

INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

To avoid risk of serious injury or death, repairs should not be attempted by an unauthorized personnel, dangerous conditions (such as exposure to electrical shock) may result.

Amana will not be responsible for any injury or property damage from improper service procedures. If performing service on your own product, assume responsibility for any personal injury or property

damage which may result.

Important Information

Important Notices for Consumers and Servicers

WARNING

CAUTION

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER AFFAIRS DEPT. OR 1-319-622-5511 or (1-800-843-0304) AMANA REFRIGERATION, INC. CALL and ask for AMANA, IOWA 52204 Consumer Affairs

If outside the United States contact:

AMANA ATTN: CONSUMER AFFAIRS DEPT. AMANA, IOWA 52204, USA Telephone: (319) 622-5511 Facsimile: (319) 622-2180 TELEX: 4330076 AMANA CABLE: "AMANA", AMANA, IOWA, USA

Recognize Safety Symbols, Words, and Labels

DANGER

DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING

WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION

CAUTION - Hazards or unsafe practices which COULD result in minor personal injury or product or property

damage.

RS5290000 Rev. 0 2 April 1998

User Operation

Features

Fresh Food Section (Refrigerator)

1. Temp-Assureä Thermostatic Control

2. Spillsaverä Shelves

3. Slide Out Shelves

4. Chiller Fresh System

5. Garden Fresh Drawers

6. Utility Rack

7. Covered Utility Bucket

8. Dairy Center

9. Snack Chiller

10. Beverage Chiller

11. Door Buckets

12. Adjustable Divider 13

Deepfreeze® Section (Freezer)

13. Deepfreeze® Shelf

14. Automatic Ice Maker

15. Stor-Morä System

16. Door Dike

17. Door Shelves

18. Tall Package Retainer

19. Ice 'N Waterä Dispenser

132184

April 1998 5 RS5290000 Rev. 0

SXD20SW

Features vary from model to model.

User Operation

Electrical Requirements

Refrigerator must be earthed and connected to a separate 230 volt, 50 hz., 10A circuit.

Model Identification

Locate product information on the nameplate, found in upper left corner of Fresh Food section. Record the following information: Model Number, Manufacturing Number, Serial or S/N Number, Date of purchase, Dealer’s name and address.

Features

Spillsaverä Shelves

Caution

To avoid personal injury or property damage, handle tempered glass shelves carefully. Shelves may break suddenly if nicked, scratched or exposed to sudden temperature change.

1. Remove shelves by lifting front and releasing hooks from metal track.

2. Replace shelves by inserting hooks into metal track and lowering front.

Dairy Center

1. Remove door by opening door, pushing in slightly near hinges and pulling out.

2. Remove shelf by lifting and pulling out.

3. Replace door and shelf by reversing steps 1-2.

Snack Chiller

1. Remove door by opening door, pushing in slightly near hinges and pulling out.

2. Remove bucket by removing Beverage Chiller door then lifting bucket.

3. Replace door and bucket by reversing steps 1-2.

Beverage Chiller

Locate control dial on left front wall of Fresh Food section to adjust amount of air.

Chiller Fresh System

Cold Coldest

Locate control on front trim to adjust amount of air circulating between drawer and sleeve.

1. Remove drawer and sleeve by lifting and pulling out.Refer to "Spillsaverä Shelves" for instructions on removing and replacing shelf. Use eighth through eleventh slots.

2. Replace sleeve then drawer by sliding in. Confirm boot is over air inlet in side wall.

Garden Fresh Crispers

Locate control on front trim to adjust to either high or low settings.

1. Remove beverage chiller door by removing lower door buckets. Slide chiller door down and out through bottom of door track.

2. Replace beverage chiller door by reversingstep

1. Retention glides must remain in place to install door.

Door Buckets

1. Remove door buckets by pushing tabs toward center and pulling out.

2. Replace door buckets by sliding in until tabs lock into place.

Door Shelves

1. Remove slide-style door shelves by lifting

Low High

1. Remove drawers by lifting and pulling out. Refer to "Spillsaverä Shelves" for instructions on removing and replacing shelf.

2. Replace drawers by sliding in.

RS5290000 Rev. 0 6 April 1998

and pulling out.

2. Replace slide-style door shelves by reversing step 1.

1. Remove hook-style door shelves by tapping up each end. Lift bottom of shelf release hooks.

2. Replace hook-style shelves by inserting hooks and lowering bottom of shelf. Tap down on ends.

User Operation

Stor-Morä System

1. Remove shelves and baskets by lifting and pulling out.

2. Replace shelves and baskets by reversing step 1.

Door Dike

1. Remove door dike by pulling forward and snapping out.

2. Replace door dike by aligning clips with holes on Deepfreeze® door. Push until dike locks in place.

Setting Controls

This refrigerator operates most efficiently in normal household temperatures of 12° to 43°C.

Fresh Food and Deepfreeze® Controls

(nonelectronic models)

Locate Fresh Food and Deepfreeze® controls on upper rear wall of Fresh Food section. When Deepfreeze® control is set to nor Deepfreeze® sections will cool. Initially, set both controls to 4. Wait 24 hours for Fresh Food and Deepfreeze® sections to reach desired temperatures. After 24 hours, adjust controls as desired. 1 is warmest setting and 7 is coldest.

off

, neither Fresh Food

Touchmaticä Electronic Controls (electronic models)

Confirm power switch is on before programming. Remove toe grille and locate black box in center of cabinet. Power switch is on right side of box.

Set temperatures precisely using a household thermometer that includes temperatures between

-20.5° to 10°C.

Put thermometer snugly between frozen packages in Deepfreeze® section. Wait 5-8 hours. If Deepfreeze temperature is not -18° to -17°C, adjust control, one number at a time. Check again after 5-8 hours.

Put thermometer in a glass of water in middle of Fresh Food section. Wait 5-8 hours. If Fresh Food temperature is not 3° to 4°C, adjust control, one number at a time. Check again after 5-8 hours.

April 1998 7 RS5290000 Rev. 0

User Operation

Locate Touchmatic® electronic control panel on refrigerator between handles. Press * pad to activate control panel. All other pads, except for Alarm Off pad, remain inactive until * pad is pressed. Once activated, pads remain programmable for at least 10 minutes.

Fresh Food and Deepfreeze® controls are preset at 5. Wait 24 hours for Fresh Food and Deepfreeze sections to reach desired temperatures. After 24 hours, adjust controls as desired. 1 is warmest setting and 9 is coldest. Refer to instructions on page 6 to set temperatures precisely.

Adjust Fresh Food or Deepfreeze® temperatures by pressing * pad then Fresh Food Temp pad or Deepfreeze® Temp pad. Press Warmer pad or Colder pad to adjust temperature setting one level at a time. Holding down Warmer pad or Colder pad adjusts temperature more than one level at a time.

Vacation Mode

Vacation mode defrosts refrigerator less often during extended non-use periods. Activate vacation mode by pressing * pad then Vacation pad. Indicator light will glow. Repeat above to deactivate vacation mode. Opening Fresh Food or Deepfreeze® door will also deactivate vacation mode.

Max Cool Mode

Max cool mode adjusts Fresh Food temperature to coldest setting. After 10 hours, Fresh Food temperature automatically returns to previous setting. Activate max cool mode by pressing * pad then Max Cool pad. Indicator light will glow. Repeat above to deactivate max cool mode before automatic reset.

Fast Freeze Mode

Fast freeze mode adjusts Deepfreeze® temperature to coldest setting. After 24 hours, Deepfreeze temperature automatically returns to previous setting. Activate fast freeze mode by pressing * pad then Fast Frz pad. Indicator light will glow. Repeat above to deactivate fast freeze mode before automatic reset.

Entry Tone

Entry tone indicates a pad was pressed and command was read and accepted. Deactivate entry tone by pressing and holding * pad for three to five seconds. Three short beeps indicate instructions were accepted. Repeat above to activate entry tone.

Door Open Alarm Door open alarm sounds and glowing indicator light blinks if either door is open for three minutes. Deactivate door open alarm by pressing Alarm Off pad or by closing either door. Activate door open alarm by pressing * pad then holding Alarm Off pad for three to five seconds. Three short beeps will sound. Repeat above to deactivate door open alarm indefinitely.

Deepfreezeâ Temp

Fresh Food Temp

Warmer

Colder

Vacation

Max Cool

Fast Freeze

Alarm Off

Display Off

RS5290000 Rev. 0 8 April 1998

User Operation

High Temperature Alarm

High temperature alarm sounds and indicator light glows if Fresh Food or Deepfreeze® temperature is high for two hours. A blinking light signals affected compartment. Deactivate high temperature alarm by pressing Alarm Off pad. Alarm discontinues when proper temperature is reached.

Thermistor Alarm

Thermistor alarm sounds and indicator lights scroll if Fresh Food or Deepfreeze® thermistor is not operating properly. Deactivate display by pressing Alarm Off pad.

If thermistor alarm sounds, contact an authorized servicer immediately. If Alarm Off pad is pressed, thermistor control retests to confirm situation has been corrected. Alarm sounds again if thermistor is still not operating properly.

Display Lights

Deactivate temperature display lights by pressing pad then pressing Display Off pad. Activate temperature display lights by pressing any of top five

pads.

Clean Condenser Coil Light

Clean condenser coil light glows once every three months as a reminder to clean condenser coil. Light automatically cancels in 72 hours. Deactivate clean condenser coil light before automatic reset by pressing Alarm Off pad.

Ice 'N Waterä Dispenser

Caution

To avoid personal injury or property damage, observe following instructions:

1. Do not operate dispenser with Deepfreeze® door open.

2. Do not put fingers, hands, or any foreign object into dispenser opening.

3. Do not use sharp objects to break ice.

Water Dispenser Operation

1. Dispense water by pressing container against water dispenser bar.

2. Shut off water by releasing pressure on bar. Slight dripping may occur. Spill shelf is not selfdraining. Large spills should be wiped dry immediately.

Ice Dispenser Operation

1. Select cubed or crushed mode (some models) by sliding lever on dispenser panel. Dispense ice by pressing wide mouthed container against ice dispenser bar. Hold container close to chute to minimize spraying ice.

Caution

Automatic Ice Maker

Refrigerator has an electrical connection in Deepfreeze® section for ice maker installation. Ice maker, model IC54, and water filter, part #R0183114, can be purchased separately.

1. Confirm ice storage bucket is in place and ice maker arm is down.

2. After Deepfreeze® section reaches normal temperature, ice maker fills with water and begins operating. Allow 24-48 hours after installation before first harvest of ice. Ice maker produces seven to nine harvests of ice in a 24-hour period under ideal conditions.

3. After ice is formed, ice maker drops ice cubes into ice storage bucket. During ice production, ice maker arm raises and lowers. When ice storage bucket is full, ice maker arm turns ice maker off.

Important: Discard first three harvests of ice so any

impurities are not consumed.

4. Stop ice maker by lifting ice maker arm. A definite click will be heard when proper position is reached. Ice maker arm will remain in that position.

Important: Do not force ice maker arm down or up past

stop position.

To avoid property damage, do not dispense ice directly into thin glass, fine china or delicate crystal.

2. Shut off ice by releasing pressure on bar before container is full. Some ice will continue to fall. Do not remove container until last ofi ce falls.

If dispensing ice continuously, dispenser motor shuts off after approximately two minutes. Motor resets after three minutes and dispensing can continue.

A slight delay occurs when switching between cubed and crushed modes. Pieces of crushed ice will vary in size and shape. “Snow” may form on door and ice chute when repeatedly dispensing crushed ice. Allow “snow” to evaporate or wipe dry.

Dispenser operates only with cubes of proper size and crescent shape. Do not add purchased ice cubes or other cubes.

Dispenser Light

A light is activated when dispensing ice or water. Some models feature a night light. Deactivate night light by pushing switch, located underneath dispenser facade and left of ice dispenser bar.

April 1998 9 RS5290000 Rev. 0

User Operation

Water Taste and Odor

Observe the following to minimize taste and odor difficulties:

1. Throw away first 10 to 14 regular glasses of water after initially connecting refrigerator to household water supply.

2. Flush water system and reservoir as above after extended periods of non-use.

3. Wrap foods in tightly sealed containers or moisture proof bags.

4. Install water filter, part #R0183114 on water line.

5. Contact local water treatment company for specialized help if difficulties persist.

Care and Cleaning

WARNING

To avoid electrical shock which can cause severe personal injury or death, disconnect power to refrigerator before cleaning. After cleaning, reconnect power.

Caution

To avoid personal injury or property damage, read and follow all cleaning product manufacturer's directions.

General

1. Wash surfaces with four tablespoons baking soda diluted in one quart warm water as needed. Rinse and dry surfaces thoroughly.

2. Do not use the following items:

• abrasive cleaners such as ammonia, chlorine

bleach, etc.

• solvents

• metal scouring pads These items can scratch, crack and discolor

surfaces.

Glass Shelves

Light Bulbs

W ARNING

To avoid electrical shock which can cause severe personal injury or death, disconnect power to refrigerator before replacing light bulb. After replacing light bulb, reconnect power.

Caution

To avoid personal injury or property damage, observe the following:

1. Allow bulb to cool.

2. Wear gloves when replacing light bulb.

Remove light bulb cover. Replace light bulb with same size and type of appliance bulb.

Door Gaskets

1. Clean door gaskets every three months or according to "General" cleaning instructions.

2. Rinse and dry gaskets thoroughly.

3. Apply a light film of petroleum jelly to keep door gaskets pliable.

Condenser Coil

Clean condenser coil every three months. Accumulated dust and lint may cause the following:

· reduced cooling performance

· increased energy usage

· premature part failure

1. Remove toe grille by pulling forward.

2. Clean coil with a vacuum cleaner hose nozzle.

3. Install toe grille by positioning top and snapping in bottom. Top is indicated on back of toe grille.

4. Pull refrigerator away from wall. Run a vacuum brush across condenser fan outlet grille on back of refrigerator.

Caution

To avoid personal injury or property damage, handle tempered glass shelves carefully. Shelves may break suddenly if nicked, scratched or exposed to sudden temperature change.

Remove glass shelf and place on a towel. Allow shelf to adjust to room temperature before cleaning.

RS5290000 Rev. 0 10 April 1998

User Operation

Vacation Tips

For short vacations, remove perishable foods. If an ice maker is installed, move ice maker arm to off position.

For long vacations, do the following:

1. Remove food from refrigerator.

2. Unplug refrigerator.

3. Clean refrigerator.

4. Clean door gaskets.

5. Prop doors open, so air can circulate inside.

6. Turn off water supply to refrigerator if an ice maker is installed and move ice maker arm to off position.

Caution

To avoid property damage, turn off water supply to refrigerator and move ice maker arm to off position before leaving on vacation.

Normal Operating Sounds

This new refrigerator may be replacing a differently designed, less efficient or smaller refrigerator. Today’s refrigerators have new features and are more energy efficient. As a result, certain sounds may be unfamiliar. These sounds are normal and will soon become familiar. These sounds also indicate refrigerator is operating and performing as designed.

Electronic Control Models Evaporator fan does not operate when either Fresh Food or Deepfreeze® door is open.

Before Calling For Service

Refrigerator does not operate.

· Confirm Deepfreeze® control is on.

· Confirm electrical power cord is plugged in.

· Check fuse or circuit breaker. Plug in another item

at that wall outlet.

· Wait 40 minutes to see if refrigerator restarts. If Deepfreeze® control is on and lights work buttwo fans and compressor are not operating, refrigerator may be in defrost cycle.

Refrigerator still won’t operate.

· Unplug refrigerator. Transfer food to another unit or place dry ice in Deepfreeze® section to preserve food until refrigerator can be serviced.

Food temperature appears too warm.

· See above sections.

· Allow adequate time for food to reach Fresh Food

or Deepfreeze® temperature if a large supply of food was recently added.

· Clean condenser coil.

· Adjust Fresh Food and/or Deepfreeze® control.

· Confirm rear air grille is not blocked. Rear air

grille is located behind left crisper.

Chiller fresh system is too warm.

· Slide control to a colder setting.

· Adjust Deepfreeze® control to a colder setting.

Food temperature is too cold.

· Clean condenser coil.

· Adjust Fresh Food control.

· Allow several hours for temperature to adjust.

Refrigerator runs too frequently.

· It may be normal to maintain an even temperature.

· Doors may have been opened frequently or for an extended period of time.

· Clean condenser coil.

· Adjust Deepfreeze® control.

· Check gasket for proper seal.

Water droplets form on inside of refrigerator.

· This is normal during periods of high humidity or ifdoors have been opened frequently.

Water droplets form on outside of refrigerator.

· Check gasket for proper seal.

Crisper drawers or chiller fresh system do not close freely.

· Check for a package which may prevent drawers from closing properly.

· Confirm drawers are in proper position.

· Clean drawer channels with warm, soapy water.

Rinse and dry thoroughly.

· Apply a thin layer of petroleum jelly to drawer channels.

· Confirm refrigerator is level.

Refrigerator has an odor.

· Clean inside of Fresh Food and Deepfreeze sections.

· Cover all foods tightly and use freezer wrap.

Ice cubes have an odor.

· See above section.

· Discard ice and clean ice bucket or trays more

frequently. Ice cubes are very porous and absorb odors very easily.

Refrigerator or ice maker make unfamiliar sounds or seems too loud.

· See "Normal Operating Sounds" section. These may be normal.

Ice cubes stick together or ‘shrink’.

· Empty ice cube bucket or trays more frequently. If used infrequently, ice cubes may stick together or shrink.

Ice forms in inlet tube to ice maker.

· Check water pressure. Low water pressure will cause valve to leak. Self-piercing valves cause low water pressure. Do not useself-piercing valves.

April 1998 11 RS5290000 Rev. 0

Installation Instructions

International Side-by-Side Installation Instructions

Introduction

A qualified engineer must connect refrigerator in accordance with these installation instructions. Measure door opening and depth and width of refrigerator. Remove handles or doors as required. Engineer must also do the following:

1. Follow local water and electrical company connection regulations.

2. Complete water supply connection before electrical supply connection.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION

Removing Handles

Caution

To avoid personal injury or property damage, hold handles securely while

removing.

1. Nonextruded Handle Models Remove top end cap. Remove door handleinsert

by pulling up.

Extruded Handle Models

Remove trim using putty knife covered with tape.

2. Remove door handles by removing screws.

Electronic Control Models

Remove electronic control panel by carefully disconnecting ribbon cable from socket.

3. Install door handles by reversing steps 1-2.

Installation Requirements

1. Install on an earthed outlet with a separate 230 volt, 50 hz., 10A circuit.

2. Protect soft flooring with cardboard or rugs.

3. Install on a floor which supports up to 429 kg.

4. Provide 25 mm clearance on top and 5 mm on sides of refrigerator.

5. 20 cubic foot Models Trim corners of counter top to a 45° angle if

counter top has 25 mm overhang.

Removing Wooden Base

Caution

To avoid personal injury or property damage, two people must remove wooden base.

1. Tape doors shut to prevent doors from opening unexpectedly.

2. Slide appliance cart under side of refrigerator.

3. Wrap refrigerator with blanket or pad. Thread strap around refrigerator. Put foam shipping pads, located in shipping carton, under strap. Tighten strap securely.

4. Lower appliance cart to floor with appliance cart handles on bottom.

5. Remove top two bolts from skid.

6. Return refrigerator and appliance cart to an upright position. Remove strap.

7. Slide appliance cart under opposite side of refrigerator.

8. Repeat steps 3-5.

9. Remove wooden base.

10. Return refrigerator and appliance cart to an upright position and remove appliance cart.

Important: Do not leave refrigerator on its side longer

than necessary to remove bolts.

RS5290000 Rev. 0 12 February 1998

Removing Doors

Caution

To avoid personal injury or property damage, two people must remove and hang doors.

1. Tape doors shut to prevent doors from opening unexpectedly.

2. Nonextruded Handle Models Remove top door trim. Leave spacer in place and slide trim away from end caps. Remove top hinge covers.

ää

Ice 'N Water

Remove top hinge covers.

All Other Models

Remove top hinge cover by lifting back and sliding forward.

3. Remove toe grille by lifting and pulling forward.

ää

Dispensing Models

Installation Instructions

4. Electronic Control Models Remove bottom door closure screw. Unplug

wiring harness from high voltage box under refrigerator. Unplug top hinge wire connectors. Unscrew green/yellow earthing wire.

5. Remove top Fresh Food hinge by removing screws.

6. Remove tape from Fresh Food door while holding door securely.

7. Remove Fresh Food door by lifting while opening.

Electronic Control Models

Slide wiring harness through slot in bottom door hinge bracket as door is raised.

Removing Handles

Caution

To avoid personal injury or property damage, hold handles securely while

removing.

Removing Doors

Caution

To avoid personal injury or property damage, two people must remove and hang doors.

1. Tape doors shut to prevent doors from opening unexpectedly.

2. Nonextruded Handle Models Remove top door trim. Leave spacer in place and

slide trim away from end caps. Remove top hinge covers.

Ice 'N Waterä Dispensing Models

Remove top hinge covers.

All Other Models

Remove top hinge cover by lifting back and sliding forward.

3. Remove toe grille by lifting and pulling forward.

4. Electronic Control Models Remove bottom door closure screw. Unplug

wiring harness from high voltage box under refrigerator. Unplug top hinge wire connectors. Unscrew green/yellow earthing wire.

1. Nonextruded Handle Models Remove top end cap. Remove door handle

insert by pulling up.

Extruded Handle Models

Remove trim using putty knife covered with tape.

2. Remove door handles by removing screws.

Electronic Control Models

Remove electronic control panel by carefully disconnecting ribbon cable from socket.

3. Install door handles by reversing steps 1-2.

February 1998 13 RS5290000 Rev. 0

5. Remove top Fresh Food hinge by removing screws.

6. Remove tape from Fresh Food door while holding door securely.

7. Remove Fresh Food door by lifting while opening.

Electronic Control Models

Slide wiring harness through slot in bottom door hinge bracket as door is raised.

Installation Instructions

8. Ice 'N Waterä Dispensing Models Loosen screw from water tube clamp. Loosen

6.4 mm plastic water tube union nut by hand. Pull water tube away from union nut and through tube clamp. Unplug top hinge wire connectors.

W ARNING

To avoid electrical shock which can cause severe personal injury or death, green/yellow earthing wire must remain attached to hinge. Do not dissassemble.

9. Remove top Deepfreezeâ hinge by removing screws.

10. Remove tape from Deepfreezeâ door while holding door securely.

11. Remove Deepfreezeâ door by lifting while opening. This will free Deepfreezeâ door from bottom hinge pin.

Ice 'N Waterä Dispensing Models

Slide plastic water tube through slot in bottom door hinge as door is raised.

12. Remove bottom hinge by removing screws.

13. Install doors by reversing steps 1-12.

Connecting Water Supply

Materials Required

2.5 m of 6.4 mm flexible copper tubing Important: Before installing ice maker, contact a

plumber to connect copper tubing to household plumbing in compliance with local codes and ordinances. Warranty will be void if

installation is improper or a self-piercing valve is used.

Procedure

Caution

To avoid property damage, observe the following:

1. Check for water leaks prior to returning refrigerator to normal location.

2. Start tubing nuts by hand to avoid cross threading. Finish tightening nuts using an adjustable wrench. Do not overtighten.

3. Check carefully for water leaks 24 hours after installation.

1. Turn off water supply to refrigerator.

2. Seal open end of copper tubing with tape.

3. Route copper tubing up to refrigerator. Copper tubing route must be above 2°C to prevent water line from freezing.

4. Remove masking tape from end of copper tubing.

5. Put other end of copper tubing into bucket. Turn on water supply to refrigerator. Water will be under considerable pressure. Allow water to run through copper tubing. Turn off water supply to refrigerator when flushing is complete.

6. Remove and retain lower cover by removing screws.

RS5290000 Rev. 0 14 February 1998

Installation Instructions

7. Assemble water valve coupling by removing nut and sleeve from adapter fitting. Slide brass nut and sleeve over end of copper tubing. Insert copper tubing completely into adapter fitting.

8 Confirm hose washer is in place by checking

fitting. Tighten adapter fitting by hand. Tighten an additional 1/2 turn. Connect nut on copper tubing to adapter fitting. Confirm copper tubing is secure by pulling on copper tubing.

9. Turn on water supply to refrigerator and check for leaks. Turn off water supply to refrigerator and correct leaks. Repeat this process until no leaks are found, then completely turn on water supply to refrigerator.

10. Install lower back cover by reversing step 6. Tuck wires inside cover. Avoid pinching wires.

11. Create service loop avoiding kinks. Secure

copper tubing at back horizontal cover using “P” clamp.

Leveling Refrigerator

1. Place level side-to-side at top front of refrigerator.

2. Remove toe grille by lifting and pulling forward.

Important

Some models have both front and rear leveling legs.

3. Adjust leveling wheels by rotating leveling

screws. Raise refrigerator by rotating leveling screws clockwise.

4. Models with Hinge Adjusting Cam

If tops of doors are not aligned, loosen refrigerator door hinge screws 1/2 turn. Turn cam clockwise 1 increment at a time until doors are aligned. Open and close doors. Tighten hinge screws.

Rear roller adjustment screw (some models)

Front roller adjustment screw

5. Install toe grille by positioning top and snapping in bottom. Top is indicated on back of toe grille.

Hinge adjusting cam (some models)

Caution

To avoid property damage, all covers must be in place.

February 1998 15 RS5290000 Rev. 0

Troubleshooting Chart

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Troubleshooting chart on following pages contains symptoms that may be seen in malfunctioning units. Each symptom is accompanied by one or more possible causes and by a possible remedy or test to determine if components are working properly.

Sympto m Possible C auses Corrective Action

Unit does not run

Refrigerator section too warm

No power to unit. Check for power at outlet. Check

fuse box/circuit breaker for blown fuse or tripped breaker. Replace or reset.

Power switch shut off or faulty. Check switch at high voltage board

(electronic models only).

Faulty service cord Check with test light at unit; if no

circuit and current is indicated at outlet, replace or repair.

Low voltage Check input voltage for proper

voltage. Take appropriate action to correct voltage supply problem.

Faulty motor or freezer temperature control

Fault y timer Chec k w ith tes t lig ht. R e place if Faulty high voltage board

compressor/condenser fan relay Faulty com pressor Check compressor motor windings

Faulty overload Check overload for continuity.

Excessive door opening Consumer education Overloading of shelves Consumer education

Warm or hot foods placed in cabinet Consumer education Refrigerator temperature control set

too war m Poor door seal Level cabinet. Adjust hinges.

Refrigerator airflow Check dam per is opening by

Interior light remains on Check switch. Replace if necessary. Faulty condenser fan or evaporator

fan Faulty com pressor Replace compressor.

Check a ll connec tions are tight a nd secure.

Jumper across terminals of control. If unit runs, replace control.

necessary. Check relay. Replace if necessary.

for opens/shorts. Perform compressor direct wiring

test. Replace is necessary.

Note:

Ensure compressor/overload are below trip temperature before testing.

Replace if necessary.

Set co n tro l to c o ld er setting.

Replace gasket.

removing grille. With door open, damper should open. Replace if faulty.

Turn co n tro l k n ob to colder p o s ition . Check airflow fan. Replace if faulty.

Check fan switch, fan, and wiring. Replace if necessary

RS5290000 Rev. 0 16 April 1998

Troubleshooting Chart

WARNING

Symptom Possible Causes Corrective Action

Refrigerator section too cold

Freezer and refrigerator sections too warm

Unit runs continuously

Unit runs continuously. Temperature normal or warm.

Unit runs continuously. Temperature too cold or too warm.

Noisy operation

Refrigerator tem perature control set too cold

Refrigerator airflow not properly adjusted

Temperature controls set too warm Reset temperature controls. Poor door seal Level cabinet. Adjust hinges.

Dirty condenser or obstructed grille C heck condenser and grille. Clean. Faulty control Test control. Replace if defective. Defrost heater remains open Check evaporator. Refrigerant shortage or restriction Check for leak or restriction. Repair,

Freezer temp control set too cold Adjust freezer tem perature controlFreezer section too cold Faulty control Test control. Replace if defective. Temperature control set too cold Adjust temperature control.

Dirty c o n dens e r o r obst ru c te d g rille Chec k condenser and grille. Clean. Poor door seal Level cabinet. Adjust hinges.

Interior light remains on Check switch. Check door activates

Faulty condenser fanor evaporator fan

Faulty control Test control. Replace if defective. Refrigerant shortage or restriction Check for leak or restriction. Repair,

Refrigerant overcharge Check for overcharge. Evacuate and

Air in system Check for low side leak. Repair,

Ice on evaporator See “Ice on evaporator.”

Faulty defrost thermostat Check thermostat. Replace if

Loose flooring or floor not firm Repair floor or brace floor. Cabinet not level Level cabinet. Tubing in contact with cabinet, other

tubing, or other metal Drain pan vibrating Adjust drain pan. Fan hitting another part Ensure fan properly aligned and all

Worn fan motor bearings Check m otor for loss of lubricant or

Compressor mounting grommets worn or missing. Mounting hardware loose or missing.

Free or loose parts causing or allowing noise during operation

Adjust refrigerator temperature control

Adju s t airflo w g ri lle to fr e e ze r . Adju st Bever age chiller and Ch il le r Fresh temperature controls.

Replace gasket.

evacuate and recharge system.

Replace gasket.

switch. Adjust or replace if switch. Check fan switch, fan, and wiring.

Replace if necessary

evacuate and recharge system.

recharge system

evacuate and recharge system.

necessary.

Adjust tubing.

attaching hardware and brackets are tight and not worn. Tighten or replace.

worn bearings. Replace if necessary. Tighten hardware. Replace

grommets if necessary.

Inspect unit for parts that m a y have worked free or loose or missing screws. Repair as required.

April 1998 17 RS5290000 Rev. 0

Troubleshooting Chart

WARNING

Symptom Po ss ible C aus es Corrective A c tion

Frost or ice on evaporator

Unit starts and stops frequently (cycles on and off)

Defrost thermostat faulty Check defrost thermostat. Replace if

defective.

Evaporator fan faulty Check fan motor. Replace if

defective.

Defrost heater remains open Check defrost heater continuity.

Replace if faulty. Defrost timer faulty Check timer and replace if defective. Open wire or connector Check wiring and connections.

Repair as necessary. Refrigerant shortage or restriction Check for leak or restriction. Repair,

evacuate and recharge system. Loose wire or thermostat

connections Supply voltage out of specification Check input voltage. Correct any

Overload protector open Check overload protector for

Faulty compressor motor capacitor Check capacitor for open/short.

Check wiring and connections.

Repair as necessary.

supply problems.

continuity. If open, replace overload.

Note: Ensure overload/compressor are below trip temperature before testing.

Replace if necessary.

Note: Discharge capacitor before testing.

RS5290000 Rev. 0 18 April 1998

Restricted condenser air flow Check condenser and grille for dirt.

Clean Refrigerant shortage or restriction Check for leak or restriction. Repair,

evacuate and recharge system.

System Diagnosis

Pressure and Temperature Relationship Chart

See “Service Procedures” section for additional information about items in this chart.

Condition Refrigerant

Overcharge

Refrigerant Shortage

Partial Restriction

Air in system

Low Ambient Installation

(Reverse from High Ambient Installation)

Suction Pressure Variation from Normal

Increase Increase Warmer Warmer Colder Increase

Decrease Decrease or

Near Normal Increase Warmer Warmer Warmer Increase

Decrease Decrease Colder Warmer Warmer Decrease

Head Pressure Variation from Normal

Increase (Restriction Symptoms)

T1 Inlet Temperature Variation from Normal

Colder Warmer Warmer Decrease

T2 Outlet Temperature Variation from Normal

T3 Suction Temperature Variation from Normal

Wattage Variation from Normal

Additional Heat Load

Inefficient Compressor

Increase Increase Warmer Warmer Warmer Increase

Increase Normal or

Decrease

Warmer or Colder

Warmer Warmer Decrease

April 1998 19 RS5290000 Rev. 0

Display Panel

Enable

Freezer Temperature

Fresh Food Temperature

Warmer

Colder

1 2 3 4 5 6 7 8

Temperature Indicators Freezer Temperature

Fresh Food Temperature Door Open

High Temperature Clean Coil Vacation

Max Cool Fast Freeze

Vacation

Max Cool

Fast Freeze

Alarm Off

RS5290000 Rev. 0 20 April 1998

Display Off

Display Panel Keyboard

Display Panel Operation

Keyboard Pad Functions

Entry Tone

Indicates a pad was pressed, command read and accepted. Turn off entry tone by pressing and holding

pad for 3 to 5 seconds.

Command Accepted Tone

Three short tones indicate command accepted.

1. Activates control panel. Control panel remains active at least 10 minutes.

2. Turns off Power Up Alarm (flashing lights) after power is first plugged in or after power outage.

Note: All pads, except

pressed.

Freezer Temp

Activates freezer temperature setting mode.

1. Freezer indicator light will glow. Freezer temperature setting will be displayed. Factory setting is 5.

2. Change freezer temperature setting by pressing

Warmer

Ref Temp

Activates refrigerator temperature setting mode.

1. Refrigerator indicator light will glow. Refrigerator temperature setting will be displayed. Factory setting is 5.

2. Change refrigerator temperature setting by pressing

Warmer

Raises temperature setting one bar at a time. If entry tone is on, tone will sound at each bar level until top level is reached.

1. Turn on temperature setting function of control panel by pressing * pad.

2. Press and hold setting at a faster rate.

Colder

Lowers temperature setting one bar at a time. If entry tone is on, tone will sound at each bar level until bottom level is reached.

1. Turn on temperature setting function of control

2. Press and hold

Fast Freeze

Activates Maximum freezer mode setting freezer temperature to coldest setting for 24 hours or until

Fast Freeze

1. Fast Freeze indicator light will glow.

2. To adjust maximum freezer mode time refer to

Pad

panel by pressing

setting at a faster rate.

Program Mode B functions.

Pad

Colder

Pad

Warmer

Pad

pad is pressed again.

Alarm Off

pad.

Colder

Warmer

pad.

Colder

, are inactive until * is

pad.

pad to raise temperature

pad to lower temperature

Max Cool

Activates maximum refrigerator mode setting refrigerator to coldest setting for 10 hours or until

Max Cool

1. Max Cool indicator light will glow.

2. To adjust maximum refrigerator time refer to Mode

Alarm Off

Turns off alarm signals. See Alarms Section to interpret alarm signals.

1. Press and hold

2. If

Display Off

1. Deactivates control panel.

2. Deactivates temperature indication area of control.

Program Mode

activates Program Mode. See Program Mode

section for description of functions available.

1. Open refrigerator door.

2. Press * pad.

3. Within 6 seconds press the following pads in this

4. Tone will sound 3 times and control will be in

Vacation

Defrost unit less often during extended periods of nonuse. To begin Vacation Mode

1. Press * pad.

2. Press To deactivate Vacation Mode, open either refrigerator

or freezer door or press * and

NOTE: See Adaptive Defrost section for more

Pad

pad is pressed again.

B functions.

Pad

Alarm Off

deactivate Door Open alarm. To reactivate Door Open alarm, press and hold seconds.

Alarm Off

alarm is not corrected, alarm will reset.

panel.

sequence:

Freeze.

Program Mode A.

information on Vacation Mode.

pad is pressed and condition causing

Pad

Max Cool, Fast Freeze, Max Cool, Fast

Vacation

pad.

pad for 3 seconds to

Alarm Off

Vacation

pad for 3

pad.

April 1998 21 RS5290000 Rev. 0

Electronic Functional Description

Alarms

Power Up Alarm

After power is initially plugged in, after a power loss, or if power switch is turned off, all temperature

indicator lights will flash until pressed.

Note: All settings return to default factory settings. Door Open Alarm

Alarm tone sounds and indicator lights blink if either refrigerator or freezer door is open more than 3 minutes.

1. Turn off Door Open alarm by pressing pad or by closing door.

2. Deactivate door open alarm by pressing * pad and then press and hold

3. Door alarm delay can be adjusted in Program Mode B.

High Temperature Alarm

Alarm sounds and indicator light shows if freezer or refrigerator temperature has gone above critical level and remained warm for 2 hours. Alarm tone stops if temperature decreases again.

1. Critical temperature for freezer is -9°C(+15°F); for refrigerator critical temperature is +15.5°C(+60°F).

2. Press

Thermistor Alarm

Alarm sounds and freezer or refrigerator indicator turns on and temperature indicators 4 through 7 flash in sequence if either thermistor circuit opens. Refer to Temperature Control Operation Section and Electronic Testing Section.

1. Press

2. Alarm will retest for normal operation. If condition

Clean Condenser Light

Clean Condenser indicator light comes on after 3 months of elapsed time as a reminder to clean condenser coil.

Press Alarm Off pad to turn off Clean Condenser indicator light.

NOTE: Clean Condenser light will turn off after 72

Alarm Off

has not been corrected, alarm will sound again.

hours.

pad to turn off alarm.

Alarm Off

or * is

Alarm Off

pad for 3 seconds.

RS5290000 Rev. 0 22 April 1998

Electronic Functional Description

Temperature Control Operation

For any temperature setting, outputs will be turned off/on based on cut-in/cut-out temperatures determined by resistance levels of freezer and refrigerator thermistors.

As the temperature decreases, resistance increases. As the temperature increases, resistance decreases.

Refrigerator and Freezer Thermistor Part # C8983701 or C8983702

Temp Resistance °C (°F) Ohms

-29 (-20) 495600 2 (36) 87510

-26 (-15) 418200 3 (38) 82740

-23 (-9) 354000 4 (39) 78300

-21 (-6) 300600 6 (43) 74100

-18 (-4) 256200 7 (45) 70170

-15 (5) 218850 8 (46) 66450

-12 (10) 187170 9 (48) 62970

-9 (16) 161040 10 (50) 59670

-7 (19) 138690 13 (55) 52290

-4 (25) 119460 16 (61) 45900

-1 (30) 103680 18 (64) 40410 0 (32) 97920 21 (70) 36540 1 (34) 92550 25 (77) 30000

Temp Resistance °C (°F) Ohms

Factory Set Freezer and Refrigerator Settings Part #10866002

Frozen Food Fresh Food

Cut-Out

°C ± 1 °

(°F ± 1.5°)

-23 (-10) -16.6 (2) -1.6 (29) 1.1 (34) 9

-22 (-8) -15.5 (4) -0.5 (31) 2.2 (36) 8

-21 (-6) -14 (6) 0.5 (33) 3.3 (38) 7

-20.5 (-5) -13.8 (7) 1.1 (34) 3.8 (39) 6

-20 (-4) -13.3 (8) 1.6 (35) 4.4 (40) 5

-19 (-3) -12.7 (9) 2.2 (36) 5 (41) 4

-18.8 (-2) -1 2.2 ( 10) 2.7 (37) 5.5 (42) 3

-17.7 (0) -11.1 (12) 3.8 (39) 6.6 (44) 2

-16.6 (2) -10 (14) 5 (41) 7.7 (46) 1

-23 (-10) -16.6 (2) — —

— — 3 .8 (39) 6.6 (44)

Cut-In °C ± 1 °

(°F ± 1.5°)

Cut-Out

°C± 1 °

(°F ± 1.5°)

Cut-In °C ± 1 °

(°F ± 1.5°)

Level

Fast

Freeze

Max Cool

Damper Control

• Refrigerator temperature setting and thermistor value will determine if damper control heater switch is to be open or closed.

• Damper closes at 9°C (48°F).

• Damper opens at least 1/4" when minimum voltage is applied at 4°C (40°F) ambient.

An open thermistor or thermistor circuit will result in failure of refrigerator to cool.

Shorted thermistor will cause refrigerator to run 100 percent of time except for defrost.

• Freezer temperature setting and thermistor value will determine if compressor/condenser fan and evaporator fan switches are open or closed. Compressor/condenser fan switch must be open for 6 minutes before switch can close again (compressor dwell time).

• Cut-out and cut-in temperature values must be reached and maintained for 15 seconds before output state will change (digital delay).

• Refrigerator and freezer control calibration can be adjusted in Program Mode B.

Damper Heater

Watts Volts (DC)

2.00 Minimum 20.5 Minimum

2.74 Nominal 24.0 Nominal

3.60 Maximum 27.5 Maximum

April 1998 23 RS5290000 Rev. 0

Electronic Functional Description

Adaptive Defrost Operation

Defrost occurs after predetermined length of compressor run time. Compressor run time between defrosts changes, or adapts, depending upon recent history of defrost lengths (time it takes for defrost terminator to open after defrost heater has been turned on).

• Defrost terminator opens at 9°C (48°F) and closes at -9°C (15°F).

• Compressor run time between defrosts (CRTD) will be one of 3 values under normal operation: CRTD 1 (6 hours) or CRTD 2 (9 hours) or CRTD 3 (12 hours).

If defrost length is low (DT-LO defined as 21 minutes) indicating small frost load, CRTD for next defrost cycle is advanced to next level.

If defrost length is high (DI - HI defined as 24 minutes) indicating large frost load, CRTD for next defrost cycle is lowered to next level.

If defrost length is between 21 and 24 minutes, CRTD for next defrost cycle remains the same.

Initial value at power up CRTD 0 is 3 hours.

• Vacation Mode CRTD equals 72 hours. Vacation Mode CRTD is interrupted with door openings. Defrost interval will revert back to interval before Vacation Mode. Three things must occur to reach Vacation Mode CRTD:

1) Defrost interval must be CRTD 3 (12 hours).

2) Both refrigerator and freezer doors must have

remained closed since last defrost cycle.

3) Defrost thermostat must have opened in less

than 21 minutes during last defrost cycle.

• Six minute dwell time occurs after defrost terminator opens before compressor and condenser fan motor will operate. Ten minute dwell time occurs after defrost terminator opens before evaporator fan motor will operate. Dwell time can be bypassed by disconnecting power to the unit for 30 seconds.

• Conventional defrost can be selected in Program Mode B.

RS5290000 Rev. 0 24 April 1998

Electronic Functional Description

Program Mode

Accessing Program Mode

Two programming modes are available. Mode A allows reading refrigerator and freezer thermistor temperatures. Mode B is used for all other programmable functions.

1. Open refrigerator door.

2. Press * pad.

3. Press

4. Press the following sequence of pads within 6

5. When access is granted, tone will sound three

6. Toggle to Program Mode B by pressing * pad.

EEPROM Update in Control Memory

EEPROM is permanent programmable memory of the control panel.

• Entry tone, door audio alarm and status are stored

• Clean coil status is stored in EEPROM after every

• Information stored in EEPROM memory is not

Mode A Functions

Reading Temperature Display

Temperature display will show thermistor temperature in binary coded decimal format (BCD). Indicator lights 1 through 4 represent the tens digit with 1 being the most significant bit. Indicator lights 5 through 8 represent ones digit with 5 being the most significant bit. Positive and negative are shown by indicator light 9; light glows to show negative value

Indicator

1 2 3 4

5 6 7 8

Coldest

Vacation

seconds:

pad.

Max Cool, Fast Freeze, Max Cool, Fast

Freeze.

time and control will be in Program Mode A. Indicator light will illuminate.

Indicator light is off.

in EEPROM after control panel is deactivated.

defrost cycle as time until clean coil alarm is activated.

affected by power loss.

Value

8 4 2 1

Add togethe r all lit indicators 1 through 4 according to their values to obtain tens colum n digit. Example: If 3 and 4 are lit the tens colu m n to ta l is 3 (2 + 1 = 3)

8 4 2 1

+/-

Add togethe r all lit indicators 5 through 8 according to their values to ge t ones co lumn digit. Example: If 6 and 7 are lit the ones column total is 6 (4+2 = 6).

Freezer Thermistor Temperature

1. Choose freezer thermistor temperature display by pressing

2. Freezer thermistor temperature displays.

Refrigerator Thermistor Temperature

1. Choose refrigerator thermistor temperature display by pressing

2. Refrigerator thermistor temperature displays.

Freezer Temp

Fresh Food Temp

pad.

Mode B Functions

Automatic Keyboard Function

Activate and deactivate keyboard by toggling

Display Off

keyboard will disable after 10 minutes. If high temperature indicator is off, keyboard is always enabled. DO NOT LEAVE KEYBOARD IN ENABLED MODE AFTER PROGRAMMING IS COMPLETE.

Door Alarm Delay

1. Press glow. One temperature indicator should glow indicating present delay setting in minutes (indicator 1 means 1 minute, 2 means 2 minutes, etc.) Default delay is 3 minutes.

2. Press

3. Press

Max Cool Run Time Duration

1. Press temperature indicator should glow indicating present increments (indicator 1 means 2 hours, 2 means 4 hours, etc.) Default duration is 10 hours.

2. Press by 2 hours.

3. Press 2 hours.

Fast Freeze Run Time Duration

1. Press One temperature indicator should glow indicating present increments (indicator 1 means 4 hours, 2 means 8 hours, etc.) Default duration is 24 hours.

2. Press duration by 4 hours.

3. Press by 4 hours.

pad. If high temperature indicator glows,

Alarm Off

Warmer Colder

Max Cool

Warmer

Colder

Fast Freeze

Warmer

Colder

pad. Door open indicator will

pad to decrease delay by 1 minute.

pad to increase delay by 1 minute.

pad.

Max Cool

run time duration in 2 hour

pad to decrease

pad to increase

pad.

Fast Freeze

run time duration in 4 hour

pad to decrease

pad to increase

light will glow. One

Max Cool

duration

duration by

light will glow.

Fast Freeze

duration

Th e c o ldest in d ic a to r is n ot lit so example is +36 F.

NOTE: Temperature reads degrees Fahrenheit only .

Use conversion formula °C=5/9(°F-32).

April 1998 25 RS5290000 Rev. 0

3 6 Degrees F.

Electronic Functional Description

Program Mode

Temperature Offset Calibration

Offset amount adjusts temperatures for refrigerator cut-ins and cut-outs by the amount of offset. The chart below shows the indicator and the amount of offset from the factory default setting.

INDICATOR OFFSET

1 +8 2 +6 3 +4 4 +2 5 0 6 -2 7 -4 8 -6

Coldest -8

Forced Pulldown (Compressor Start)

Compressor start can be forced by pressing and holding changes will be saved permanently in EEPROM. Compressor, evaporator fan, damper heater, and condenser fan will come on.

Fast Freeze

pad for 3 seconds. Program

Exiting Program Mode

Press

pad for 3 seconds to exit Program Mode. Tone will sound three times. Changes made in Program Mode will be permanently saved in EEPROM.

NOTE: If no pad is pressed for 10 minutes, Program

Mode will be automatically exited. No changes will be saved if Program Mode exits automatically .

• Setting Refrigerator Temperature Offset Press

Fresh Food Temp

indicator and one indicator will glow. Press

Warmer

setting. Press next colder setting. Factory default refrigerator offset is +2.

• Setting Freezer Temperature Offset Press

indicator and one indicator will glow. Press Warmer pad to move offset to the next warmer setting. Press Colder pad to move offset to the next colder setting. Factory default freezer offset is 0.

Defrost Mode Selection

Toggle conventional defrost mode. Vacation indicator glows when adaptive defrost has been selected. If Vacation indicator is off, conventional defrost is selected. Conventional defrost uses 6 hour CRTD value.

Forced Defrost

Defrost can be forced to start by pressing and holding the

Alarm Off

will be saved permanently in EEPROM and program mode will exit to Run Mode.

pad to move offset to the next warmer

Colder

Freezer Temp

Vacation

pad to select adaptive or

pad for 3 seconds. Program changes

pad. Refrigerator

pad to move offset to the

pad. Freezer temperature

RS5290000 Rev. 0 26 April 1998

Electronic Functional Description

Electronic Testing

Electronic Testing Mode

Forced Defrost Start

1. Press * pad to activate control panel.

2. Simultaneously press and hold

Display Off

Forced Compressor Start

1. Press * pad to activate control panel.

2. Simultaneously press and hold and

Display Off

Open Thermistor Detect

Alarm sounds and freezer or refrigerator indicator light shows and temperature indicators 4 through 7 will turn on in sequence if either thermistor circuit opens. Refer to Temperature Control Operation Section and Electronic Testing Section.

1. Press

2. Alarm will retest for normal operation. If condition has not been corrected, alarm will sound again.

Evaporator Fan Suppression

The evaporator fan will turn off every time either refrigerator or freezer door is open.

To test if this function is operating:

1. Perform forced pull down procedure as noted above –evaporator fan should be on.

2. Open the refrigerator or freezer door–the fan should turn off.

3. Push the light switch off–the evaporator fan should start.

If fan does not toggle off and on when refrigerator light switch is turned off and on and it has been determined evaporator fan motor is operational, perform following tests to determine failure:

pads for 3 seconds.

pad for 3 seconds.

Alarm Off

pad to turn off alarm.

Max Cool

Fast Freeze

and

pad

2. Check for voltage on terminal E7 on high voltage board. Output voltage should toggle with toggling of light switch. If output voltage does not toggle, high voltage board needs replacing.

3. If terminal 7 on high voltage board changes with opening and closing of door, orange wire in low voltage harness is broken (check for continuity between pin 7 on high voltage board and pin 10 on low voltage board) or low voltage board needs replacing.

DANGER

To avoid electrical shock, personal injury or death, avoid contacting high voltage parts. Disconnect power to unit and discharge capacitor before handling.

1. Check for line voltage on terminal E8 on high voltage board. With freezer door open, reading should be 230 VAC. With door closed, reading should be approximately 0 VAC. If voltage does not change with light switch and light switch is turning light off and on, violet/white wire is broken between switch and high voltage board.

2. Check for voltage on pin 7 on pin connector of high voltage board. Output voltage should toggle with toggling of light switch. If it does not toggle, high voltage board needs replacing.

3. If voltage on pin 7 on pin connector on high voltage board changes with opening and closing of door, orange wire in low voltage harness is broken (check for continuity between pin 7 on high voltage pin connector and pin 10 on low voltage board) or low voltage board needs replacing.

DANGER

To avoid electrical shock, personal injury or death, avoid contacting high voltage parts. Disconnect power to unit and discharge capacitor before handling.

1. Check for line voltage on terminal E7 on high voltage board. With refrigerator door open (refrigerator light ON) reading should be 230 VAC. With refrigerator door closed (refrigerator light OFF) reading should be approximately 0 VAC.

If voltage does not change with light switch and light switch is turning light off and on, red/white wire is broken between switch and high voltage board.

April 1998 27 RS5290000 Rev. 0

Electronic Functional Description

WARNING

To avoid electrical shock which can cause severe personal injury or death, disconnect power to refrigerator using power switch before servicing. Discharge capacitors through a resistor before handling. Wires removed during disassembly must be replaced on proper terminals to insure correct earthing and polarization. After servicing, reconnect power using power switch.

COIL TERMINALS

SWITCH TERMINALS

LINE VOLTA GE

E10 E11 E12

RELAY COILS

EARTH

COMP/COND FAN RELAY

DEFROST RELAY

EVAP FAN RELAY

NEUTRAL (L2)

FREEZER DOOR OPEN

REFRIGERATOR DOOR OPEN

DEF ROST HEAT E R RELAY

COMP/CO N D FA N RELA Y CO IL

DEFROST HEATER RELAY COIL

EVAPORATOR FAN RELAY COIL

DAMPER HE ATER

R10

D11

12 PIN CO NNECTOR

RS5290000 Rev. 0 28 April 1998

Electronic Functional Description

WARNING

Resistance Checks Made at High Voltage Board

E10

Defrost Heat e r

Evaporator Fan Motor

Defrost Term inator

Power Switch

6.5 Ohms

39 8 Ohms

1 Ohm or less

Yellow Wire Ev a p. Fa n Mot or Relay

Red W ire Def ros t Re la y

Br own Wir e Comp ressor Relay

Refrig er ator Light Switch

E10

Freezer Light Switch

Overload

Cond ens e r Fan Mot or

Compressor

1 Ohm or less

Compressor Relay

Gray

Wire

Black Wire

April 1998 29 RS5290000 Rev. 0

Electronic Functional Description

WARNING

Refrigeration and Defrost Component Checks Made at High Voltage Board

Power Swtich Is ON

Low voltage board input W1 to D1 1 -25 VDC High voltage board input E10 (L)/E9 (N) 220 VA C

Compressor/condenser Blue/White Wire Contacts Closed 220 VAC Fan motor Comp/Relay to E9 Contacts Open 0 V AC

Compressor/condenser E4 to E12 Contacts Closed 220 VAC Fan motor Contacts Open 0 VAC Relay coil

Defrost heater E6 to E9 Contacts Closed 220 VAC

Contacts Open 0 VAC

Defrost heater E3 to E12 Contacts Closed -25 VDC Relay Coil Contacts Open 0 VDC

Defrost terminator E6 to E9 Contacts Closed 220 VAC (Klixon) Contacts Open 0 VAC

Damper heater output E1 to E11 Contacts Closed -25 VDC From high voltage board Contacts Open 0 VDC

Damper heater input R10 to E11 Contacts Closed -11 VDC From low voltage board Contacts Open -25 VDC From high voltage board

Evaporator Fan Motor E2 to E12 Contacts Closed -25 VDC Relay Coil Contacts Open 0 VDC

RS5290000 Rev. 0 30 April 1998

Electronic Functional Description

WARNING

230 VAC

Freezer Compartment

As freezer thermistor warms the resistance decreases allowing low voltage signal to be sent to electronic control. Electronic control send two low voltage signals, one to the compressor relay coil (C1) and one to the evaporator fan relay coil (E1).

When both relay coils are energized and both relay

April 1998 31 RS5290000 Rev. 0

contacts are closed, high voltage circuits to evaporator fan motor and compressor/condenser fan motor are complete.

As thermistor cools during refrigeration cycle, resistance through thermistor increases blocking low voltage signal to electronic control interrupting circuit.

Electronic Functional Description

WARNING

230 VAC

Refrigerator Compartment

As fresh food thermistor warms, resistance decreases allowing low voltage signal to be sent to the electronic control. Electronic control sends two low voltage signals, one to damper heater and one to evaporator fan relay coil (E1).

Damper heater warms damper control bellows, opening damper door at the same time relay coil closes high voltage contacts to evaporator fan motor.

RS5290000 Rev. 0 32 April 1998

With evaporator fan operating and damper door open, freezer air circulates into fresh food compartment. As fresh food thermistor cools, resistance increases blocking low voltage signal to electronic control interrupting circuit to evaporator fan motor relay coil and damper heater.

Electronic Functional Description

WARNING

230 VAC

Refrigerator and Freezer Compartment

If both freezer and fresh food thermistors are warm, the electronic control signals for compressor/ condenser fan motor operation and for damper door to open.

After freezer thermistor cools sufficient to block signal to electronic control the compressor/condenser fan motor will shut off. However, evaporator fan motor and damper heater will continue to run until fresh food thermistor cools and signal is blocked to electronic control.

April 1998 33 RS5290000 Rev. 0

If fresh food thermistor cools before freezer thermistor, electronic control will interrupt circuit to damper heater closing damper door while evaporator fan motor will continue to run under control of freezer thermistor.

Electronic Functional Description

WARNING

230 VAC

IMPORT ANT : When the power switch is

isolator see’s line voltage which keeps the electronic controller from signaling the evaporator fan motor or the compressor relay coils and also keeps the damper heater off.

Adaptive Defrost

After designated compressor run time, refrigeration cycle is interrupted and electronic control sends a low voltage signal to defrost relay coil (def D1).

Powering the relay coil closed relay contact (D1) completing high voltage circuit to defrost heater through closed defrost terminator (closes at -9°C).

Isolator, which is part of high voltage PC board, recognizes presence of line voltage to defrost heater and sends low voltage signal to electronic control. Electronic control keeps count of number of minutes defrost terminator remains closed (opens at 9°C).

RS5290000 Rev. 0 34 April 1998

Length of time defrost terminator is closed determines if the next defrost cycle advances by 3 hours of compressor run, stays at the same interval, or delays by 3 hours of compressor run.

If defrost terminator does not open before 29 minutes, defrost cycle is automatically terminated by electronic control and refrigeration cycles will resume after 6 minute dwell time.

OFF

, the

Component Testing

Component Description Test Procedures

Capacitor

Run capacitor connects to rel ay terminal 3 and L side of line.

Auger motor capacitor is i n series with auger motor. Auger motor capacitor does not have identified terminals and can be wired without regard to polarity.

To avoid electrical shock which c an cause severe personal injury or death, discharge capacitor through a resistor before handling.

1. Disconnect power to refrigerator.

2. Remove capacitor cover and disconnect capacitor wires.

3. Discharge capacitor by shorting across terminals with a resistor for 1 minute.

4. Check resistance across capaci tor terminals with ohmmet er set on “X1K” scale.

• Good—needle swings to 0 ohms and slowly moves back to i nf i ni ty.

• Open—needle does not move. Replace capacitor.

• Shorted—needle moves to zero and stays. Replace capacitor.

• High resistance leak—needle jumps toward 0 and then moves back to

constant high resistance (not infinity).

WARNING

Capillary tube Capillary is sized in diameter and length

to feed proper amount of refrigerant to evaporator.

Capillary is soldered to suction line to transfer heat from capillary and add additional superheat to gas refrigerant i n compressor suction line.

Capillary discharges into evaporator.

Restricted or clogged capillary tube mus t be replaced with tube of same inner diameter and length.

Follow all procedures for evacuation and charging of sealed system and for safe handling of refrigerant.

April 1998 35 RS590000 Rev. 0

Component Testing

Component Description Test Procedures

Compressor When compressor elec t ri cal circuit is

energized, the start winding c urrent causes relay to heat. A fter an amount of starting time, the start winding circui t turns off. The relay will switch off the start winding circuit even though compressor has not started (for example, when attempting to rest art after momentary power interruption).

With “open” relay, compressor will not start because there i s little or no current to start windings. Overload protection will open due to high locked roto r run winding current.

With “shorted” relay or capacitor, compressor will start and ov erload protector will quickly open due to high current of combi ned run and start windings.

With open or weak capacitor, compressor will start and run as normal but will consume more energy.

Resistance test

1. Disconnect power to unit.

2. Discharge capacitor by shorting across terminals with a resistor for 1 minute.

3. Remove leads from c o mpressor terminals.

4. Set ohmmeter to lowest scale.

5. Check for resistance bet ween

Term i nal s “S” and “C” Term i nal s “R” and “C”

If either com pressor winding reads open (infinite or very high resistance) or dead short (0 ohms), repl ace compressor.

Earthing test

1. Disconnect power to refrigerator.

2. Discharge capacitor by shorting terminals thro ugh a res i ster.

3. Remove compressor leads and use an ohmmet er set on highest scale.

4. Touch one lead to compressor body (clean point of contac t ) and the other probe to each compressor terminal. If a reading is obtained, compressor is earthed and must be replaced.

Operation test

If voltage, capac i t or, overload, and motor winding tes t s do not show cause for failure, perform the following test:

1. Disconnect power to refrigerator using power switch.

2. Discharge capacitor by shorting capacitor term i nal s through a resistor.

3. Remove leads from c o mpressor terminals.

4. Wire a test cord to power switch.

5. Place time delayed fuse with UL rating equal to amp rati ng of motor in test cord socket. (S ee Technical Data Sheet)

6. Remove overload and relay.

7. Connect start, common and run leads of test cord on appropriate terminals of compressor.

8. Attach capacitor leads of test cord together. If capacitor is used, attach capacitor lead to a known good capacitor of same c apacity.

To AC supply

Switch

Compress

Fuses

9. Plug test cord into volt -watt meter to determine start and run wattage as well as check for low voltage which can also be a source of trouble.

10. With power to volt-meter, press start cord switch and release.

• If compressor motor starts and draws normal wattage, compressor i s

okay and trouble is in capacitor, relay/overload, freezer temperature control, or elsewhere in system.

• If compressor does not start when direct wired, recover s ys tem at high

side. After system is recovered, repeat compressor di rect wire test. If compressor runs after recovery but would not run when direct wired before recover, a restric t i on in sealed system is indicated.

• If compressor does not run when wired direct after recover, repla c e

faulty compressor.

CRS

Capacitor

RS590000 Rev. 0 36 April 1998

Component Testing

Component Description Test Procedures

Condenser Condens er i s a tube and wire

construction and is located in compressor compartment.

Leaks in condenser can usuall y be det ected by using an electronic leak detector or soap solution. Look for s i gns of compressor oil when check i ng f or l eaks. A certain amount of compressor oil is circul ated with refrigerant.

Condenser is on the high pressure discharge side of com pressor. Condenser function is to t ransfer heat absorbed by refrigerant to ambient .

Higher pressure gas is routed to condenser where, as gas temperature i s reduced, gas condenses into a hi gh pressure liquid state. Heat transfer takes place because discharged gas i s at a higher temperature than air that i s passing over condenser. It i s very important that adequate ai r f l ow over condenser is maintai ned.

Condenser is air cooled by condenser fan motor. If efficiency of heat transfer from condenser to surrounding ai r i s impaired, condensing temperature becomes higher. High liqui d t emperature means the liquid will not remove as much heat during boiling in evaporator as under normal conditions. Thi s would be indicated by higher than normal head pressures, long run tim e, and high wattage. Remove any lint accumulation, etc. that would restrict normal air movement through condens er.

From condenser the refrigerant flows into a post condenser loop which helps control exterior condensation on flange, center mullion, around freezer door and then through the drier to the evaporator and into the compressor through the suction line.

Leaks in post condenser loop are rare bec ause loop is a one-piece copper tube. For minute leaks

1. Separate condenser from rest of refri geration system and pressurize condenser up to a maximum of 16 bars (235 PSI) with a refrigerant and dry nitrogen combination.

2. Recheck for leaks.

WARNING

To avoid severe personal injury or death observe the f ol l owing:

• Protect against a sudden eruption if hi gh pressures are required for leak checking.

• Do not use high pressure compressed gas es in refrigeration systems without a reli abl e pressure regulator and pressure relief valve in the lines.

Damper Control Damper c ont rol bal ances the air delivery

between refrigerator and freezer compartments . Integral capillary activates damper control and door closes rest ri cting flow of air from freezer compartment to refrigerator compartment. There are no electrical connecti ons to damper control on non-electronic units. See Electronic Functi onal Description for explanation of damper control on electronic units.

Subject capillary to appropriate temperat ure (see tech sheet for model being serviced). Damper door should close to withi n 6 mm of completel y s hut.

If altitude adjustment is required, turn altit ude adj ustment screw 1/8 turn clockwise for each 305 m et ers increase in altitude.

April 1998 37 RS590000 Rev. 0

Component Testing

Component Description Test Procedures

Control, freezer temperature (Non-electronic units)

Drier Drier is placed at post condenser loop

Freezer temperature control is a capillary tube operating a single pole, singl e throw switch.

Altitude Adjustment When altitude adj us tment is required on a G.E. control, turn altitude adjustment screw 1/7 turn clockwise for eac h 305 meters increase in altitude up to 3,050 meters. In most cases the need for altitude adjustments can be avoi ded by simply turning temperature control knob to colder setting.

outlet and passes liquefi ed refrigerant to capillary.

Check for proper calibration with thermoc ouple capillary in air supply well by recording cut-in and cut-out t emperatures in middle setting. See tech sheet for model being serviced for expected t emperatures. Check control contacts are opening by disconnecting elect ri cal leads to control turning control knob to coldest setting and checking f or continuity across terminals.

Altitude correction must be done on both “cut-in” and “cut-out ” screws.

Altitude Counter in Meters Meters Cloc kwise Turns

610 915 1220 1525 1830 2135 2440 2745 3050

Drier must be changed every time the system is opened f or t esting or compressor replacement.

NOTE: Drier used in R12 sealed system is not interchangeable with

drier used in R134a sealed system. Always replace the drier with Amana

part number B2150504.

Before opening refrigeration syst em, recover HFC134a refrigerant for safe disposal. Cut drier out of system using the following procedure. Do not unbraze drier. Applying heat to remove drier will drive moisture into the system.

1. Score capillary tube close to drier and break.

2. Reform inlet tube to drier allowing enough space f or l arge t ube cutter.

3. Cut circumference of drier 3 cm below condenser inlet tube joint to drier.

4. Remove drier.

5. Apply heat trap paste on post condenser tubes to protect grommets from

high heat.

6. Unbraze remaining part of drier. Remove drier from system.

7. Discard drier in safe place. Do not leave drier with customer. If refrigerat or i s

under warranty, old drier must accompany warranty claim.

7/60 13/60 19/60 25/60 31/60 37/60 43/60 49/60 55/60

Evaporator Inner volume of evaporator allows

liquefied refrigerant discharged from capillary to expand into refrigerant gas.

Expansion cools evaporate tube and fin temperature to approximately -29° C (-20°F) transferring heat from freezer section to refrigerant.

Passing through sucti on l i ne to compressor, the refrigerant picks up superheat (a relationship between pressure and temperature that assures complete vaporization of l i qui d refrigerant) as result of capillary on suction line.

Refrigerant gas is pulled through s uction line by compressor to complete the refrigerant cycle.

CAUTION

To avoid death or severe personal injury, cut dri er at correct location. Cutting drier at incorrect locati on will allow desiccant beads to scatter. If spilled, complet el y clean area of beads.

Test for leaks in evaporator with electronic leak detector or with soap s ol ution. Compressor oil is c i rculated with refrigerant; check for oi l when chec king for leaks.

WARNING

To avoid severe personal injury or death observe the f ol l owing:

• Protect against a sudden eruption i f high pressures are required for leak checking.

• Do not use high pressure compressed gases in refrigeration systems without a reliable pressure regulator and press ure rel i ef valve in the lines.

For minute leaks

1. Separate evaporator from rest of refrigerat i on system and pressurize condenser up to a maximum of 10 bars (140 PSI) with a refrigerant and dry nitrogen combination.

2. Recheck for leaks.

RS590000 Rev. 0 38 April 1998

Component Testing

Fusible link Fusi bl e l i nk is part of evaporator heater

Heater, door Applied to back of ice and water cavity to

Heater, evaporator (defrost)

Ice Maker See “Ice Maker” section for service Motor, auger Located behind ice bucket. Drives helix

wiring harness and is in a series ci rcuit with defrost terminator, defrost heater, and evaporator fan motor.

If the defrost terminator fails to open and temperature increases to fusible link, fuse will open breaking circuit so defrost heater will be shut down.

help prevent condensation from forming on face of cavity.

Activated when defrost thermostat or adaptive defrost control completes the circuit through the heater.

information. auger and cube crusher. PSC (Permanent Split Capacitor) motor

requiring a run capacitor. Controlled by ice actuator switch in

series with freezer door auger interlock switch and cube/crushed ice switch.

If fusible link interrupts opens, evaporator heater wiring harness must be replaced.

Be sure harness is wire tied against evaporator heater over white mark on evaporator heater.

Some models have spare heater foamed in place at fact ory. See tech sheet for model being serviced.

Check resistance across heater (for resistance values see tech sheet for model being serviced).

Check resistance across heater. To check defrost system

1. Thermocouple defrost thermostat and plugging refrigerator into wattmeter.

2. Force into defrost mode (see section on electronic testing). Wattmeter should read specified watts (ac cording to tech sheet).

3. When defrost thermos tat reaches specified temperature (see tech sheet) ±5°F; therm ostat should interrupt power to heater.

Disconnect power and ohm winding and check f or earthing. Crushed/Cube Dispensing Models:

At room ambient temperature check resistance between wire leads (see tech sheet for colors on uni t being serviced).

Cube Dispensing Models:

At room ambient temperature check resistance cross motor windings. For resistance values see t ech sheet for model being servic ed.

Internal overload trips out aft er approximately 90 second of conti nuous run and resets in approximately 3

Motor, condenser Condenser fan moves cooling ai r ac ross

Motor, evaporator fan

Overload/Relay Overload is a temperature and current

minutes. condenser coil and compressor body. Condenser fan motor is in parall el circuit

with compressor.

Evaporator motor moves air across evaporator coil and throughout refrigerator.

Evaporator fan is in a series c i rcuit with temperature control, defrost terminator, and defrost heater.

sensing device. Overload opens when high current or

high compressor temperature is sensed. After overload opens, reset c an requi re

up to two hours depending on ambient temperature and residual heat load i n compressor.

Relay (See PTC Relay)

Check resistance across winding (for resistance value see t ech sheet for model being serviced).

1. Disconnect power to unit.

2. Disconnect fan motor leads.

3. Check resistance from earth connection solder. Trace to m otor frame must not exceed .05 ohms.

4. Check for voltage at connector to motor with terminator and temperature control closed.

1. Disconnect power to the refrigerator.

2. Remove relay cover and pull relay off compressor. Pull overload protec tor off compressor common terminal.

3. With ohmmet er, check the resistance between m al e terminal and female pin receptacle terminal whic h pus hes onto compressor common terminal. A t ambient room temperature overload protector should have less than 1 ohm resistance. An open overload protect or will have infinite res i stance.

April 1998 39 RS590000 Rev. 0

Component Testing

Relay, PTC When voltage is connected and relay is

cool, current passes through relay to start winding. After a short time, current heats the resist or i n rel ay and resistance will rise blocking current flow through relay. Start winding remains in the circuit through run capacitor.

Solid state relay plugs directly on compressor start and run terminals. Relay terminals 2 and 3 are c onnected within relay. Run capacitor is connected to relay terminal 3. L2 side of 230 VAC power is connected to relay terminal 2.

Switch, keyboard Semiconductor switch for c ont rol panel

keyboard.

With power off check resistance across terminals 2 and 3:

Normal = 3 to 12 ohms Shorted = 0 ohms Open = infinite ohms

Switch Functions

Enable Key S1 1 and 3

Freezer Temperature S2 3 and 6

Refrigerator Temperature S3 3 and 7

Warmer S4 6 and 7

Colder S 5 4 and 6

Vacation S6 4 and 7

Max Cool S7 7 and 8

Fast Freeze S 8 4 and 8

Alarm Off S9 4 and 5

Display Off S10 5 and 8

Keypad Symbol

Continuity Test

PERIMETER STATIC GUARD

Switch, SPDT icemaker interlo ck

Interrupts connect i on to auger motor and icemaker when freezer door is open. Turns freezer light on when door is open.

In series with auger mot or and

cube/crushed switch and freezer light. Switch, crushed/cubed

Switch, refrigerator light, freezer light,

Selects between cubed or crus hed i ce

feature.

Completes circuit to allow indicated

function. See tech sheet and wiring

diagram for individual switch. refrigerator fan

Switch, power SPDT

Electronic mo dels only. Disconnect s

power to high voltage board when switch

is off (open.)

Unit shipped with switch on.

Check resistance across terminals.

Continuity across t erminals 1 and 2 – light Continuity across t erminals 1 and 3 – auger motor

Check resistance across terminals.

Switch left

Middle terminal to left terminal 0 ohms Middle terminal to right terminal infinite ohms

Switch right

Middle terminal to right terminal 0 ohms Middle terminal to left terminal infinite ohms

Check resistant across terminals.

Switch arm down

“NC” terminals Cl osed “NO” terminals Open

Switch arm up

“NC” terminals O pen “NO” terminals Closed

Check resistance across terminals

Swtch OFF 0 ohms Switch ON infinite ohms

RS590000 Rev. 0 40 April 1998

Component Testing

Switch, photosensitive

Thermistor Senses temperatures within refrigerator

Thermostat Thermostat is in a series circ ui t with

In series with cavity light switch and cavity light. Senses low light condition to complete circuit to cavity light.

Switch must not generate line conducted noise or radiate inference more than three feet on the AM, FM, VHF, or USH Frequency bands.

and freezer compartm ents.

defrost termi nat ors, defrost heater, and evaporator fan motor. Ci rcuit is compl ete if evaporator fan mot or operates when cold.

Controls the circui t from freezer thermostat t hrough defrost terminator t o defrost heater. Opens and breaks circuit when thermostat sens es preset high temperature.

After defrost t hermostat opens, thermostat remains open until end of defrost cycle and refrigerator starts cooling again and defrost t hermostat senses a preset low temperature and closes.

1. To check light sensor with cavity light switch on, cover light sensor eye. Cavity lamp should light at approximately 50% of full illumination.

2. If lamp fails to illuminat e, activate water or ice dispenser switch. Lamp should illuminate at full illumination and water or ice should be dispens ed.

3. If light illuminates, dis connect power and replace light sensor.

4. If lamp does not illuminat e, disconnect power and check cavit y lamp and socket.

Check resistanc e across terminals. See tech sheet for bell c urve resistance chart at given temperatures .

Test continuity ac ross terminals. With power off and evaporator coil below freezing, therm ostat should check

continuous when checked wit h ohmmeter. See “Heater, evaporator (defrost)” section for additi onal tests.

Timer, defrost Timer motor operates only when freezer

control is clos ed. After specified amount of actual com pressor run time, inner cam in timer throws the contacts from terminal 4, the compressor circuit to terminal 2, and defrost thermostat/ defrost heater circuit.

After 33 minutes of defrost cycle ti me, timer cam resets the circuit ry through terminal 4 to compressor.

Valve, water Cont rol s water flow to the ice mak er and

cavity.

1. To check timer motor winding, check for cont i nuity between terminals 1 and 3 of timer.

2. Depending on the rotation of the c am, terminal 1 of timer is common to both terminal 2, the defrost modes, or terminal 1, the compres sor mode. There should never be continuity b etween terminals 2 and 4.

3. With conti nui ty between terminals 1 and 4, rota t e timer knob clock wise unt i l audible click is heard. When the cl i ck is heard, the reading between terminals 1 and 4 shoul d be infinite and there should be c ontinuity between terminals 1 and 2.

4. Continuing to rotate tim e knob until a second cli ck is heard should restore circuit between term i nal s 1 and 4.

Check resistanc e across coil windings.

April 1998 41 RS590000 Rev. 0

Product Design

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Refrigeration System

Compressor forces high temperature vapor into fancooled tube and wire condenser where vapor is cooled and condensed into high pressure liquid by circulation of air across condenser coil. (See Refrigerant Flow Diagram.)

High pressure liquid passes through molecular sieve drier and into capillary tube. Small inside diameter of capillary offers resistance decreasing pressure and temperature of liquid discharged into evaporator. Capillary diameter and length is carefully designed for each system.

Capillary enters evaporator at top back. Combined liquid and saturated gas flows through back to bottom of coil and into suction line. Aluminium tube evaporator coil is located in freezer compartment where circulating evaporator fan moves air through coil and into fresh food compartment.

Large surface of evaporator allows heat to be absorbed from both fresh food and freezer compartments by airflow over evaporator coil causing some of the liquid to evaporate. Temperature of evaporator tubing near end of running cycle may vary from -25° to -32°C.

Saturated gas is drawn off through suction line where superheated gas enters compressor. To raise temperature of gas, suction line is placed in heat exchange with capillary.

Nonelectronic Temperature Controls

Freezer compartment temperature is regulated by air sensing thermostat at top rear of fresh food compartment which actuates compressor. Control capillary is inserted in well which routes capillary into freezer. Control should be set to maintain freezer temperature between -17° to -18°C.

Fresh food compartment temperature is regulated an air damper control governing amount of refrigerated air entering fresh food compartment from freezer. Fresh food compartment temperature should be between 3° and 4°C.

Electronic Control

Electronic control is not repairable. If any component in control is faulty, entire control must be replaced.

NOTE: Repair or replace all faulty line voltage

components before testing or replacing electronic control. Do not assume problems are caused by electronic control system. Opened, shorted, earthed or otherwise faulty line voltage components (including power cord and wiring) can create problems that appear to be caused by electronic control.

Refrigerated Chiller Fresh Deli Drawer

Chiller Fresh system is a deli drawer in a sleeve. Control on inner wall of fresh food compartment allows freezer air to circulate into sleeve maintaining temperature 4°C ±1° colder than fresh food compartment.

Boot must be in place over air inlet. Set to maintain desired temperature in deli drawer.

Beverage Chiller

Control on left inner wall of fresh food compartment allows freezer air to circulate into beverage chiller maintaining temperature up to 3°C colder than fresh food compartment. Valve on outside wall of refrigerator door allows freezer air to pass to beverage chiller.

Fresh food compartment temperature can be affected by additional cold air so freezer temperature control may need adjustment after beverage chiller temperature is set.

RS5290000 Rev. 0 42 April 1998

Product Design

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Defrost System–Nonelectronic Models

Every 6 or 8 hours of compressor run time defrost timer activates radiant electric defrost heater suspended from evaporator. After 33 minutes of defrost cycle time, timer restores circuit to compressor.

Defrost terminator (thermostat) and fusible link are wired in series with defrost heater and evaporator fan motor. Terminator opens and breaks circuit when preset high temperature is reached. After defrost thermostat opens, thermostat remains open until end of defrost cycle until cooling cycle starts and terminator senses present low temperature and closes.

Fusible link opens if terminator fails open and preset high temperature is reached.

Defrost heater is suspended on left side of evaporator coil and across bottom to keep defrost drain free flowing during defrost. Defrost water is caught in trough under evaporator coil and flows through drain hole in liner and drain tubing into drain pan. Heated air circulated by condenser fan over pan evaporates water.

Defrost System–Electronic Models

See “Electronic Functional Description.”

April 1998 43 RS5290000 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Service Equipment

Listed below is equipment needed for proper servicing of HFC134a systems. Verify equipment is confirmed by manufacturer as being compatible with HFC134a and ester oil system.

Equipment must be exclusively used for HFC134a. Exclusive use of equipment only applies to italic items.

• Evacuation pump Check with vacuum pump supplier to verify equipment is compatible for HFC134a. Robinair, Model 15600, 2 stage, 170 litres (6 cubic feet) per minute pump is recommended.

• Four-way manifold gauge set, with low loss hoses

• Leak detector

•

Charging cylinder

• Line piercing saddle valve

(Schroeder valves). Seals must be HFC134a and ester oil compatible. Line piercing valves may be used for diagnosis but are not suitable for evacuation or charging, due to minute holes pierced in tubing. Do not leave mechanical access valves on system. V alves eventually will leak. Molecules of HFC134a are smaller than other refrigerants and will leak where other refrigerants would not.

• Swagging tools

•

Flaring tools

• Tubing cutter

• Flux

• Sil-Fos

• Silver solder

• Oil for swagging and flaring

Use only part #R0157532

• Copper tubing

Use only part #R0174075 and #R0174076

• Dry nitrogen

99.5% minimum purity , with -40°C (-40°F) or lower dew point

• Crimp tool

• Tube bender

• Micron vacuum gauge

• Process tube adaptor kit

• Heat trap paste

• ICI appliance grade HFC134a

Drier Replacement

Prior to opening refrigeration system, recover HFC134a refrigerant for safe disposal.

Every time sealed HFC134a system is repaired, drier filter must be replaced with, part # B2150504.

Cut drier out of system by completing the following steps. Do not unbraze drier filter. Applying heat to remove drier will allow moisture into system.

WARNING

To avoid death or severe personal injury, cut drier at correct location. Cutting drier at incorrect location will allow desiccant beads to scatter. Completely clean area of beads, if spilled.

1. Score capillary tube close to drier and break.

2. Reform inlet tube to drier allowing enough space for large tube cutter.

3. Cut circumference of drier at 3 cm (1-1/4"), below condenser inlet tube joint to drier.

4. Remove drier.

5. Apply heat trap paste on post condenser tubes to protect grommets from high heat.

6. Unbraze remaining part of drier. Remove drier from system.

7. Discard drier in safe place. Do not leave drier with customer. If refrigerator is under warranty, old drier must accompany warranty claim.

RS5290000 Rev. 0 44 April 1998

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all wires are connected before certifying unit as repaired and/or operational.

Refrigerant Precautions

WARNING

To avoid personal injury, do not allow refrigerant to contact eyes or skin.

CAUTION

To avoid risk of property damage, do not use refrigerant other than that shown on unit serial number identification plate.

NOTE: All precautionary measures recommended by

refrigerant manufacturers and suppliers apply and should be observed.

Line Piercing Valves

Line piercing valves can be used for diagnosis, but are not suitable for evacuating or charging due to holes pierced in tubing by valves.

NOTE: Do not leave line piercing valves on system.

Connection between valve and tubing is not hermetically sealed. Leaks will occur.

Open Lines

During any processing of refrigeration system, never leave lines open to atmosphere. Open lines allow water vapor to enter system, making proper evacuation more difficult.

Compressor Operational Test

(short term testing only) If compressor voltage, capacitor, overload, and motor

winding tests are successful (do not indicate a fault), perform the following test:

1. Disconnect power to unit.

2. Discharge capacitor by shorting capacitor terminals through a resistor.

3. Remove leads from compressor terminals.

4. Attach test cord to compressor windings.

• Common lead on test cord attaches to C terminal on compressor.

• Start lead on test cord attaches to S terminal on compressor.

• Run lead on test cord attaches to M terminal on compressor.

To AC supply

Switch

Compressor

Fuses

Attaching Capacitor for Compressor Test

5. Connect a known good capacitor into circuit as shown above. For proper capacitor size and rating, see Technical Sheet for unit under test.

NOTE: Ensure test cord cables and fuses meet

specifications for unit under test (see Technical Sheet for unit under test).

6. Replace compressor protector cover securely.

7. Plug test cord into outlet, then press and release start cord switch.

CRS

Capacitor

CAUTION

To avoid damage to compressor windings, immediately disconnect (unplug) test cord from power source if compressor does not start. Damage to compressor windings occurs if windings remain energized when compressor is not running.

If compressor runs when direct wired, it is working properly. Malfunction is elsewhere in system.

If compressor does not start when direct wired, recover system at high side. After the system is recovered, repeat compressor direct wire test.

If compressor runs after system is recovered (but would not operate when wired direct before recovery) a restriction in sealed system is indicated.

If motor does not run when wired direct after recovery, replace faulty compressor.

April 1998 45 RS5290000 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Dehydrating Sealed Refrigeration System

Moisture in a refrigerator sealed system exposed to heat generated by the compressor and motor reacts chemically with refrigerant and oil in the system and forms corrosive hydrochloric and hydrofluoric acids. These acids contribute to the breakdown of motor winding insulation and corrosion of compressor working parts, causing compressor failure.

In addition, sludge, a residue of the chemical reaction, coats all surfaces of sealed system, and will eventually restrict refrigerant flow through capillary tube.

To dehydrate sealed system, evacuate system (see paragraph Evacuation).

Leak Testing

DANGER

To prevent serious injury or death from violent explosions, NEVER use oxygen or acetylene for pressure testing or clean out of refrigeration systems. Free oxygen will explode on contact with oil. Acetylene will explode spontaneously when put under pressure.

It is important to check sealed system for refrigerant leaks. Undetected leaks can lead to repeated service calls and eventually result in system contamination, restrictions, and premature compressor failure.

Testing Systems Containing a Refrigerant Charge

1. Stop the operation (turn refrigerator off).

2. Holding leak detector exploring tube as close to system tubing as possible, check all piping, joints, and fittings.

NOTE: Use soap suds on areas leak detector cannot

reach or reliably test.

Testing Systems Containing No Refrigerant Charge

1. Connect cylinder of nitrogen, through gauge

manifold, to process tube of compressor and liquid line strainer.

2. Open valves on nitrogen cylinder and gage

manifold. Allow pressure to build within sealed system.

3. Check for leaks using soap suds.

If a leak is detected in a joint, do not to attempt to repair by applying additional brazing material. Joint must be disassembled, cleaned and rebrazed. Capture refrigerant charge (if system is charged), unbraze joint, clean all parts, then rebraze.

If leak is detected in tubing, replace tubing. If leak is detected in either coil, replace faulty coil.

Refrigerant leaks are best detected with halide or electronic leak detectors.

RS5290000 Rev. 0 46 April 1998

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Restrictions

Symptoms

Restrictions in sealed system most often occur at capillary tube or filter drier, but can exist anywhere on liquid side of system.

Restrictions reduce refrigerant flow rate and heat removal rate. Wattage drops because compressor is not circulating normal amount of refrigerant.

Common causes of total restrictions are moisture, poorly soldered joints, or solid contaminants. Moisture freezes at evaporator inlet end of capillary tube. Solid contaminants collect in filter drier.

If restriction is on low side, suction pressure will be in a vacuum and head pressure will be near normal

If restriction is on high side, suction pressure will be in a vacuum and head pressure will be higher than normal during pump out cycle.

Refrigeration occurs on low pressure side of partial restriction. There will be a temperature difference at the point of restriction. Frost and/or condensation will be present in most case at the point of restriction. Also, system requires longer to equalize.

Slight or partial restriction can give the same symptoms as refrigerant shortage including lower than normal back pressure, head pressure, wattage, and warmer temperatures.

Total restriction on the discharge side of compressor when restriction is between compressor and first half of condenser results in higher than normal head pressure and wattage while low side is being pumped out.

Testing for Restrictions

To determine if a restriction exists:

1. Attach gauge and manifold between suction and discharge sides of sealed system.

2. Turn unit on and allow pressure on each side to stabilize. Inspect condenser side of system. Tubing on condenser should be warm and temperature should be equal throughout (no sudden drops at any point along tubing).

• If temperature of condenser tubing is consistent throughout, go to step 4.

• If temperature of condenser tubing drops suddenly at any point, tubing is restricted at point of temperature drop (if restriction is severe, frost may form at point of restriction and extend down in direction of refrigerant flow in system). Go to step 5.

3. Visually check system for kinks in refrigeration line which is causing restriction. Correct kink and repeat step 2.

4. Turn unit off and time how long it takes high and low pressure gauges to equalize:

• If pressure equalization takes longer than 10 minutes, a restriction exists in the capillary tube or drier filter. Go to step 5.

• If pressure equalization takes less than 10 minutes, system is not restricted. Check for other possible causes of malfunction.

5. Recover refrigerant in sealed system. NOTE: Before opening any refrigeration system,

capture refrigerant in system for safe disposal.

6. Remove power from unit.

CAUTION

To reduce risk of personal injury or property damage, take necessary precautions against high temperatures required for brazing.

7. Remove and replace restricted device.

8. Evacuate sealed system.

9. Charge system to specification. NOTE: Do not use captured or recycled refrigerant in

Amana units. Captured or recycled refrigerant voids any Amana and/or compressor manufacturer's warranty .

NOTE: Charge system with exact amount of refrigerant.

See Technical Sheet or refer to unit nameplate for correct refrigerant charge. Inaccurately charged system will cause future problems.

April 1998 47 RS5290000 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Evacuation and Charging

CAUTION

To avoid risk of fire, sealed refrigeration system must be air free. To reduce risk of air contamination, follow evacuation procedures exactly.

NOTE: Before opening any refrigeration system, EPA

regulations require refrigerant in system to be captured for safe disposal.

Proper evacuation of sealed refrigeration system is an important service procedure. Usable life and operational efficiency greatly depends upon how completely air, moisture and other non-condensables are evacuated from sealed system.

Air in sealed system causes high condensing temperature and pressure, resulting in increased power requirements and reduced performance.

Moisture in sealed system chemically reacts with refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These acids attack motor windings and parts, causing premature breakdown.

Before opening system, evaporator coil must be at ambient temperature to minimize moisture infiltration into system.

Evacuation

To evacuate sealed refrigeration system:

1. Connect vacuum pump, vacuum tight manifold set with high vacuum hoses, thermocouple vacuum gauge and charging cylinder as shown in illustration.

Evacuation should be done through I.D. opening of tubes not through line piercing valve.

2. Connect low side line to compressor process tube.

3. Connect high side line to drier/process tube.

4. Evacuate both simultaneously. With valve “C” and “F” closed, open all other valves and start vacuum pump.

High Side Gauge

Valve

Chargi ng Hose

Drier/Process Tube

Valve

Charging

Cylinder

Thermistor

Vacuum Gauge

Compressor

Low Side Gauge

Chargi ng Hose

Compressor Process Tube

.6 cm Copper

Tubing

Valve

Vacuum Pump

Equipment Setup For Evacuation And Charging

5. After compound gauge (low side) drops to approximately 29 inches gauge, open valve “C” to vacuum thermocouple gauge and take micron reading.

NOTE: A high vacuum pump can only produce a good

vacuum if oil in pump is not contaminated.

6. Continue evacuating system until vacuum gauge registers 600 microns.

7. At 600 microns, close valve “A” to vacuum pump and allow micron reading in system to balance. Micron level will rise.

• If in 2 minutes, micron level stabilizes at 1000

microns or below, system is ready to be charged.

• If micron level rises above 1000 microns and

stabilizes, open valve “A” and continue evacuating.

• If micron reading rises rapidly and does not

stabilize, a leak still exists in system. Close valve “A” to vacuum pump and valve “C” to

vacuum gauge. Invert charging cylinder and open charging cylinder valve “F” to add partial charge for leak checking. With leak detector, check manifold connections and system for leaks. After locating leak, capture refrigerant, repair leak, and begin at step 1.

RS5290000 Rev. 0 48 April 1998

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Charging NOTE: Do not use captured or recycled refrigerant in

Amana units. Captured or recycled refrigerant voids any warranty .

NOTE: Charge system with exact amount of refrigerant.

See Technical Sheet or refer to unit serial plate for correct refrigerant charge. Inaccurately charged system will cause future problems.

To charge system:

1. Close valves “A” to vacuum pump and “C” to vacuum gauge and “E” to low side manifold gauge.

2. Set scale on dial-a-charge cylinder for corresponding HFC134a pressure reading.

3. Open valve “F” to charging cylinder and let exact amount of refrigerant flow from cylinder into system. Close valve.

Low side gauge pressure should rise shortly after opening charging cylinder valve as system pressure equalizes through capillary tube.

If pressure does not equalize, a restriction typically exists at capillary/drier braze joint.

4. If pressure equalizes, open valve “E” to low side manifold gauge and pinch off high side drier process tube.

5. Start compressor and draw remaining refrigerant from charging hoses and manifold into compressor through compressor process tube.

6. To check high side, pinch-off drier process tube. Close valve “D” to high side gauge. If high side pressure rises, repeat high side pinch-off and open valve “D”. Repeat until high side pinch-off does not leak.

7. Pinch-off compressor process tube and remove charging hose. Braze stub closed while compressor is operating.

8. Disconnect power. Remove charging hose and braze high side drier process tube closed.

9. Recheck for refrigerant leaks.

Refrigerant Charge

Refrigerant charge in all capillary tube systems is critical and exact amount is required for proper performance. Factory charges are shown on serial plate. Do not use refrigerant other than shown on serial plate.

April 1998 49 RS5290000 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

HFC134a Service Information

HFC134a is alternative refrigerant for CFC12. HFC134a has an ozone depletion potential (ODP) factor of 0.0 and a global warming potential (GWP) factor of 0.27. HFC134a is not flammable and has acceptable toxicity levels. HFC134a is not interchangeable with CFC12. There are significant differences between HFC134a and CFC12 which must be considered when handling and processing refrigeration system.

Health, Safety, and Handling

Health, safety and handling considerations for HFC134A are virtually no different than those for CFC12.

Health, Saf ety, and Handling CFC12 HFC1 34a

Allowable overall exposure limit 1,000 ppm Same Vapor exposure to skin No effect Same

Liquid exposure to skin Can cause frostbite Same Vapor exposure to eye Very slight eye irritant Sam e Liquid exposure to eye Can cause frostbit Same Above minimum exposure limit Can cause Asphyxiation,

Safety and handling Wear appropriate skin

Spill management Remove or extinguish

Fire explosion hazards May decompose if

Disposal procedures Recycle or reclaim. Same

Tachycardia, and Cardia Arrhythmias

and eye protection. Use with adequate ventilation.

ignition or combustion sources. Evacuate or ventilate area.

contact with flames and heating elements. Container may explode if heated due to resulting pressure rise. Combustion products are toxic.

Comparison of CFC12 and HFC134a Properties

Properties/Characteristics CFC12 HFC134a

Ozone Depletion Potential (ODP) 1.0* 0.0* Global Warming Potential (GPW) 3.2* 0.27* Molecular weight 121 102 Boiling point at 1 atmosphere -22°F (-30°C) -15°F (-

Vapor pressure at 77°F (25°C) 80 psig 82 psig Liquid density at 77°F (25°C) 82 lb/ft Flammability No No High-side system operating Pressure at 65°F (18°C) Low-side system operating Pressure at 65°F (18°C)

HFC134a approximately 3 psig higher than CFC12 HFC134a approximately 2 psig lower than CFC12

Same

26°C)

75 lb/ft

Caution

To minimize contamination, exercise extreme care when servicing HFC134A sealed systems.

• No trace of other refrigerants is allowed in HFC134a systems. Chlorinated molecules in other refrigerants such as CFC12, etc. will lead to capillary tube plugging.

• Ester oil is used in HFC134a systems. Do not use mineral oil. HFC134a and mineral oils cannot be mixed. If mineral oils were used in HFC134a systems, lubricant would not return to compressor and would cause early compressor failure. If significant amount of oil has been lost from compressor, replace oil rather than adding oil.

• Ester oils used in HFC134a systems are so hydroscopic that by the time an inadequate system performance is detected, oil will be saturated with moisture.

• CFC12 has much higher tolerance to system processing materials, such as drawing compounds, rust inhibitors, and cleaning compounds, than HFC134a. Such materials are not soluble in HFC134a systems. If materials were to be washed from system surfaces by ester oils, they could accumulate and eventually plug capillary tube.

• Care must be taken to minimize moisture from entering HFC134a system. Do not leave compressor or system open to atmosphere for more than 10 minutes. Excessive moisture in HFC134a system will react with compressor oil and generate acid.

• Compressor must be replaced when performing low side leak repair.

• Drier filter must always be replaced with service drier filter, part #B2150504.

Important: Unbrazing drier filter from tubing will drive moisture from desiccant and into system, causing acids to form. Do not unbraze filter drier from tubing. If CFC12 service drier was installed in HFC134A system, drier could overload due to excessive moisture.

• HFC134a compatible copper tubing, part #R0174075

and part #R0174076 must be used when replacing tubing.

• Avoid system contamination by using T owerdraw E610 evaporating oil, part # R0157532, when flaring, swagging, or cutting refrigeration tubing.

RS5290000 Rev. 0 50 April 1998

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require power to be connected. Ensure all earth wires are connected before certifying unit as repaired and/or operational.

Replacement Service Compressor

HFC134a service compressors will be charged with ester oil and pressurized with dry nitrogen. Before replacement compressor is installed, pull out 1 rubber plug. A a Positive pressure in compressor is vital to keep moisture out of ester oil. Do not leave compressor open to atmosphere for more than 10 minutes.

Compressor Testing Procedures

pop

from pressure release should be heard. If

pop

sound is not heard, do not use compressor.

WARNING

To avoid death or severe personal injury, never use oxygen, air or acetylene for pressure testing or clean out of refrigeration system. Use of oxygen, air, or acetylene may result in violent explosion. Oxygen may explode on contact with oil and acetylene will spontaneously explode when under pressure.

Refer to “Temperature and Relationship Chart” for operating watts, test points, and temperature relationship test.

• T emperature testing is accomplished by using 3 lead thermocouple temperature tester in specific locations. Test point T-1 is outlet on evaporator coil and T-2 is inlet. Test point T-3 is suction tube temperature midway between where armaflex ends and suction port of compressor (approximately 12 inches from compressor).

• Thermocouple tips should be attached securely to specified locations.

• Do not test during initial or balanced temperature condition to occur before proceeding with testing.

• Refrigerator must operate minimum of 20 minutes after thermocouples are installed.

• Turn control to colder to obtain required on time.

• Wattage reading must be recorded in conjunction with temperature test to confirm proper operation.

• Suction and head pressures are listed on “Temperature and Relationship Chart” Normally these are not required for diagnosis but used for confirmation on systems which have been opened.

pull down

. Allow one off cycle

Brazing

CAUTION

To reduce risk of personal injury or property damage, take necessary precautions against high temperatures required for brazing.

Satisfactory results require cleanliness, experience, and use of proper materials and equipment.

Connections to be brazed must be properly sized, free of rough edges, and clean.

Generally accepted brazing materials are:

• Copper to copper joints: SIL-FOS (alloy of 15 percent silver, 80 percent copper, and 5 percent phosphorous). Use without flux. Recommended brazing temperature is approximately 760°C (1400°F).

Do not use for copper to steel connection.

• Copper to steel joints: SILVER SOLDER (alloy of 30 percent silver, 38 percent copper, 32 percent zinc). Use with fluoride based flux. Recommended brazing temperature is approximately 649°C (1200°F).

• Steel to steel joints: SILVER SOLDER (see copper to steel joints).

• Brass to copper joints: SILVER SOLDER (see copper to steel joints).

• Brass to steel joints: SILVER SOLDER (see copper to steel joints).

Checking Electric Heater Assembly

1. Disconnect power to unit.

2. Ensure heater element is cold, then remove

suspect heater and visually inspect element for obvious damage (breaks, cracks in element, etc.).

3. Attach ohmmeter to element leads. Check for

continuity (see tech sheet for unit under test).

If element reads open (infinite or very high resistance):

4. Check disc type thermostat for continuity (see tech

sheet for open and close values). If open replace.

April 1998 51 RS5290000 Rev. 0

Refrigerant Flow

FLANGE LOOP

CAPILLARY/SUCTION LINE HEAT EXCHANGER

EVAPORA TOR INLET

(REFRIGERANT LIQUID)

FLANGE LOOP

CENTER MULL ION LOOP

EVAPORATOR OUTLET (VAPOR)

EVAPORATOREVAPORATOR

CAPILLARY TUBE

COMPRESSOR SUCTION LINE

1/4 0.D. PROCESS TUBE

HIGH SIDE DRIER

CONDENSER FAN

COMPRESSOR

1/4 0.D. PROCESS TUBE

CONDENSER OUTLETCONDENSER OUTLET

CONDENSERCONDENSER

COMPRESSOR DISCHARGE LINE

RS5290000 Rev. 0 52 April 1998

CENTER MULL ION LOOP

“T” Model Side x Side

Refrigerant Flow Diagram

22/25/27 Cubic Foot Only

Refrigerant Flow

EVAPORATOR OUTLET (VAPOR)

April 1998 53 RS5290000 Rev. 0

“T” Model Side x Side

Refrigerant Flow Diagram

20 Cubic Foot Only

Cabinet Air Flow

BEVERAGE CHILLER AIR SUPPLY (SOME MODELS)

RS5290000 Rev. 0 54 April 1998

“T” Model Side x Side

Air Flow Diagram

22/25/27 Cubic Foot Only

Cabinet Air Flow

April 1998 55 RS5290000 Rev. 0

“T” Model Side x Side

Air Flow Diagram

20 Cubic Foot Only

Water Flow

ICE & WATER DISPENSER

1/4" O.D. PLASTIC TUBING

ICE MAKER

1/4" O.D. PLASTIC TUBING

INCOMING WATERINCOMING WATER LINE CONECTIONLINE CONECTION (HOSE COUPLING(HOSE COUPLING X 1/4" O.D.X 1/4" O.D. COPPER TUBECOPPER TUBE FITTINGFITTING

SOLENOID VALVE (DOUBLE)

1/4" O.D. X 5/16" O.D. PLASTIC COMPRESSION UNION

Dispenser Water Temperature Chart

5/16" O.D. PLASTIC TUBING

1/4" O.D. PLASTIC TUBING

“T” Model Side x Side

Ice & Water Dispenser

Water Flow Diagram

Water Temperature Chart (Approximate)

WATER RESERVOIR

Temperature in Celsius

12345

Water temperature has stabilized for at least 12 hours in water reservoir

Fresh food compartment temperature is 3-4 degrees Celsius

RS5290000 Rev. 0 56 April 1998

Number of 8-ounce Glasses of Water

90° Ambient Normalized 39°

64° Ambient Normalized 39°

Typical External Sweat Pattern

CLASSIFICATION OF CONDENSATION 1=Haze or Fog 2=Beading 3=Beads or small drops 4=Drops running together

BTM

April 1998 57 RS5290000 Rev. 0

Disassembly

WARNING

To avoid risk of electrical shock, personal injury , or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Freezer or Refrigerator Door

1. Remove toe grille.

Electronic Models

2. Unplug wiring harness from voltage box.

High Voltage Box

Dispenser Models

3. Loosen water tube clamp screw. Loosen plastic water tube union nut. Pull water tube away from union nut and through tube clamp.

Plastic water tube union nut

Water tu b e

Water Tube Connection

Door Stop and Top Door Closure

1. Remove door from cabinet.

2. Remove screw mounting top door closure.

Water tube clamp screw

Freezer Door Top Hinge

1. Secure freezer door to cabinet in closed position with strapping tape.

CAUTION

To prevent personal injury or property damage due to door falling, always secure door to cabinet with strapping tape before top hinge is removed.

Wire harness

Hinge cover

2. Remove freezer hinge cover.

3. Unplug cabinet to freezer door wiring harness connector blocks.

4. Remove earthing screw and three freezer hinge to cabinet mounting screws.

5. If present, slide hinge and nylon door bushing out of door and off freezer door wiring harness.

Combination Door Closure and Lower Hinge

1. Remove door from cabinet.

2. Remove one bottom door closure mounting screw and remove closure.

3. Remove two hinge mounting screws and door hinge.

Door hinge screws

Top hinge

connectors

Ground wire

3. Remove two screws mounting door stop to bottom edge of door.

RS5290000 Rev. 0 58 April 1998

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Freezer Door Wiring Harness (All Non-electronic Dispenser Models) NOTE: Freezer door wiring harness on electronic

models is foamed into place at factory and is not replaceable as a separate part.

1. After removing door, remove inner door liner, cavity styrofoam cavity liner and insulation around cavity.

2. Locate wiring harness inside place sleeve along handle flange of door.

3. Attach a string or wire to wiring harness going through top hinge. Pull string through as harness is removed.

NOTE: For reassembly , pull new harness into place

through plastic sleeve using string to guide new harness.

Freezer Door Water Tube

1. Remove freezer door.

2. Remove inner door liner

3. Locate water tube next to left flange of door. Water tube runs inside large plastic sleeve.

4. Free tube from cavity and slide water tube down and out through hole in door closure.

Refrigerator Door

Refrigerator door wiring harness on some models is foamed into place in door and is not replaceable.

1. Remove toe grille.

2. Disconnect 12-pin connector from high voltage board.

3. Remove refrigerator door top hinge cover and unplug wire connector.

4. Remove earthing wire screw.

5. With refrigerator door open, remove single screw mounting door closure to top of bottom hinge.

6. With refrigerator door closed, remove three top hinge screws and pull wiring harness through hinge.

7. Lift door about 3 inches to allow lower door closure to clear hinge pin.

8. Carefully rest bottom edge of door on protective pad wile removing hinge pin which press fits into refrigerator bottom hinge bracket.

NOTE: On electronic models when replacing bottom

door bushing, hinge pin, or door extract low voltage wiring from connector at high voltage board. The wiring colors and corresponding pin connector numbers are shown below.

#1 2

BLUE GRAYWHITE LT. BLUE

GREE N/YELLOW #8 SPACE IS OPEN ORANGE TAN VIOL ET PINK GRAY

YELLOW

BLUE/WHITE

A straightened standard size paper clip can be used to push pins down and out of connector to release wires.

When reinstalling pins, make certain pins lock into connector. It may be necessary to gently pry up on pin before reinstalling to assure it locks into connector when reinstalled.

Refrigerator Door Handle (Built-in and Electronic Models)

1. Remove top and bottom caps by pulling away from door handles.

2. Remove plastic insert by sliding insert up and out of door handle.

3. Remove seven mounting screws from handle and lift handle away from door.

NOTE: On electronic models, carefully disconnect

control ribbon connector from low voltage board.

Refrigerator or Freezer Handle (Free Standing Models)

1. Unsnap top and bottom door handle trim by carefully prying up under outside edge of trim to release trim from retainer.

NOTE: Be careful to catch trim pieces located between

trim strips and door handle.

2. Remove door handle by removing two screws, exposed after trim is removed.

April 1998 59 RS5290000 Rev. 0

WARNING

To avoid risk of electrical shock, personal injury , or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Handle Side Door Trim Retainers

1. Remove door trim by prying up carefully under outside edge of retainer.

2. Remove phillips mounting screws.

Door Gasket

1. Remove door.

2. Place door face down on a protected surface with door handle extending beyond the edge of surface.

3. Lift gasket away from door and loosen all mounting screws.

4. Pull gasket out and away from door liner.

Inner Door Liner

1. Remove door.

2. Place door face down on a protected surface with door handle extending beyond edge of surface.

Door Position to Remove Inner Door Liner

3. Lifting gasket away from the door, remove all mounting screws, retainers (freezer door only), and gasket.

Low Voltage Board

1. Remove door handle.

2. Remove four mounting screws holding circuit board to refrigerator door.

3 Tilt board and pull board from cavity.

4. Unplug connector from board by inserting flat blade screwdriver in either end of connector and pry apart.

NOTE: Do not try to unplug connector by pulling on wire

harness.

Ice and Water Cavity

1. Remove escutcheon by removing two phillips screws at bottom of escutcheon and lifting escutcheon off.

2. Remove electric mounting bracket by removing mounting screws at each side of plate.

3. Remove ten screws securing perimeter of cavity to door.

4. Pull out top of cavity slightly exposing where waterline held in notch by washer type clip.

5. Push electrical grommet back and out of cavity hole in left side of cavity.

6. Tip cavity out at top and lift slightly so cavity sump clears bottom edge of opening.

Cavity Heater

1. After removing cavity, unplug cavity heater from door harness.

2. Carefully peel cavity heater off back of cavity.

Electrical Mounting Bracket

1. Remove escutcheon by removing two phillips mounting screws at bottom of escutcheon and lifting escutcheon off.

2. Remove mounting screws at each side of plate.

3. Separate bracket from cover to access Ice Dispenser Switch, Water Dispenser Switch, Cavity Light Switch, Cavity heater Switch, Cube/Crushed Switch, and Cavity light bulb.

Water Actuator Arm

1. Remove escutcheon and electrical mounting bracket.

2. Remove two screws and two retainers.

3. In reassembly, return spring straddles arm and rides up against top section of arm.

Ice Actuator Arm

1. Remove escutcheon and electrical mounting bracket.

2. Remove two screws and the two retainers.

3. Slide arm down and out from under chute door while disconnecting door closure delay mechanism.

Door Closure Delay Mechanism (Ice and Water Models)

1. Remove one screw.

2. Disconnect from ice actuator arm and remove.

Chute Door (Ice and Water Models)

1. Remove escutcheon, electrical bracket, and ice actuator arm.

2. Remove two screws to remove chute door, spring, and hinge from cavity.

3. To separate chute door from hinge, remove pin.

RS5290000 Rev. 0 60 April 1998

Disassembly

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Cabinet Components

Refrigerator Temperature Control

1. Remove control knobs (nonelectronic models).

2. Loosen bracket on bottom left of cover to allow cover to be rotated forward.

3. Pull bottom of cover out until it unsnaps. Continue tilting cover out until top tabs release and remove cover.

4. Remove insulation over top of damper.

5. Remove styrofoam filler piece from control body exposing two mounting screws.

6. Remove mounting screws to remove control.

Air Duct Gasket

Insu la tion

Control Kno bs

Freezer Control

Control Cover

Control Co ver Bracket

Air Duct Gasket

Damper Front Gaske t

Da mper Gasket

Damper Control

Dampe r Co n tr o l Ins er t

Spacers

Air Duct Clamp

Thermistor

Spacer

Damper

Control Cover

Damper Front Gasket

Damper Control Insert

Gasket

Damper Control

Air Duct Clamp

Electronic Models Temperature Control

Freezer Temperature Control (Nonelectronic Models)

1. Remove control knobs.

2. Loosen brace on bottom left of cover to allow cover to be rotated forward.

3. Pull bottom of cover out until it unsnaps. Continue tilting cover out until top tabs release and remove cover.

4. Remove two control mounting screws.

5. Remove sealer from control capillary well.

NOTE: Replace sealer during reassembly .

6. Pull control out of bracket.

7. Disconnect wiring from rear of control.

8. Remove capillary from well and remove control.

Non-electronic Models Temperature Control

Refrigerator Light Switch

1. Remove two screws on rear corners of lens.

2. Remove two screws located on front of shield, behind trim piece.

3. Remove two screws on rear of light shield and slide shield back until released.

4. Slide switch mounting plate back until released from refrigerator top.

5. Remove wiring to switch.

6. Press in on tab located on the opposite side of electrical tabs and push switch through mounting plate.

Freezer Light/Auger Motor Interlock Switch

1. Remove two mounting screws from plate.

2. Slide switch mounting plate back until released.

3. Remove wiring to switch.

4. Press in on tabs and push switch through mounting plate.

April 1998 61 RS5290000 Rev. 0

Disassembly

WARNING

To avoid risk of electrical shock, personal injury , or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Refrigerator Light Lens and Light Bulbs

CAUTION

To avoid risk of burns, be sure bulb is cool before removing.

1. Remove two mounting bolts on rear corners of lens.

2. Loosen two mounting bolts on front of lens behind trim piece.

3. Slide lens back until it releases from mounting bolts.

NOTE: Bulbs are standard base screw in type 25 watt

appliance bulbs.

Refrigerator Light Socket

1. Remove two mounting bolts on rear corners of lens.

2. Loosen two mounting bolts on front of lens behind trim piece.

3. Slide lens back until it releases from mounting bolts.

4. Remove wiring to socket.

5. Socket snaps out of shield by pressing on two tabs on top and bottom of socket.

Freezer Light Bulb, Light Socket.

CAUTION

To avoid risk of burns, be sure bulb is cool before removing.

1. Remove ice bucket (if applicable).

2. Remove lens top mounting screw and remove lens by lifting up.

NOTE: Bulbs are standard base screw in type 25 watt

appliance bulbs.

3. Remove two plate mounting screws from behind facade and pull facade and mounting plate away from freezer ceiling.

4. Disconnect wiring to socket.

5. Remove socket by pressing on tabs on either side of socket.

Center Mullion

Center mullion is not replaceable.

Freezer Wire Shelf and Shelf Retainers

1. Maneuver stops around retainers and pull wire shelves or baskets out from retainers.

2. Grasp retainer firmly and slide up until released.

Freezer Basket Slide Retainer

• Remove two mounting screws and remove retainer.

Evaporator

Freezer Evaporator Cover

1. Remove freezer shelves, freezer basket, ice service rack, and icemaker.

2. Remove 1/4" hex head mounting screws on evaporator cover.

3. Push ice maker electrical block through opening in panel. Remove panel.

Freezer Thermistor (Electronic Models)

1. Remove eight 1/4” hex head screws retaining evaporator cover.

2. Remove leads.

3. Remove thermistor by removing 2 screws.

Defrost Thermostat (Terminator)

1. Remove eight 1/4” hex head scres retaining evaporator cover.

2. Unclip thermostat from outlet on evaporator coil.

3. Disconnect leads.

4. Slide clamps from around evaporator tubing and remove thermostat.

Evaporator Defrost Heater

1. Remove evaporator cover and thermistor, if necessary.

2. Remove one 1/4" hex head screw from left side of coil and 2 from right side.

3. Remove defrost thermostat.

4. Tip bottom of evaporator coil out.

5. Remove 2 wire clips.

6. Slide heater down and out from coil.

7. Unplug heater leads.

RS5290000 Rev. 0 62 April 1998

Disassembly

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Evaporator NOTE: Evaporator and heat exchanger must be

replaced as an assembly . Reclaim refrigerant before proceeding with evaporator removal. To avoid refrigeration system contamination, do not leave refrigeration system or compressor open for more than 10 minutes.

1. Remove evaporator cover and thermistor, if

necessary.

2. Remove one 1/4" hex head screw from left side of

coil and 2 from right side.

3. Remove defrost thermostat.

4. Remove defrost heater by removing wire clips

holding heater to bottom of evaporator coils.

5. Remove machines compartment and heat

exchanger covers.

NOTE: On some models special driver (part

#921 13P01) will be necessary to remove screws

securing heat exchanger cover.

6. Shield interior components from heat source and

unbraze suction tube at compressor.

7. Score and break capillary tube at drier.

8. Straighten heat exchanger and pull evaporator out

of plastic clips holding it to back wall of unit. Pull evaporator and heat exchanger through front of refrigerator as a unit.

NOTE: If styrofoam block on outer case back wall is

damaged during evaporator removal, seal

damaged area with mastic sealer.

Evaporator Fan Motor

1. Remove ice bucket and freezer shelves.

2. Remove freezer back panel.

3. Remove two 5/16" hex head screws from

evaporator fan motor mounting bracket.

4. Maneuver motor/bracket from housing.

5. Remove lead and earthing wires.

6. Remove two 1/4" hex head screws from brackets.

Fan Blade

Fan Motor Bracket

Fan Grommet

Fan Motor

Fan Motor Bracket

Fan Grommet

Evaporator Fan Blade

1. See Evaporator Fan Motor steps 1-4

2. Pull fan blade off motor shaft. When replacing fan blade, 1.2 cm (1/2") of motor shaft should extend through hub of fan blade.

Auger Motor (Ice and Water Models)

1. Remove ice bucket.

2. Remove left-handed locking nut from motor shaft.

3. Remove motor mounting backet cover by removing two mounting screws.

4. Remove four bolts securing motor to auger motor support and back motor out of bracket. Remove leads from motor.

Auger Motor

Driver

Locking Nut

Capaci tor

Auger Motor Support

Auger Motor Cover

Auger Motor

Front Roller Assembly

Refrigerator can not be installed when replacing roller assembly.

1. Remove toe grille

2. Raise front of refrigerator 10 cm (4”) from floor.

3. Remove two hex head screws mounting roller brack housing.

4. Remove leveling bolt and disassemble housing from roller bracket assembly.

Rear Roller Assembly

1. Remove machine compartment cover.

2. Raise left or right side of refrigerator on 10 cm (4”) block.

3. Remove #27 torx bolt going up through rear rail and into bottom of cabinet foot.

4. Drop rail slightly and slide roller pin towards outside of cabinet and out of rail.

April 1998 63 RS5290000 Rev. 0

Evaporator Fan

Disassembly

WARNING

To avoid risk of electrical shock, personal injury , or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Water Valve

1. Remove machine compartment cover and heat exchanger cover on rear of unit.

NOTE: On some models special driver (part

#92113P01) will be necessary to remove screws securing heat exchanger cover.

2. Disconnect water supply.

3. Remove brass nuts at water valve inlet and outlet.

4. Pull copper tubing from water valve. Anti-kink springs are installed in plastic tubing connecting to valve.

Water Valve

Brass Sleeve Nut

Plastic Tube

Anti-kink Spring

Plate

Water Valve

5. Unplug wiring harness.

Water Tank (Ice and Water Models)

Before removing water tank have container available to catch contents of water tank.

1. Remove shelves and drawers in refrigerator and unsnap top of tank cover and remove cover. OR

2. Remove four screws mounting machine compartment air baffle.

3. Remove water lines by loosening two B-nuts securing water lines to tank.

4. Remove two tank mounting screws at top of tank.

Shelf Support Ladders

1. Remove shelves

2. Remove four #15 torx screws for each ladder.

Machine Compartment

1. Remove machine compartment cover on rear of unit and heat exchanger cover.

Note: Some models have two tamper resistant screws

and will require special driver part #92113P01 to remove.

Note: Always recover refrigerants before any sealed

system component repair or replacement. Replace drier when performing a sealed system repair with Amana drier.

2. Remove one bolt from left and one bolt from right of compressor base pan.

3. Pull compressor base pan slowing towards rear reforming tubing carefully as necessary to avoid kinking and pinching.

4. Pull pan out a maximum of approximately 20 cm (8”) from rear. This will allow compressor to be removed, leak check of all condenser joints, and/ or replacement or cleaning of condensate pan. Pulling pan out more than 20 cm (8”) will drop base pan off front glide rail.

Condensate Drain Pan (20 Cubic Foot Models Only)

Before removing drain pan, have towels ready to absorb condensation.

1. Remove toe grille.

2. Pull pan forward.

Condensate Drain Pan (All Other Models)

1. Remove machine compartment cover on rear of unit and heat exchanger cover.

2. Remove one bolt from left and one bolt from right of compressor base pan.

3. Pull compressor base pan slowing towards rear reforming tubing carefully as necessary to avoid kinking and pinching.

4. Pull pan out a maximum of approximately 20 cm (8”) from rear. Reform tubing as necessary to avoid kinking and pinching.

5. Condensate drain pan clips into place on top of condenser. Release from tabs on condenser by pulling drain pan up.

RS5290000 Rev. 0 64 April 1998

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Compressor

1. See

Machine Compartment, Condenser,

Condenser Fan Access.

Note: Always replace drier when repairing refrigeration

system. Wear eye protection.

2. See

3. Remove two screws securing condenser fan

4. Unclip machine compartment wire harness from

5. Capture refrigerant charge.

6. Remove four 7/16" hex head shoulder bolts

7. Unbraze suction and discharge tubing from

8. Remove earthing wire screw to compressor.

9. Disconnect electrical leads at overload and relay.

Low Voltage Board

1. See

Overload and Relay

shroud to outer case back, if necessary.

condenser fan shroud and drier/filter from its metal clip.

mounting compressor to machine compartment floor.

compressor.

Low and High Voltage Board and Showroom

Switch Access.

2. Remove 4 Phillips screws.

3. Disconnect edge connector from right edge of board.

4. Take readings at low voltage board.

High Voltage Board

1. Remove toe grille.

NOTE: The high voltage board is in the high voltage

board box mounting on the side of condenser on 20 cubic foot models and on front of condenser on 27 cubic foot models.

2. Remove the mounting screw holding high voltage board cover to chassis. Mounting screw on 20 cubic foot models is at front of mounting box. Mounting screw on 27 cubic foot models is on right of mounting box.

WARNING

To avoid electrical shock which can cause severe personal injury or death, discharge capacitor before handling.

3. Slide box foward (20 cubic foot) or to right until box rear clip disengages from condenser.

4. Pull box out front of unit.

5. Carefully, remove wiring and harness from board.

6. Transfer wiring from old board to replacement board.

7. Remove mounting screws securing high voltage board to box.

Power Switch (Electronic Models Only)

Power switch at front of high voltage box interrupts circuit to high voltage board.

1. See

2. Remove two screws mounting protective flap and

3. Disconnect leads from switch.

Compressor Run Capacitor (Fan Shroud Mounted)

1. Remove compressor compartment rear cover and

NOTE: On some models special driver (part

2. Remove two screws securing condenser fan

3. Unclip machines compartment wire harness from

4. Remove one bolt from left and one bolt from right

5. Pull compressor base pan slowly towards rear

6. Pull pan out a maximum of approximately 20 cm

7. Disconnect wiring to capacitor.

High Voltage Box

switch to high voltage box.

heat exchanger cover.

#921 13P01) will be necessary to remove screws securing heat exchanger cover.

shroud to out case back.

condenser fan shroud and unclip drier.

of compressor base pan.

reforming tubing carefully as necessary to avoid kinking and pinching.

(8”) from rear. This will allow compressor to be removed, leak checking of all condenser joints, and/or replacement or cleaning of condensate pan. Pulling pan out more than 20 cm (8”) will drop base pan off front glide rail.

WARNING

To avoid electrical shock which can cause severe personal injury or death, discharge capacitor before handling.

8. Remove nut securing capacitor to shroud and remove capacitor.

April 1998 65 RS5290000 Rev. 0

WARNING

To avoid risk of electrical shock, personal injury , or death, disconnect electrical power source to unit and discharge capacitor through a resistor before attempting to service, unless test procedures require power to be connected. Ensure all earthing wires are connected before certifying unit as repaired and/or operational.

Compressor Run Capacitor (Control Housing Mounted)

1. Remove toe grille.

2. Remove mounting screw securing timer/capacitor housing to condenser.

3. Remove top from housing by removing screw securing top to housing.

4. Disconnect wiring to capacitor.

WARNING

To avoid electrical shock which can cause severe personal injury or death, discharge capacitor before handling.

5. Remove nut securing capacitor to housing and remove capacitor.

Overload and Relay

1. See

2. Remove bale strap from compressor terminal

3. Remove electrical leads from overload and relay.

4. Pull overload lead off compressor common termal

Condenser Fan Blade

1. See

2. Remove nut from motor shaft.

3. Remove fan blade. Replace rubber washer behind

Condenser Fan Motor

1. See

2. Remove compressor electrical cover and remove

3. Remove three hex head screws mounting motor to

Compressor, Condenser, Condenser Fan

Access.

cover and remove cover.

and pull relay off compressor start and run terminals.

Compressor, Condenser, Condenser Fan

Access.

fan blade when reassembling.

Condenser Fan Blade

both motor leads from overload and relay and earthing wires.

brackets.

Condenser

1. See

2. See

Note: Condenser is only available as assembly with

Drain Tube

1. Remove machine compartment rear cover and heat

NOTE: On some models special driver (part

2. Remove two screws securing condenser fan

3. Unclip machine compartment wire harness from

4. Remove one bolt from left and one bolt from right

5. Slide compressor compartment out rear of unit

6. Remove “P” clamps attaching drain tube to the

7. Pull drain tube off nipple in machine compartment

Compressor, Condenser, Condenser Fan

Access.

Condenser Fan Motor,

base pan.

exchanger cover.

#921 13P01) will be necessary to remove screws securing heat exchanger cover.

shroud out case back, if necessary.

condenser fan shroud. Unclip drier.

side of compressor compartment pan.

approximately 8 cm (3”).

ceiling of machine compartment.

ceiling.

steps 1-3.

RS5290000 Rev. 0 66 April 1998

Ice Maker

Operation

When the thermostat has sensed temperature -8.3° ±1.5° C (17° ±3° F), the thermostat closes. The current now has a path through the thermostat to the motor (see wiring diagram). The motor is linked with the drive gear. From the module, there are copper contacts that ride on copper strips on backside of drive gear. As the drive gear rotates, these contacts will make or break a circuit (tract) to the copper strips to operate the ice maker.

The design of the ice maker allows all of the components to be tested without removing the ice maker or moving the refrigerator away from the wall to access the water valve.

Remove the cover and you will see the test points identified on the module.

N = Neutral side of line M = Motor connection H = Heater Connection T = Thermostat connection L = L1 side of line V = Water valve connection

NOTE: Read this section completely before doing any testing or adjusting.

The test holes are identified as

N, M, V,

etc.

Specifications

Mold Heater -185 Watts, 264 Ohms Thermostat -Close -8 ±1°C (17 ±3°F) (Bimetal) Opens 0° ±1°C (17 ±3°F) Water Fill -140 cc, 7.5 Sec. Motor Cycle - Stamped in Circuit, Plug in Connec-

tors, One Revolution of blades take three minutes plug stall time on ice. (Eject and Water Fill)

Testing Procedures

Ice maker plugged into power, shut-off arm down, freezer cold

1. Test point L and N will verify 230 volts to Ice maker module. Make sure test probes go into test points

1.3 cm (1/2").

2. Test points T and H will verify the bimetal thermostat is open or closed

Short T and H with an insulated piece of wire to run motor. If the motor doesn't run, replace module assembly.

If the motor runs, replace the bimetal thermostat.

3. Leave the jumper in for half of a revolution, touch the heater mold. If the mold feels warm, the heater is working properly.

Remove jumper and the water valve will be energized in last half of revolution providing mold heater has not failed.

(Make sure the freezer temperature is cold enough to close the bimetal thermostat.)

April 1998 67 RS5290000 Rev. 0

CAUTI O N

Damage to ice maker can result if any other contacts are shorted together other than those specified.

(POWER TO ICE MAKER)

VOLT AGE

Ice Maker

Shunt Connection

A wire shunt made from an insulated piece of 14gauge wire with the ends stripped back about 5/8 inch (1.5 cm).

MODULE OHMMETER CHECKS

(NO POWER TO ICE MAKER & EJECTOR

BLADES IN END OF CYCLE POSITION)

TEST POINTS COMPONENT

L - H MOLD HEATER

L - M MOTOR

MODULE

POSITION

ATTACHED TO

SUPPORT

SEPARATED

FROM HEATER

OHMS

264

16,100

Module, Motor, and Support Assembly

Insert phillips driver in access ports in module. Loosen both screws. Disconnect shut-off arm. Pull mold from support assembly. To remove module only, remove three phillips screws and pull module out of housing.

MODUL E VOLT AGE CHE CKS WIT H MET E R OR T ES T LIGHT

TEST POINTS COMPONENT

L - N MODULE POWE R OK NO POWE R T - H BIMETAL OPEN CLOSED L - H HE AT E R ON OFF L - M MOTOR ON OFF N - V WATER VALVE ON OFF

LIN E

0 VOLT S

Disassembly Procedures

Cover

Pull water adjustment knob first and snap off cover. Note knob position and reinstall in same position for same water fill.

CAUTION

To avoid possible electrical shock always turn off power before beginning any disassembly.

Shut-Off Arm

Pull out from white bushing. Reinsert to full depth. Follow steps 1, 2, and 3 below.

1. Push arm into center slot in bushing bottom out.

Into Bushing

Water adjustmet knob location (not on all models)

3. Arm should be insi d e housin g edge.

Shut-off arm Down position

Fill cup

2. Push arm through fill cup flange hole past notch

Module and Heater Assembly

Remove module and support assembly. Install on new mold and heater assembly.

RS5290000 Rev. 0 68 April 1998

Ice Maker

Fill Cup

Remove module and support assembly. Remove ejector blades and shut-off arm. Pull fill cup from mold.

Remove ap propriate f ill cu p sl ot .

Ejector Blades or Stripper

Remove module and support assembly. When reinstalling ejector blades, realign "D" coupling with module cam.

F orcefully pull cup up and out of s l ot.

CAUTION

To avoid damange to main assembly, do not rotate blades or drive gear.

There are several switches which will jam if manually turned counterclockwise and gears will be destroyed if turned clockwise. To advance the ice maker into the cycle, use a jumper to bridge H to R and unless the motor is defective, it will run. (The shut-off arm must be in the on position.)

NOTE: There are several slotted shafts on the motor assembly board. Do not under any circumstances insert a screwdriver and attempt to turn these shafts. The slots are to permit assembly only.

NOTE: There are not repairable or replaceable components in the module. Unless you are replacing the module, there should be no need to remove it when diagnosing or repairing the ice maker.

Accessing Control box

To remove motor and contact assembly from control box, take out three screws (arrows) and pull free after disconnecting shut-off arm.

Water valve

energized

7.5 seconds 140cc fill

about 11:00

o'clock

Ejector blade stop position

(about 1:30 o'clock

Start position:

thermost at c loses,

moto r on,

heater on

Mold and Heater Screw Access Ports

April 1998 69 RS5290000 Rev. 0

Thermost at

opens in this

range of

rotation then

heater is off

6:00 o'c loc k

posit io n

Ejector stall on ice,

Motor on (30 seconds

to 5 minutes) about

4:00 o'c loc k

Ice Maker

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 time the water valve is energized, since the contact ring is tapered at the end of the fill time.

Turning screw clockwise decreases fill; counterclockwise increase fill amount.

1/2 turn equals 20 cc or 1.2 seconds Full turn equals 40 cc or 2.4 seconds

CAUTION

Maximum adjustment is one full turn either direction. Additional rotation could damage module.

If water valve adjustment screw falls out, just put it back in and align the hole in the hole as shown.

close. Where required, install the ASAP grandular activated carbon, odor, tastes, and sediment filter, Part Number R0183114.

Mineral contact 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 fill cup and stripper.

Temperature Problems

Temperatures in freezer section which average above the normal -18°±1°C (0° ±2°F) will slow production of ice. Complaints of inadequate ice cube production may be corrected by simply setting the freezer to a colder temperature. The thermostat cycling temperature in the 1-revolution ice maker is -8° ±1°C (17° ±3°F). Obviously, the ice will be well frozen when these temperatures are achieved but cycling time will be slowed if freezer temperature is not cold enough to achieve these mode temperatures easily.

NOTE: Only the thermostat, mold, with heater and wiring harness, are replaceable. Any other failure (including the motor) requires replacement of the module assembly. The service replaceable mold assembly comes with a new mold heater installed.

External plastic parts are also replaceable. A failed mold heater requires complete replacement of

the mold and mold heater assembly.

Water Adjustment Area

When small hole is centered in larger hole, the water fill adjus tm e nt is for 7.5 sec ond fill tim e ( normal).

Water Problems

Water quality can cause ice makers to fail, or produce unacceptable cubes. If mineral content or sand is a problem, the screen in the fill valve can restrict, or 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

Servicing Thermostat

The thermostat can be removed and replaced having been diagnosed as inoperative. Remove control box from mold by taking out two phillips screws.

RS5290000 Rev. 0 70 April 1998

Ice Maker

Pull (front of Black Housing) free of the mold, and see the thermostat on mold side.

Using needle nose pliers, grasp one of the thermostat clips and pull out. Press in new thermostat, making sure pins are properly indexed. Using this procedure, it is not necessary to remove the electrical assembly.

If replacing the module, transfer the clips to the new mold support. (Use new thermal bonding material.)

Servicing Wire Harness

To remove wiring harness, depress retaining tab and pull plug free.

Dual Water Valve

The dual water valve has two solenoids. When the tan encapsulated solenoid is energized the amount of water allowed to enter ice maker mold is directly proportional to the length of time the water valve switch is held closed by the timing cam.

Inside the valve is a flow washer which acts as a water pressure regulator. Proper ice maker fill is 140 cc ±10 cc at 7.5 seconds of water fill at an inlet pressure ranging from 1.4 to 8.2 bar (20 to 120 PSI).

When the light blue encapsulated solenoid is energized water flows through the coiled water tank to the cavity spickett.

The water flow rate is to be 1.7 to 3.5 liter per minute with 1.4 to 8.2 bar (20 to 120 PSI)pressure drop across valve.

The valve also incorporates a 80 mesh screen water strainer.

Wiring Harness

A one-time thermal fuse micro device 78°C (170° F) is incorporated into the ice maker wiring harness to protect the plastic liner from melting if the ice maker should overheat. The thermal fuse is spliced into the red wire of the ice maker harness. The thermal fuse is a 78° C (170°F) nonresettable fuse. A "No Ice" complaint could be caused by excessive heat. Replacing only the wiring harness will only temporarily solve the problem. The ice maker thermostats should also be replaced

CAUTION

To avoid property damage, always test for water leaks after repair or replacement of the water valve. Do not over tighten connection to household water supply.

April 1998 71 RS5290000 Rev. 0

Ice Maker Troubleshooting Chart

I. NO ICE/LOW ICE PRODU CTION

1. Freezer not cold enough 1. Adjust Freezer or Repair Freezer

2. Broken Locking Tab on Vertical Cam 2. Change Ice Maker Module

3. Module Shut-Off Switch And Contacts Shorted & Burned 3. Change Ice Maker Module

4. Motor Stalled or Stripped 4. Change Ice Maker Module

5. Check Ej ector Positio n A. Park (2:3 0 Ej ector Positio n) 1 Contaminated Modu le (No run when j ump ed

through "T" and "H" probe holes) 2 Open/Missing Thermostat 2. Install or Replace Themostat (Apply Fresh Alumilastic) 3 No Power To Icemaker (Harness) 3. Trace Power to Determine Discontinuity 4 Jammed Cube s (Notice size of Cube, Hollow?) 4. Unjam Cube, Check Fill Tube & Fill-Cup Assembly 5 Little o r No Water to Ice Ma ker (No te Cu be S ize)

a. Frozen Fill Tube (Leaky Water Valve) a. Change Ice Maker Valve

b. Kinked Water Line b. Un-Kink Line, Check for Weak Spots

c. Obstruct ed Water L in e t o Ic e M ake r o r

Refrigerator d. Clogged Water Valve d. Change Water Valve e. No Power to Water Valve e. Trace Power to Determine Discontinuity f. Low Water Pressure (NOTE: Jump Cycle

through "T" & "H" Probe holes for 10 Sec. ,

Then Remove Jumpers)

Catch Water in Glass g. Open Heater Circuit g. Change Mold and Heater Assembly h. Closed Thermostat h. Change Thermostat i. Damaged Heate r Tulips on Module i. Change Module

1. Change Ice Maker Module

c. Water Line Must Be Cleared

f. Water Pressure Must Be Increased (20 -120 psi) (1.4 -

8.2 bar) Should be About 140 cc's

j. Heater Pins Too Short - Not Contacting

Module

6 Bail Shut-off Arm In Vacation Mode - No Ice 6. Lower Bail Shut-off Arm To Begin Cycle 7 Bail Shut-off Arm Binds When Raised or Lowered

a. Water/Ice in Actuator/Housing Hole a. Remove Module, Dry Actuator and Housing Hole b. Housing Hole Sma ll or Bu rred b. Repair or Replace Ice Maker c. Actuator O.D. Large or Burred c. Replace Ice Maker Module d. Module Housing Damaged d. Replace Ice Maker Mod ule e. Bail Shut-off Arm Misformed e. Replace Bail Shut-off Arm

8 Little/No Alumila stic o n Th ermo stat 8. Apply Fresh Coat of Alumilastic to Thermostat 9 Housing to Mold Screws Not Seated 9. Tighten Two Screws With Ph illips D river (2 0-2 6 In .lb)

10 Heater Not Staked In Mold 10 Replace Mold/Heater Assembly, Apply fresh Coat of

11 Wrong Heater Temperature 11 Replace Mold/Heater Assembly, Apply fresh Coat of

12 Broken S/O Lever (Mislocated Shut-Off Switch) 12 Replace Ice Maker M odule

j. Change Mold/Heater Assembly

(22.8 - 29 .6 cm/kg )

Alumilastic

RS5290000 Rev. 0 72 April 1998

Ice Maker Troubleshooting Chart

I. NO ICE/LOW ICE PRODUCTION (cont.)

5. Check Ejector Position (cont) B. 3:00 Ejector Position

Contamination 1. Replace Ice Maker Module

Cube Jammed (Notice Size of Cube, Hollow?) 2. Un-Jam Cubes

Ice Maker or Refrigerator Not Level 3. Level as Needed

No Power To Ice Maker 4. Trace Power to Determine Discontinuity

Excessive Water-Fill Volume (Large Cubes) 5. Adj. Volume Screw on Module, Change Water Valve or

Rack of Cubes Fell Back Into Mold During Ejection

6. C. 4:00 Ejector Position

Contamination 1. Change Ice Maker Module

Thermostat out of calibration 2. Change Out Thermostat, Apply Fresh Coat Of Alumilastic

Open Heater Circuit (Motor Should be Oscillating)

Little/No Alumilastic on Thermostat 4. Apply Fresh Coat Of Alumilastic

Heater Not Staked In Mold 5. Change Mold/Heater Assy, Apply Fresh Coat Of

Broken Locking Tabs on Vertical Cam 6. Change Module

6. D. 6:00 Ejector Position

Contamination 1. Change Ice Maker Module

Hollow Cubes 2. Refer to Section III, "Hollow Cubes"

Insufficient Water To Ice Maker, Small Cubes 3. Refer to Section III, "Hollow Cubes"

3. E. 7:30 Ejector Position

Contamination (Motor Will Not Oscillate) 1. Change Ice Maker Module

Bail Arm Stuck in Ice or Obstructed 2. Remove Obstruction, Replace Ice Maker Module

Pac-Man Cubes (Cubes not formed properly) 3. Un-Jam Unit, Check Fill Cup And Fill Tube Assy.

3. F. 9:00 Ejector Position

Contamination 5. Change Ice Maker Module

Cube Frozen to Fill Cup or Mold 5. Un-Jam Unit, Install New Fill Cup and Module

Lower Pressure

6. Install New Fill Cup, Check Fill Tube Assy.

3. Change Mold/Heater Assy, Apply Fresh Coat Of Alumilastic

Alumilastic

April 1998 73 RS5290000 Rev. 0

Ice Maker Troubleshooting Chart

II. OVER PRODUCTION OF ICE

1. Bail Shut-off Arm Not in Actuator 1. Replace Bail Shut-off Arm in Actuator, Note for Loose

2. Misformed Bail Shut-off Arm 2. Replace Bail Shut-off Arm

3. Shut-Off Lever Broken or Bypassing Vertical Cam 3. Replace Ice Maker Module

4. Broken Module Actuator 4. Replace Ice Maker Module

III. HOLLOW ICE CUBES

1. Water Fill Volume Too Low 1. Adj. Screw On Module, Clear Water Path Or Change

2. Improper Freezer Air-Flow 2. Re-Direct Air Flow Away from Ice Maker Thermostat

3. Thermostat Out Of Calibration 3. Change Thermostat, Apply Fresh Alumilastic

IV. FLOODING OR ICE SLABS IN BUCKET OR FREEZER

1. Thermostat Out Of Calibration 1. Change Thermostat, Apply Fresh Alumilastic

2. Jammed Cube Stalled In Water-Fill Cycle 2. Remove Cube, Determine Reason For Stall

3. Leaky Water Valve 3. Change Water Valve

4. Fill Volume of Water Valve Excessive 4. Change Water Valve

5. Motor Stalled In Water-Fill Cycle (12:00 Ejector Position) 5. Change Ice Maker Module

6. Contaminated Module 6. Change Ice Maker Module

7. Refrigerator or Ice Maker Not Level 7. Level As Necessary

8. Excessive Water Pressure 8. Lower Water Pressure (20-120 psi) (1.4 - 8.2 bar)

9. Module Shut-Off Switch and Contacts Shorted And Burned

10. Broken Locking Tab On Verticle Cam (Stalled in Waterfill)

11. Fill-Tube Not Properly Located In Fill Cup 11 Reposition Fill Tube

12. Fill Cup Water Opening Flashed Over/Plugged 12 Change Fill Cup

13. Cubes Fell Over Back Of Ice Maker, Melting Into Freezer

Fit

Water Valve

9. Change Ice Maker Module

10 Change Ice Maker Module

13 Install New Fill Cup

RS5290000 Rev. 0 74 April 1998

Ice Maker Wiring Diagram and Parts Layout

230

April 1998 75 RS5290000 Rev. 0

Kit Instructions

HGK300 Black Handle and Toe Grille Kit Installation Instructions

Parts List

Description Quantity Part

Number

Toe grille 1 12321806 Bottom trim, refrigerator door 1 10810512 Top trim, freezer door 1 10810311 Door handle 2 12139306 Center trim, freezer door 1 10810603 Black handle insert (top) 2 10953115 Bottom trim, freezer door 1 10810511 Black handle insert (bottom) 2 10953116 Top trim, refrigerator door 1 10810312 Door stop 2 C8972403 Center trim, refrigerator and freezer door

2 10810403 Installation Instructions 1 10035710

Description Quantity Part

Number

Introduction

Read entire manual before installing kit. Confirm all parts listed are included in kit. If parts are missing, contact source from whom kit was purchased.

Important

• Mechanical experience is required to install trim kit.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

Procedure

CAUTION

Important

Save all screws and reuse in original location.

1. Remove upper and lower handle trim from both doors by grasping trim along inside edge of door and pulling foreward. Remove inserts above and below each handle.

To avoid property damage, protect soft vinyl or other flooring with cardboard, rugs, or other protective material.

CAUTION

To avoid personal injury, protect hands and arms. Trim pieces may have sharp edges.

2. Remove door handles by removing screws.

RS5290000 Rev. 0 76 April 1998

Kit Instructions

3. Dispenser Models Remove crushed/cubed ice switch cover on dispenser by pulling forward. Remove screws from bottom of dispenser cover. Release bottom clips on dispenser cover by placing taped edge of putty knife underneath cover and pulling out. Release top clips by holding bottom of dispenser cover out and sliding up.

4. Non Dispenser Models Remove center trim by grasping trim along inside edge of door and pulling forward.

Dispenser Models

Remove center trim on refrigerator door by grasping trim along inside edge of door and pulling forward. Remove center trim on freezer door by removing screws.

5. Non Dispenser Models Install new black center trim by snapping in place.

Dispenser Models

Install new black center trim on refrigerator door by snapping in place. Install new black center trim on freezer door by placing trim on door. Insert and tighten screws.

Important

One piece of center trim will not be used.

6. Dispenser Models Replace dispenser cover by snapping in place. Insert and tighten screws. Replace switch by snapping in place.

7. Install new black handles by placing handles on refrigerator. Insert and tighten screws.

8. Place new black inserts above each handle. Install new black trim above each handle by snapping in place. Hold new black inserts below each handle. Install new black trim below each handle by snapping in place.

9. Remove toe grille by pulling forward. Install new black toe grille by inserting clips in holes and snapping in.

10. Remove door stops by removing screws. Install new black door stops by placing door stops on doors. Insert and tighten screws.

April 1998 77 RS5290000 Rev. 0

Kit Instructions

DS18 and DS22 1/4" Trim Kits

Introduction

Included in this kit are trim pieces for installing 1/4 inch (6 millimeter) decorator panels. Read entire manual before installing panels. Confirm all parts listed are included in kit. If parts are missing, contact source from whom kit was purchased.

Important

• Mechanical experience is required to install trim kit.

• Depending on installer’s knowledge and skill,

installation can take from one to three hours.

• T ransfer food to an alternate cooling source. Check refrigerator warranty certificate for specific coverage. Warranty does not cover food loss.

• Ensure trim pieces adhere properly by confirming surfaces are clean, dry and free of adhesive residue.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

Decorator Panel Dimensions

Listed below are required height x width dimensions for decorator panels. Panels are not supplied with this kit and can be purchased locally .

Caution

To avoid personal injury or property damage, refrigerator panels should not weigh more than 30 pounds (14 kilograms) and freezer panels should not weigh more than 15 pounds (7 kilograms).

19 cubic foot Panel Dimensions

Without Dispenser

Refrigerator Door 61 15/16" x 15 13/32"

(1573 mm x 391 mm)

Freezer Door 61 15/16" x 13 1/2"

(1573 mm x 343 mm)

With Dispenser

Refrigerator Door 61 15/16" x 15 13/32"

(1573 mm x 391 mm)

Upper Freezer Door 17 1/4" x 13 1/2"

(438 mm x 343 mm)

Lower Freezer Door 31 13/16" x 13 1/2"

(808 mm x 343 mm)

20, 22, 25 cubic foot Panel Dimensions

Without Dispenser

Refrigerator Door 61 15/16" x 19 5/32"

(1573 mm x 487 mm)

Freezer Door 61 15/16" x 13 1/2"

(1573 mm x 343 mm)

With Dispenser

Refrigerator Door 61 15/16" x 19 5/32"

(1573 mm x 487 mm)

Upper Freezer Door 17 1/4" x 13 1/2"

(438 mm x 343 mm)

Lower Freezer Door 31 13/16" x 13 1/2"

(808 mm x 343 mm)

RS5290000 Rev. 0 78 April 1998

Kit Instructions

Parts List

Item Description Qty Length

1 Side Trim, Refrigerator

and Freezer Door

Bottom Trim, Refrigerator Door

Bottom Trim, Freezer Door

Top Trim, Refrigerator Door

5 Top Trim, Freezer Door 1 X X X X X X 6

Top Trim, Dispenser

Bottom Trim, Dispenser

Panel Trim, Refrigerator and Freezer Door

Panel Trim, Lower Ice and Water Freezer Door

Panel Trim, Upper Ice and Water Freezer Door

2 X X X X X X

1 X X X X X X

1 13 7/8" X X X X X X 1 13 9/16" X X X X X X

2 61 29/32" X X X X X X

1 32 1/8" X X X X X X

1 17 7/32" X X X X X X

DS18E

Black

DS18L

Almond

DS18S

Satin

DS18W

White

DS22E

Black

DS22S

Satin

Screw, Bottom Trim

Spacer, Refrigerator Door Bottom Trim

Spacer, Freezer Door Bottom Trim

Installation Instructions

5 X X X X X X

1 X X X X X X

1 X X X X X X 1 X X X X X X

April 1998 79 RS5290000 Rev. 0

Kit Instructions

Procedure

Caution

To avoid personal injury or property damage, two people should remove and rehang each door.

Caution

To avoid personal injury or property damage, temporarily tape doors shut.

Important

Save all screws and reuse in original location.

1. Tape doors shut using masking tape.

WARNING

To avoid electrical shock which can cause severe personal injury or death, green ground wire must remain attached to hinge.

2. Remove top hinge covers by removing screws. Trace around top hinges with a pencil. This helps alignment when reassembling. On dispenser models, unplug top hinge wire connectors. Remove top hinge screws.

Caution

To avoid property damage, drain water from water tube into small bucket.

5. Dispenser Models Loosen water tube clamp screw. Loosen plastic water tube union nut. Gently pull water tube away from union nut and through tube clamp.

6. Remove tape from freezer door. Grasp freezer door securely and lift up while opening. This will free door from bottom hinge pin. On dispenser models, plastic water tube must slide through slot in bottom door hinge as door is raised.

7. Remove door stops by removing screws. Install spacer and bottom trim by placing spacer and trim on bottom of doors. Insert and tighten bottom trim screws (Item #1 1). Replace door stops by placing door stops on bottom of doors. Insert and tighten screws.

3. Remove tape from refrigerator door. Grasp refrigerator door securely and lift up while opening. This will free door from bottom hinge pin. Top hinge may come off door .

4. Remove toe grille by pulling forward.

RS5290000 Rev. 0 80 April 1998

8. Rehang doors by positioning bottom sockets onto bottom door hinge pins. Position so doors are flush with side of refrigerator cabinet. Handle side of doors should be approximately 1/8 inch (3.2 millimeters) higher than hinge side of doors. Doors will settle when loaded with food. On dispenser models, when replacing freezer door, thread water tube through hinge pin then water tube clamp.

Kit Instructions

Caution

To avoid personal injury or property damage, temporarily tape doors shut.

9. Tape doors shut using masking tape.

10. Replace top hinges by placing top hinges on refrigerator. Insert and tighten screws. On dispenser models, reconnect top hinge wire connectors by snapping together. Replace top hinge covers by placing hinge covers over hinges. On dispenser models, carefully place wires under cover to avoid pinching wires. Insert and tighten screws.

WARNING

To avoid electrical shock which can cause severe personal injury or death, green ground wire must be attached to freezer door hinge.

Important

Permanent, double-sided tape is used to attach some trim pieces to refrigerator. Before removing paper backing, check placement of trim pieces on refrigerator. Trim pieces may be damaged if adjustment or removal is attempted after installation.

1 1 . Install top door trim. There may be some

interference between top trim and top handle trim. If there is interference, complete the following steps:

• Remove upper and lower handle trim from both doors by grasping trim along inside edge of trim and pulling forward.

• Remove inserts above and below each handle.

12. Non Dispenser Models Remove nameplate by placing putty knife covered with masking tape under nameplate and pulling forward. Discard nameplate.

Important

Confirm front surface of decorator door panels and trim are facing forward when installing trim.

Refrigerator Door

13. Install panel trim (Item #8) by placing trim at an angle on left edge of refrigerator door panel. Press trim onto panel. Center trim on side of panel.

Freezer Door -- Non Dispenser Models

14. Install panel trim (Item #8) by placing trim at an angle on right edge of freezer door panel. Press trim onto panel. Center trim on side of panel.

Freezer Door -- Dispenser Models

15. Install top dispenser trim (Item #6) by placing trim at an angle on bottom edge of upper freezer panel. Press trim onto panel. Install upper ice and water freezer door panel trim (Item #10) by placing trim on right edge of upper freezer panel. Press trim onto panel. Trim pieces must overlap at the corner.

16. Install bottom dispenser trim (Item #7) by placing trim at an angle on top edge of lower freezer panel. Press trim onto panel. Install lower ice and water freezer door panel trim (Item #9) by placing trim on right edge of lower freezer panel. Press trim onto panel. Trim pieces must overlap at the corner.

Caution

To prevent property damage, place masking tape on back of panel at each corner. Tape prevents panel from damaging doors.

17. Place masking tape on back of panels at each corner.

18. Slide decorator door panels into place under handle trim until panels are secure.

Discard inserts.

• Replace upper and lower handle trim by snapping in place. Confirm trim is flush with handle.

Peel off 1 1/2 inches (38 millimeters) of backing. Place trim firmly against inside of door and against back of door. After checking placement, peel of f backing and press into place.

April 1998 81 RS5290000 Rev. 0

Kit Instructions

19. Install side door trim by peeling off 1 1/2 inches (38 millimeters) of backing. Place trim against top corner of refrigerator cabinet over edge of top trim. After checking placement, peel off backing and press into place. Place side door trim over edge of bottom trim.

20. Push water tube into plastic union nut and tighten union nut by hand. Gently pull on tube to confirm nut is tight. Tighten water tube clamp screw.

Caution

To avoid property damage, confirm water tube union nut is secure and check for leaks before replacing toe grille.

21. Replace toe grille by inserting clips in holes and snapping in.

RS5290000 Rev. 0 82 April 1998

Kit Instructions

DS19, DS20 and DS21 1/16" Trim Kits with 1/4" Retainers

Introduction

Important

• Mechanical experience is required to install trim kit.

• Depending on installer’s knowledge and skill, installation can take from one to three hours.

• T ransfer food to an alternate cooling source. Check refrigerator warranty certificate for specific coverage. Warranty does not cover food loss.

• Ensure trim pieces adhere properly by confirming surfaces are clean, dry and free of adhesive residue.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

Decorator Panel Dimensions

Listed below are required height x width dimensions for decorator panels. Panels are not supplied with this kit and can be purchased locally .

Caution

To avoid personal injury or property damage, refrigerator panels should not weigh more than 30 pounds (14 kilograms) and freezer panels should not weigh more than 15 pounds (7 kilograms).

21 cubic foot 1/16" (2 mm) Panel Dimensions

Without Dispenser

Refrigerator Door 61 7/8" x 15 13/16"

(1572 mm x 402 mm)

Freezer Door 61 7/8" x 13 15/16"

(1572 mm x 354 mm)

With Dispenser

Refrigerator Door 61 7/8" x 15 13/16"

(1572 mm x 402 mm)

Upper Freezer Door 17 9/16" x 13 15/16"

(446 mm x 354 mm)

Lower Freezer Door 32 3/16" x 13 15/16"

(818 mm x 354 mm)

21 cubic foot 1/4" (6 mm) Panel Dimensions

Without Dispenser

Refrigerator Door 61 1/4" x 15 3/16"

(1556 mm x 386 mm)

Freezer Door 61 1/4" x 13 5/16"

(1556 mm x 338 mm)

With Dispenser

Refrigerator Door 61 1/4" x 15 3/16"

(1556 mm x 386 mm)

Upper Freezer Door 16 7/8" x 13 5/16"

(429 mm x 338 mm)

Lower Freezer Door 31 3/8" x 13 5/16"

(797 mm x 338 mm)

27 cubic foot 1/16" (2 mm) Panel Dimensions

Non Electronic

Refrigerator Door 61 7/8" x 19 9/16"

(1572 mm x 497 mm)

Upper Freezer Door 17 9/16" x 13 15/16"

(446 mm x 354 mm)

Lower Freezer Door 32 3/16" x 13 15/16"

(818 mm x 354 mm)

Electronic

Refrigerator Door 61 7/8" x 17 3/4"

(1572 mm x 451 mm)

Upper Freezer Door 17 9/16" x 13 15/16"

(446 mm x 354 mm)

Lower Freezer Door 32 3/16" x 13 15/16"

(818 mm x 354 mm)

27 cubic foot 1/4" (6 mm) Panel Dimensions

Non Electronic

Refrigerator Door 61 1/4" x 18 15/16"

(1556 mm x 481 mm)

Upper Freezer Door 16 7/8" x 13 5/16"

(429 mm x 338 mm)

Lower Freezer Door 31 3/8" x 13 5/16"

(797 mm x 338 mm)

Electronic

Refrigerator Door 61 1/4" x 17 3/8"

(1556 mm x 441 mm)

Upper Freezer Door 16 7/8" x 13 9/16"

(429 mm x 344 mm)

Lower Freezer Door 31 3/8" x 13 9/16"

(797 mm x 344 mm)

April 1998 83 RS5290000 Rev. 0

Kit Instructions

Parts List

Description Qty Length

Trim, Refrigerator and Freezer Door Sides

Trim, Refrigerator Door Bottom Trim, Freezer Door Bottom Trim, Refrigerator Door Top Trim, Freezer Door Top Retainer, Freezer Door Top and

Bottom Retainer, Freezer Door Top Retainer, Freezer Door Bottom Retainer, Refrigerator Door Top and

Bottom Retainer, Refrigerator Door Top and

Bottom

Retainer, Refrigerator Door Top

DS19E

Black

2 X X X X X 1 X X X X X 1 X X X X X 1 X X X X X 1 X X X X X

4 13 516" X X X 2 13 27/32" X X 2 13 17/32" X X

2 19 9/32" X X

2 15 17/32" X

1 17 5/16" X X

DS19S

Stainless

DS20E

Black

DS20S

Stainless

DS21S

Stainless

Retainer, Refrigerator Door Bottom

Retainer, Upper Freezer Door Sides Retainer, Upper Freezer Door Side Retainer, Lower Freezer Door Sides Retainer, Lower Freezer Door Side Retainer, Refrigerator Door Sides Retainer, Refrigerator and Freezer

Door Sides Retainer, Refrigerator Door Side Insert, Refrigerator Door Handle Insert, Freezer Door Handle Screw, Bottom Trim Spacer, Trim Installation Instructions

1 17 21/32" X X 2 17 7/32" X X X 1 17 7/32" X X 2 31 3/4" X X X 1 31 3/4" X X 2 61 7/32" X X

4 61 7/32" X 1 61 7/32" X X 1 X X 1 X X 6 X X X X X 3 X X X X X 1 X X X X X

RS5290000 Rev. 0 84 April 1998

Kit Instructions

Procedure

Extruded Handle Models

Caution

To avoid personal injury, protect hands and arms. Trim pieces may have sharp edges.

Important

Save all screws and reuse in original location.

1. Remove top handle end caps by removing screws.

3. Remove door handle inserts by placing screwdriver at top of door handles in area between handle and insert and pulling out.

4. Pull inserts out along length of handles.

Important

If installing 1/16 inch (2 millimeter) panels, proceed to step 6. If installing 1/4 inch (6 millimeter) panels, proceed with step 2.

2. Remove crushed/cubed ice switch cover on dispenser by pulling forward. Remove screws from bottom of dispenser cover. Release bottom clips on dispenser cover by placing taped edge of putty knife underneath cover and pulling out. Release top clips by holding bottom of dispenser cover out and sliding up.

5. Install new handle inserts by reversing steps 3-4.

6. Replace dispenser cover by snapping in place. Insert and tighten screws. Replace switch by snapping in place.

7. Remove thin section on top handle end caps to allow room for panels. Discard section. Replace top handle end caps by placing end caps on handles. Insert and tighten screws.

Thin Section

April 1998 85 RS5290000 Rev. 0

Kit Instructions

All Models

Important

Use cardboard spacers carefully . Spacers must be reused to provide correct clearance at top and bottom edges of each door.

8. Use masking tape to place two cardboard spacers on front surface of doors flush with top edge. Place spacers approximately 2 inches (51 millimeters) in from handle side of door and 2 inches (51 millimeters) from hinge side of door.

Cardboard Spacers

9. On extruded handle models, check top trim fit by aligning end of top trim against handle cap. On non extruded handle models, check top trim fit by aligning end of trim with handle-side edge of door.

10. Install top door trim. There may be some interference between top trim and top handle trim. If there is interference, complete the following steps:

• Remove upper and lower handle trim from both doors by grasping trim along inside edge of trim and pulling forward.

Important

• Rounded edge of trim must be installed toward front of door. Channel holds and frames 1/16 inch (2 millimeter) panels or 1/4 inch (6 millimeter) retainers.

• Permanent, double-sided tape is used to attach some trim pieces to refrigerator. Before removing paper backing, check placement of trim pieces on refrigerator. Trim pieces may be damaged if adjustment or removal is attempted after installation.

• Top trim covers only section of top door surface in front of hinge.

• Remove inserts above and below each handle. Discard inserts.

• Replace upper and lower handle trim by snapping in place. Confirm trim is flush with handle.

Peel off 1 1/2 inches (38 millimeters) of backing. Place trim firmly against inside of door and against back of door. After checking placement, peel off backing and press into place.

1 1. Remove cardboard spacers and replace spacers on

front surface of doors flush with bottom edge. Place spacers approximately 2 inches (51 millimeters) in from handle side of door and 2 inches (51 millimeters) from hinge side of door.

Important

Bottom trim covers only section of bottom door surface in front of hinge. Do not overtighten screws.

12. Check bottom trim fit by aligning trim with holes in bottom of door and against handle. Insert screws and tighten.

13. Remove cardboard spacers from doors.

14. On non dispenser models, remove nameplate by placing putty knife covered with masking tape under nameplate and pulling forward. Discard nameplate.

Important

If installing 1/16 inch (2 millimeter) panels, refer to "1/16 inch (2 millimeter) Panels" section. If installing 1/4 inch (6 millimeter) panels, refer to "1/4 inch (6 millimeter) Panels" section.

RS5290000 Rev. 0 86 April 1998

Kit Instructions

DS21S Kit - Non Dispenser Models

Install 1/4 inch (6 millimeter) freezer door top retainer (Item #6) by placing trim at an angle on top edge of panel. Align straight end of trim flush with panel corner. Press trim onto panel. Install freezer door side retainer (Item #17), freezer door bottom retainer (Item #6) then freezer door side retainer (Item #17) on panel. Notched end of trim must overlap straight end of previously installed trim. Confirm trim is secure. Remove nameplate by placing putty knife covered with masking tape under nameplate and pulling forward. Discard nameplate.

DS21S Kit - Dispenser Models

Install 1/4 inch (6 millimeter) upper and lower freezer door top retainers (Item #6) by placing trim at an angle on top edge of panel. Align straight end of trim flush with panel corner. Press trim onto panel. Install upper and lower freezer door right side retainers (Items #12 or #14, respectively), upper and lower freezer door bottom retainers (Item #6) then upper and lower freezer door left side retainers (Items #12 or #14, respectively) on panel. Notched end of trim must overlap straight end of previously installed trim. Confirm trim is secure.

All Models

Caution

To prevent property damage, place masking tape on back of panel at each corner. Tape prevents panel from damaging doors.

1. Place masking tape on back of panels at each corner.

2. Slide decorator door panels into place until panels are secure. On DS19 and DS21 kits, handle side of panel trim slides under handle trim. On DS20 and DS20 kits, handle side of panel slides under handle insert.

3. Install side door trim by peeling off 1 1/2 inches (38 millimeters) of backing. Place trim against top corner of refrigerator cabinet over edge of top trim. After checking placement, peel off backing and press into place. Place side door trim over edge of bottom trim.

April 1998 87 RS5290000 Rev. 0

Kit Instructions

DS23, DS24, DS25, and DS26 1/4" Trim Kits

Introduction

Important

• Mechanical experience is required to install trim kit.

• Depending on installer’s knowledge and skill, installation can take from one to three hours.

• T ransfer food to an alternate cooling source. Check refrigerator warranty certificate for specific coverage. Warranty does not cover food loss.

• Ensure trim pieces adhere properly by confirming surfaces are clean, dry and free of adhesive residue.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

Decorator Panel Dimensions

Listed below are required height x width dimensions for decorator panels. Panels are not supplied with this kit and can be purchased locally .

Caution

To avoid personal injury or property damage, refrigerator panels should not weigh more than 30 pounds (14 kilograms) and freezer panels should not weigh more than 15 pounds (7 kilograms).

Without Dispenser

Refrigerator Door 61 15/16" x 19 3/8"

(1573 mm x 492 mm)

Freezer Door 61 15/16" x 13 3/4"

(1573 mm x 349 mm)

With Dispenser

Refrigerator Door 61 15/16" x 19 3/8"

(1573 mm x 492 mm)

Upper Freezer Door 17 1/4" x 13 3/4"

(438 mm x 349 mm)

Lower Freezer Door 31 13/16" x 13 3/4"

(808 mm x 349 mm)

Electronic

Refrigerator Door 61 15/16" x 17 5/8"

(1573 mm x 448 mm)

Upper Freezer Door 17 1/4" x 13 3/4"

(438 mm x 349 mm)

Lower Freezer Door 31 13/16" x 13 3/4"

(808 mm x 349 mm)

RS5290000 Rev. 0 88 April 1998

Kit Instructions

Parts List

Description Quantity Refrigerator, Freezer door side trim, 2 Refri ger ator door bottom trim, 1 Freezer door bottom trim,1 Refri ger ator door top trim, 1 Freezer door top trim 1, Dispenser trim, 2 B 8391242 B8391243 B8391240 B8391241 B8391242 B8391240 B8391241 Door handle insert DS24,26 1 DS23,25 2 Ice and Water Door handle insert, 1 Bottom trim screw, 5 Refri ger ator door bottom trim spacer, 1 Freezer door bottom trim spacer, 1 Installation instructions, 1

DS23E Black 10494518 10494519 10494513 10494517 10494518 10494513 10494517

10602605 10602608 10602609 10602607 10602605 10602609 10602607 10602505 10602507 10602508 10602506 10602505 10602508 10602506 10765207 10765205 10765209 10765203 10765212 10765213 10765211 10765208 10765206 10765210 10765204 10765208 10765210 10765204

10945907 10945906 10945908 10945905 10945907 10945908 10945905

10945931 10945932 10945929 10945930 10945931 10945929 10945930

M0211018M0211018M0211018M0211018M0211018M0211018M021101 10494603 10494603 10494603 10494603 10494603 10494603 10494603

10494604 10494604 10494604 10494604 10494604 10494604 10494604

DS23L Almond

DS23S Satin

DS23W White

DS24E Black

DS24S Satin

DS24W White

Description Quantity Refrigerator, freezer door side trim, 2 Refrigerator door bottom trim, 1 Freezer door bottom trim, 1 Refrigerator door Top trim, 1 Freezer door top trim, 1 Dispenser trim, 2 B8391218 B8391218 Door handle insert DS25, 2 DS26, 1 Ice and water door handle insert, 1 Bottom trim screw, 5 M0211018 M0211018 Refrigerator door bottom trim spacer, 1 Freezer door bottom trim spacer, 1 Installation Instructions

DS25S Stainless Steel 10494522 10494522

10602603 10602603 10602503 10602503 10765216 10765215 10765214 10765214

10945908 10945908 10945929 10945929

10494603 10494603 10494604 10494604

DS26S Stainless Steel

April 1998 89 RS5290000 Rev. 0

Kit Instructions

Procedure

Caution

To avoid personal injury or property damage, two people should remove and rehang each door.

Caution

To avoid personal injury, protect hands and arms. Trim pieces may have sharp edges.

Important

Save all screws and reuse in original location.

1. Remove top handle end caps by removing screws.

3. Remove door handle inserts by placing screwdriver at top of door handles in area between handle and insert and pulling out.

4. Pull inserts out along length of handles.

2. Dispenser Models Remove crushed/cubed ice switch cover on dispenser by pulling forward. Remove screws from bottom of dispenser cover. Release bottom clips on dispenser cover by placing taped edge of putty knife underneath cover and pulling out. Release top clips by holding bottom of dispenser cover out and sliding up.

5. Install new handle inserts by reversing steps 3-4.

Important

One door handle insert (Item #7 or #8) will be discarded on DS23 kits.

6. Remove thin section on top handle end caps to allow room for panels. Discard section. Replace top handle end caps by placing end caps on handles. Insert and tighten screws.

Thin Section

RS5290000 Rev. 0 90 April 1998

Kit Instructions

7. Dispenser Models Replace dispenser cover by snapping in place. Insert and tighten screws. Replace switch by snapping in place.

8. Remove toe grille by pulling forward.

9. Electronic Control Models Unplug wiring harness from voltage box in center of refrigerator cabinet behind toe grille.

10. Electronic Control Models Release wiring harness from plastic retainer clips on bottom of refrigerator cabinet. Open door approximately 120° and locate screw holding plastic door closure to top of bottom hinge. Remove screw and close door.

Plastic Door Closure

Trace around top hinges with a pencil. This helps alignment when reassembling. On electronic and dispenser models, unplug top hinge wire connectors. Remove top hinge screws.

WARNING

To avoid electrical shock which can cause severe personal injury or death, green ground wire must remain attached to hinge.

13. Remove tape from refrigerator door. Grasp refrigerator door securely and lift up while opening. This will free door from bottom hinge pin. Top hinge may come off door. On electronic control models, wiring harness must slide through slot in bottom hinge.

Screw

Caution

To avoid personal injury or property damage, temporarily tape doors shut.

1 1 . Tape doors shut using masking tape.

12. Remove top hinge covers by removing screws.

Caution

To avoid property damage, drain water from water tube into small bucket.

14. Dispenser Models Loosen water tube clamp screw. Loosen plastic water tube union nut. Gently pull water tube away from union nut and through tube clamp.

April 1998 91 RS5290000 Rev. 0

Kit Instructions

15. Remove tape from freezer door . Grasp freezer door securely and lift up while opening. This will free door from bottom hinge pin. On dispenser models, plastic water tube must slide through slot in bottom door hinge as door is raised.

16. Remove door stops by removing screws. Install spacer and bottom trim by placing spacer and trim on bottom of doors. Insert and tighten bottom trim screws (Item #9). Replace door stops by placing door stops on bottom of doors. Insert and tighten screws.

20. Remove tape from doors.

Important

21. Install top door trim by peeling off 1 1/2 inches (38 millimeters) of backing. Place cut end of trim against handle cap and firmly against back of door. After checking placement, peel off backing and press into place.

22. Dispenser Models Install dispenser trim on freezer panels by sliding trim on bottom edge of upper freezer door panel and top edge of lower freezer door panel.

23. Non Dispenser Models Remove nameplate by placing putty knife covered with masking tape under nameplate and pulling forward. Discard nameplate.

24. Slide decorator door panels into place until panels are secure under handle inserts.

17. Rehang doors by positioning bottom sockets onto bottom door hinge pins. Position so doors are flush with side of refrigerator cabinet. Handle side of doors should be approximately 1/8 inch (3.2 millimeters) higher than hinge side of doors. Doors will settle when loaded with food. On electronic control models, when replacing refrigerator door, thread wiring harness in slot in bottom hinge. On dispenser models, when replacing freezer door, thread water tube through bottom hinge pin and water tube clamp.

Caution

To avoid personal injury or property damage, temporarily tape doors shut.

18. Tape doors shut using masking tape.

19. Replace top hinges by placing top hinges on refrigerator. Insert and tighten screws. On electronic control and dispenser models, reconnect top hinge wire connectors by snapping together. Replace top hinge covers by placing hinge covers over hinges. On electronic control and dispenser models, carefully place wires under cover to avoid pinching wires. Insert and tighten screws.

25. Install side door trim by peeling off 1 1/2 inches (38 millimeters) of backing. Place trim against top corner of refrigerator cabinet over edge of top trim. After checking placement, peel off backing and press into place. Place side door trim over edge of bottom trim.

WARNING

To avoid electrical shock which can cause severe personal injury or death, green ground wire must be reattached to refrigerator or freezer door hinge.

RS5290000 Rev. 0 92 April 1998

Kit Instructions

26. Dispenser Models Push water tube into plastic union nut and tighten union nut by hand. Gently pull on tube to confirm nut is tight. Tighten water tube clamp screw .

Caution

To avoid property damage, confirm water tube union nut is secure before replacing toe grille.

27. Electronic Control Models Plug wiring harness into voltage box in center of refrigerator cabinet behind toe grille. Snap wiring harness into plastic retainer clips on bottom of refrigerator cabinet. Align hole in plastic door closure with hole in bottom hinge. Insert and tighten screw.

28. Replace toe grille by inserting clips in holes and snapping in.

April 1998 93 RS5290000 Rev. 0

Kit Instructions

PK201 and PKD201 1/4" Decorator Door Panel Kits

Parts List

Description Qty PK201E

(Black) Refrigerator door panel 1 1009694 4 10096940 10096944 1009 694 0 Freezer door panel 1 10096943 10096939 Freezer door upper panel 1 10096949 1009694 5 Freezer door lower panel 1 10096986 10096983 Refrigerator door spacer 1 10234611 10234611 1023 461 1 10234613 Freezer door spacer 1 1023461 2 10234612 Freezer door upper spacer 1 10234609 10234609 Freezer door lower spacer 1 10234625 10234625 Installation instructions 1 10599708 10599708 10599708 10599708

PK201W

(White)

PKD201E

(Black)

PKD201W

(White)

Introduction

To avoid personal injury and property damage, observe all safety instructions.

To avoid property damage, protect soft vinyl or other flooring with cardboard, rugs, or other protective material.

Read entire manual before installing kit. Confirm all parts listed are included in kit. If parts are missing, contact source from whom kit was purchased.

Important

• Mechanical experience is required to install trim kit.

• Depending on installer’s knowledge and skill, installation can take from one-half to one hour.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

CAUTION

Procedure

CAUTION

To avoid personal injury , protect hands and arms. T rim pieces may have sharp edges.

Important

Save all screws and reuse in original location.

1. Remove top handle end caps by removing screws.

RS5290000 Rev. 0 94 April 1998

Kit Instructions

3. Remove door handle inserts by placing screwdriver at top of door handles in area between handle and insert and pulling forward.

4. Pull edge of inserts forward along length of handles.

CAUTION

To avoid personal injury or property damage, hold handles when removing.

CAUTION

To avoid property damage, place masking tape on back of panel at each corner. Tape prevents panel from damaging doors.

7. Cover back edges of cardboard with masking tape. Place several evenly spaced strips of masking

tape on rear of cardboard.

8. Non Dispenser Models

Open doors. Place bottom of panels in bottom trim then place top of panels under top trim. Slide panels into place until panels are seated firmly under side trim.

Dispenser Models

Open doors. Place bottom of refrigerator panel in bottom trim then place top of panel under top trim. Place bottom of lower freezer door panel in bottom trim then place top of panel under dispenser cavity . Place bottom of upper freezer door panel in top of dispenser cavity then place top of panel under top trim. Slide panels into place until panels are seated firmly under side trim.

9. Replace door handles by placing door handles on

doors. Insert and tighten screws. Replace handle inserts by snapping in place.

10. Dispenser Models

Replace dispenser cover by snapping in place. Insert and tighten screws. Replace switch by snapping in place.

1 1 . Remove thin section on top handle end caps to allow

room for panels. Discard section. Replace top handle end caps by placing end caps on handles. Insert and tighten screws.

5. Remove door handles by removing screws.

Important

Do not remove cardboard from panels. Panels will not fit properly if cardboard is removed.

6. Dispenser Models Locate dispenser trim in top crisper drawer. Install dispenser trim on freezer panels by sliding trim on bottom edge of upper freezer door panel and top edge of lower freezer door panel.

April 1998 95 RS5290000 Rev. 0

Thin Section

12. Peel protective wrap off front of panels.

Kit Instructions

HTGK200, HTGK220, HTK200 and Conversion Kits Parts List

Description Qty

Top Cap, Refrigerator Door Top Cap, Freezer Door Bottom Cap, Refrigerator Door Bottom Cap, Freezer Door Hinge Cover, Right Hinge Cover, Left Side Trim, Refrigerator Door Side Trim, Freezer Door Top Trim, Refrigerator Door Top Trim, Freezer Door

Bottom Trim, Refrigerator Door

Bottom Trim, Freezer Door Trim, Dispenser

HTK200E

Black

1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X 1 X X X X X X

1 X X X X X X 1 X X X X X X 2 X X X

HTK200S

Brushed

Aluminum

HTGK200W

White

HTK220E

Black

HTK220S

Brushed

Aluminum

HTGK220W

White

Door Stop Handle, Freezer Door Handle, Refrigerator Door Toe Grille Handle Insert, Refrigerator

Door Handle Insert, Freezer Door Screw, Top Trim Installation Instructions Clip, Toe Grille Tape, Double Back

2 X X X X 1 X X X X X X 1 X X X X X X 1 X X

1 X X X X X X 1 X X X X X X 6 X X 1 X X X X X X 2 X X

122" X X X X X X

RS5290000 Rev. 0 96 April 1998

Kit Instructions

Introduction

Important

• Mechanical experience is required to install trim kit.

• Depending on installer’s knowledge and skill, installation can take from one to three hours.

• T ransfer food to an alternate cooling source. Check refrigerator warranty certificate for specific coverage. Warranty does not cover food loss.

• Ensure trim pieces adhere properly by confirming surfaces are clean, dry and free of adhesive residue.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

Decorator Panel Dimensions

Listed below are required height x width dimensions for decorator panels. Panels are not supplied with this kit and can be purchased locally .

Caution

To avoid personal injury or property damage, refrigerator panels should not weigh more than 30 pounds (14 kilograms) and freezer panels should not weigh more than 15 pounds (7 kilograms).

Procedure

Caution

To avoid personal injury or property damage, two people should remove and rehang each door.

Caution

To avoid personal injury, protect hands and arms. Trim pieces may have sharp edges.

Important

Save all screws and reuse in original location.

Without Dispenser

Refrigerator Door 63 3/32" x 19 3/8"

(1603 mm x 492 mm)

Freezer Door 63 3/32" x 13 3/4"

(1603 mm x 349 mm)

With Dispenser

Refrigerator Door 63 3/32" x 19 3/8"

(1603 mm x 492 mm)

Upper Freezer Door 18 3/8" x 13 3/4"

(467 mm x 349 mm)

Lower Freezer Door 31 13/16" x 13 3/4"

(808 mm x 349 mm)

1. Remove top handle end caps by removing screws.

April 1998 97 RS5290000 Rev. 0

Kit Instructions

3. Remove door handle inserts by placing screwdriver at top of door handles in area between handle and insert and pulling out.

4. Pull edge of inserts forward along length of handles.

8. Remove trim on sides of doors by placing taped edge of putty knife underneath trim and pulling out.

Caution

To avoid personal injury or property damage, temporarily tape doors shut.

9. Tape doors shut using masking tape.

10. Remove top hinge covers by removing screws. Trace around top hinges with a pencil. This helps alignment when reassembling. On dispenser models, unplug top hinge wire connectors. Remove top hinge screws.

Caution

To avoid personal injury or property damage, hold handles when removing.

5. Remove door handles by removing screws. Bottom inserts are removed with handle.

WARNING

To avoid electrical shock which can cause severe personal injury or death, green ground wire must remain attached to hinge.

11. Remove tape from refrigerator door. Grasp refrigerator door securely and lift up while opening. This will free door from bottom hinge pin. Top hinge may come off door .

12. Remove toe grille by pulling forward.

6. Remove top door trim by removing screws.

7. If refrigerator has decorator panels, carefully slide panels out. On dispenser models, remove dispenser trim.

RS5290000 Rev. 0 98 April 1998

Kit Instructions

Caution

To avoid property damage, drain water from water tube into small bucket.

13. Dispenser Models Loosen water tube clamp screw. Loosen plastic water tube union nut. Gently pull water tube away

from union nut and through tube clamp.

14. Remove tape from freezer door. Grasp freezer door securely and lift up while opening. This will free door from bottom hinge pin. On dispenser models, plastic water tube must slide through slot in bottom door hinge as door is raised. Top hinge will remain attached to door.

15. Remove bottom door trim by removing screws. When installing HTK200S, HTGK200W, HTK220S and HTK220W kits, remove door stops. Confirm support plate is under door trim. Install new bottom door trim by placing trim on bottom of doors. Insert and tighten screws. When installing HTK200S, HTGK200W, HTK220S and HTK220W kits, install new door stops by placing door stops on bottom of doors. Insert and tighten screws.

16. Rehang doors by positioning bottom sockets onto bottom door hinge pins. Position so doors are flush with sides of refrigerator cabinet. Handle side of doors should be approximately 1/8 inch (3.2 millimeters) higher than hinge side of doors. Doors will settle when loaded with food. On dispenser models, when replacing freezer door, thread water tube through bottom hinge pin and water tube clamp.

Caution

To avoid personal injury or property damage, temporarily tape doors shut.

17. Tape doors shut using masking tape.

Important

• Ensure trim pieces adhere properly by confirming surfaces are clean, dry and free of adhesive residue.

• Discard factory installed trim and handles.

18. Replace top hinges by placing top hinges on refrigerator. Insert and tighten screws. On dispenser models, reconnect top hinge wire connectors. Install new top hinge covers by placing hinge covers over hinges. On dispenser models, carefully place wires under cover to avoid pinching wires. Insert screws and tighten.

WARNING

To avoid electrical shock which can cause severe personal injury or death, green ground wire must be attached to freezer door hinge.

19. Install new bottom door handle caps by pushing up into bottom of new handles until caps snap in place.

20. Install new door handles by placing door handles on door. Insert and tighten screws. Install new handle inserts by snapping in place.

April 1998 99 RS5290000 Rev. 0

Kit Instructions

21. Remove thin section on top handle end caps to allow room for panels. Discard section. Replace top handle end caps by placing end caps on handles. Insert and tighten screws.

Thin Section

22. Dispenser Models Replace dispenser cover by snapping in place. Insert and tighten screws. Replace switch by snapping in place.

23. Install new top door trim by placing trim on top of doors. Insert screws but do not completely tighten. When installing HTK200E and HTK220E, install new color coordinated screws taped to trim.

24. Dispenser Models Install new dispenser trim on freezer panels by sliding trim on bottom edge of upper freezer door panel and top edge of lower freezer door panel.

25. Slide decorator door panels into place until panels are secure under door handle inserts.

26. Install side door trim by peeling off 1 1/2 inches (38 millimeters) of backing. Place trim against bottom corner of refrigerator cabinet over edge of bottom trim. After checking placement, peel off backing and press into place. Place side door trim under edge of top trim. Tighten top trim screws.

Side Trim

Bottom Trim

27. Push water tube into plastic union nut and tighten union nut by hand. Gently pull on tube to confirm nut is tight. Tighten water tube clamp screw .

Caution

To avoid property damage, confirm water tube union nut is secure before replacing toe grille.

28. Install new toe grille (if supplied) by inserting clips in holes and snapping in.

Important

RS5290000 Rev. 0 100 April 1998

Kit Instructions

HTGK100 and HTGK110 Black 1/4" Trim and Handle Conversion Kits

Introduction

Important

• Mechanical experience is required to install trim kit.

• Depending on installer’s knowledge and skill, installation can take from one to three hours.

• T ransfer food to an alternate cooling source. Check refrigerator warranty certificate for specific coverage. Warranty does not cover food loss.

• Ensure trim pieces adhere properly by confirming surfaces are clean, dry and free of adhesive residue.

• If unable to solve a problem during installation, contact source from whom kit was purchased.

Decorator Panel Dimensions

Listed below are required height x width dimensions for decorator panels. Panels are not supplied with this kit and can be purchased locally .

Caution

To avoid personal injury or property damage, refrigerator panels should not weigh more than 30 pounds (14 kilograms) and freezer panels should not weigh more than 15 pounds (7 kilograms).

Without Dispenser

Refrigerator Door 61 15/16" x 19 3/8"

(1573 mm x 492 mm)

Freezer Door 61 15/16" x 13 3/4"

(1573 mm x 349 mm)

With Dispenser

Refrigerator Door 61 15/16" x 19 3/8"

(1573 mm x 492 mm)

Upper Freezer Door 17 1/4" x 13 3/4"

(438 mm x 349 mm)

Lower Freezer Door 31 13/16" x 13 3/4"

(808 mm x 349 mm)

Parts List

Description Qty

Top Cap, Refrigerator Door

Top Cap, Freezer Door 1 X X Bottom Cap, Refrigerator

Door Bottom Cap, Freezer

Door Hinge Cover 2 X X Toe Grille 1 X X Side Trim, Refrigerator

and Freezer Doors Door Stop 2 X X Top Trim, Refrigerator

Door Top Trim, Freezer Door 1 X X Bottom Trim,

Refrigerator Door Bottom Trim, Freezer

Door Trim, Dispenser 2 X Handle, Refrigerator

Door Handle, Freezer Door 1 X X Handle Insert,

Refrigerator Door Handle Insert, Freezer

Door Handle

HTGK100E

Black

1 X X

2 X X

1 X X

HTGK110E

BLACK

April 1998 101 RS5290000 Rev. 0

Installation Instructions 1 X X Screw, Bottom Trim 5 X X Spacer, Refrigerator

Bottom Trim Spacer, Freezer Bottom

Trim Clip, Toe Grille 2 X X Tape, Double Back .032" 28.5" X X Tape, Double Back .187" 122" X X

1 X X

Kit Instructions

Procedure

Caution

To avoid personal injury or property damage, two people should remove and rehang each door.

Caution

To avoid personal injury, protect hands and arms. Trim pieces may have sharp edges.

Important

Save all screws and reuse in original location.

3. Remove door handle inserts by placing screwdriver at top of door handles in area between handle and insert and pulling out.

4. Pull edge of inserts forward along length of handles.

1. Remove top handle end caps by removing screws.

Caution

To avoid personal injury or property damage, hold handles when removing.

5. Remove door handles by removing screws. Bottom inserts are removed with handle.

RS5290000 Rev. 0 102 April 1998

Amana SXD520T, SR520T, SRD520T, SBDT520T, SBDX520T Service

Specifications and Main Features

Frequently Asked Questions

User Manual