Reach-In Refrigerators and Freezers
Service Manual
This manual conta ins important information regarding the installatio n and upkeep of your new Koolaire refrigerator or freezer.
Please read the manual thoroughly prior to equipment handling, se t -up, operat ion, and maintenance.
Part No. 80-1205-3
7/1/00
Safety Notices
Procedural Notices
As you work on a Manitowocâ Koolaire reach-in,
be sure to pay close attention to the safety notices in
this manual. Disregarding the notices may lead to
serious injury and/or damage to the equipment.
Throughout this manual, you will see the following
types of safety notices:
WARNING
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
CAUTION
Text in a Caution box alerts you to a situation in
which you could damage the equipment. Be sure to
read the Caution statement before proceeding, and
work carefully.
As you work on a Manitowocâ Koolaire reach-in,
be sure to read the procedural notices in this manual.
These notices supply helpful information which may
assist you as you work.
Throughout this manual, you will see the following
types of procedural notices:
Important
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will
not cause damage or injury, but it may slow you
down as you work.
NOTE: Text set off as a Note provides you with
simple, but useful, extra information about the
procedure that you are performing.
About This Manual
This manual contains important information on the installation, use, and upkeep of your new your Manitowocâ
Koolaire reach-in. Each reach-in has been carefully inspected for the highest possible quality. With proper
installation and care, you will enjoy many years of reliable performance.
Please read and understand the information contained in this manual prior to installation, start-up, and operation.
If you do not understand any part of the information contained in this manual, please contact your Manitowocâ
Koolaire dealer or call the factory at 1-877-582-5086.
Table of Contents
Table of Contents
Section 1 - Warranty
Model/Serial Number Location.........................................................................................................................1-1
Warranty.............................................................................................................................................................1-1
Warranty Service ...............................................................................................................................................1-1
Section 2 - Installation
General................................................................................................................................................................2-1
Positioning the Cabinet......................................................................................................................................2-1
Heat of Rejection................................................................................................................................................2-1
Uncrating.............................................................................................................................................................2-2
Leveling the Cabinet..........................................................................................................................................2-3
Shelf/Tray Slide Installation .............................................................................................................................2-3
Section 3 - Start-Up
Electrical Requirements.....................................................................................................................................3-1
Electrical Specifications.....................................................................................................................................3-2
Condensate Water Removal .............................................................................................................................3-3
Defrost Systems
General..........................................................................................................................................................3-3
Defrost Settings.............................................................................................................................................3-3
Setting Time of Day......................................................................................................................................3-3
Adjusting Defrost Duration.........................................................................................................................3-3
Temperature Controls
Refrigerators and Freezers..........................................................................................................................3-4
Loading Shelves .................................................................................................................................................3-4
Section 4 - Cleaning
Exterior ...............................................................................................................................................................4-1
Interior ................................................................................................................................................................4-1
Cleaning the Condenser Coil ............................................................................................................................4-2
Section 5 - Adjustments and Calibrations
Adjustments
Solid Door Adjustment................................................................................................................................5-1
Glass Door Adjustment................................................................................................................................5-1
Calibrations
Thermometer Calibration ...........................................................................................................................5-2
Continued on next page...
i
Table of Contents
Table of Contents (cont.)
Section 6 - Before Requesting Service
Troubleshooting Guide......................................................................................................................................6-1
Section 7 - Electrical Specifications
Main Power Switch ...........................................................................................................................................7-1
Temperature Control........................................................................................................................................ 7-1
Light Switch....................................................................................................................................................... 7-2
Defrost Terminator / Fan Delay Switch - Freezers ........................................................................................7-2
Defrost Timer - Freezers................................................................................................................................... 7-3
Defrost Heater Element - Freezers .................................................................................................................. 7-3
Evaporator Drain Pan Heater - Freezers........................................................................................................ 7-4
Anti-Condensate Door Heaters........................................................................................................................7-4
Compressor Overload Protector......................................................................................................................7-5
Compressor Start Relay.................................................................................................................................... 7-5
Compressor Windings.......................................................................................................................................7-6
Wiring Diagrams............................................................................................................................................... 7-7
Section 8 - Refrigeration
Temperature/Pressure/Refrigerant Charge Charts - Refrigerators/Freezers............................................. 8-1
Recovery/Evacuation and Recharging............................................................................................................ 8-2
Charging Procedures ........................................................................................................................................8-3
System Contamination Clean-up.....................................................................................................................8-4
Refrigeration Re-Use Policy............................................................................................................................. 8-6
Section 9 Replacement Procedures
Evaporator Fan Assembly – 1 Section Cabinets ............................................................................................9-1
Light Switch....................................................................................................................................................... 9-3
Evaporator Fan Assembly – 2 & 3 Section Cabinets.....................................................................................9-4
Temperature Control........................................................................................................................................ 9-5
Defrost Heater Element - Freezers .................................................................................................................. 9-7
Digital Thermometer Display and Probe........................................................................................................ 9-8
Digital Thermometer Transformer.................................................................................................................9-10
Door Handle – Solid Doors..............................................................................................................................9-11
Door Handle – Glass Doors.............................................................................................................................9-12
Door Hinge – Solid Doors................................................................................................................................9-12
Door Gasket – Solid Doors ..............................................................................................................................9-13
Door Gasket – Glass Doors..............................................................................................................................9-14
Vinyl Breaker Strips........................................................................................................................................9-15
Anti-Condensate Door Heaters.......................................................................................................................9-16
Defrost Terminator / Fan Delay Switch - Freezers .......................................................................................9-16
ii
Section 1 Warranty
Section 1
Warranty
Model/Serial Number Location
The Koolaire data plate, which includes the model
number and serial number, as well as important
electrical and technical information, is located on the
left interior wall of the cabinet at approximately eye
level.
For convenience and quick reference, record the
model and serial numbers, voltage, and installation
date in the spaces below:
Model Number
Serial Number
Voltage
Installation Date
Warranty
Warranty coverage on a Koolaire reach-in begins
on the date it is installed. Please read the warranty
certificate included with the cabinet for details.
PARTS COVERAGE
1. A Koolaire reach-in cabinet and the
refrigeration and mechanical components are
warranted against defects in materials and
workmanship for a period of two (2) years from
the date of original installation.
2. The evaporator coil and compressor are covered
by an additional three (3) years (five years total)
warranty beginning on the date of the original
installation.
NOTE: The additional three year evaporator coil
warranty does not apply to parts such as fan motors,
defrost elements, housings, electrical wiring, or
controls that are attached to the evaporator coil.
EXCLUSIONS FROM WARRANTY
1. Normal start-up, maintenance, adjustments, and
cleaning.
2. Interior cabinet light bulb.
3. Repairs due to unauthorized modifications to the
Refrigeration System/Reach-In Cabinet or the use
of non-standard parts without prior written
approval.
4. Damage caused by improper installation of the
Reach-In cabinet, electrical supply, water supply
or drainage, or damage caused by floods, storms,
or other acts of God.
5. Premium labor rates due to holidays, overtime,
travel time, mileage flat rate, service call charges
and miscellaneous tools and material charges not
listed on the payment schedule. Additional labor
charges resulting from inaccessibility of the
Reach-In are also excluded.
6. Parts or assemblies subjected to misuse, abuse,
neglect or accidents.
7. Damage to the interior of cabinet or refrigeration
system as a result of storing open acidic food
containers.
8. Claims for special indirect or consequential
damages, including food spoilage or product loss.
Warranty Service
To insure warranty coverage, a qualified service
company must perform the warranty repair.
If the dealer the Koolaire reach-in was purchased
from does not perform warranty service, please call 1877-582-5086 for assistance.
LABOR COVERAGE
Labor is covered to repair or replace defective
components for two (2) years from the date of the
original installation.
1-1
Warranty Section 1
THIS PAGE INTENTIONALLY LEFT BLANK
1-2
Section 2 Installation
Section 2
Installation
General
CAUTION
These instructions are of the utmost importance in
assuring that the Manitowocâ Koolaire cabinet
operates as designed, and must be followed closely.
Positioning the Cabinet
CAUTION
When selecting a permanent location for the
cabinet, observe the following guidelines. Failure to
do so may cause reduced performance and
efficiency, cause damage, and void your warranty.
Heat of Rejection
CABINET LOCATION GUIDELINES
• Install the cabinet in an indoor environment only.
• The air temperature entering the refrigerator or
freezer condenser should be between 55°F (13°C)
and 100°F (38°C).
• Allow space for air circulation in the refrigeration
condensing unit compartment on refrigerators and
freezers. The minimum space requirements are:
• 10” (25 cm) on top
• 4” (10 cm) at the back
• 4” (10 cm) on each side
• The floor must be strong enough to support the
weight of the cabinet and product load.
CAUTION
A fully loaded reach-in cabinet can weigh more
than 3,000 pounds.
All refrigeration equipment rejects heat through the condenser. It is helpful to know the amount of heat rejected,
to determine the additional load that will be placed on air conditioning equipment.
Refrigerators
Model Solid
Door
KR-1 KR-101 -- 2600
1 Door
KR-2 KR-201 -- 2600
2 Door
KR-3 KR-301 -- 3780
3 Door
Half
Door
-- -- KR-1GD 3780
-- -- KR-2GD 4600
-- -- KR-3GD 5580
Glass
Door
Refrigerator
BTU Per
Hour
Freezers
Model Solid Door Half
Door
1 Door KF-1 KF-101 1700
2 Door KF-2 KF-201 2840
3 Door KF-3 KF-301 3450
Freezer BTU
Per Hour
2-1
Installation Section 2
Uncrating
WARNING
Never attempt to tilt the cabinet alone. Always use
two or more people when tilting the cabinet to
remove the shipping skid or to move it through
doorways.
1. Remove the bottom shipping skid using one of
the methods below:
• Lay the cabinet on its back, elevated and
supported by wooden blocks. Remove the
skid mounting bolts and separate the skid
from the cabinet.
• Tilt the cabinet from side to side and remove
the mounting bolts. Support the weight of the
cabinet apart from the skid.
2. Install the legs or casters and torque them to 360
inch-pounds. Refer to the drawing at right.
3. Return the cabinet to the upright position.
4. Remove any remaining crating materials.
THREAD LEVELING
LEG INTO BASE OF
CABINET
THREAD FOOT IN
AS FAR AS
POSSIBLE
SV1342
CAUTION
If the cabinet was placed on its back while moving
it or while removing the bottom shipping skid,
wait at least two hours after returning the cabinet
to the upright position before starting the
refrigeration system.
CAUTION
Never use sharp instruments to cut the plastic or
cardboard crating materials. Damage to the cabinet
exterior may result.
Installing Cabinet Legs
2-2
Section 2 Installation
Leveling the Cabinet
The cabinet must be leveled after it is positioned in
its permanent location. This insures proper door
alignment on all cabinets, and adequate condensate
water drainage and proper refrigeration system
operation.
Leveling the Cabinet
CAUTION
If casters are installed instead of legs, the floor
must be leveled before final positioning of the
cabinet.
1. Place a level on top of the cabinet.
2. Turn the leveling foot of the lowest corner leg to
center the bubble in the level.
3. Adjust each of the other corners until the bubble
is centered and the cabinet is stable.
4. Re-check the cabinet from side to side and from
front to rear with the level. Adjust the leg levelers
as necessary.
Shelf/Tray Slide Installation
SHELVES
1. Determine the desired shelf location.
SHELF
CLIP
Shelf Installation
TRAY SLIDES
Tray slides are optional accessories and must be
ordered separately. To install a tray slide:
1. Locate the appropriate square shelf standard holes
at the desired height.
2. Insert the tabs of each slide into the 3/8" holes in
the shelf support standards and pull it straight
down to lock it into place (Refer to drawing
below).
SHELF
SUPPORT
STANDARD
SER.3
NOTE: The shelves may be located at any position in
1" increments. Optimum spacing is one shelf near the
bottom of the cabinet, one shelf near center height,
and one shelf at eye level (Refer to drawing).
2. Install four clips per shelf, one at each corner. The
shelf clips slip into the 3/8" holes and slide down.
3. Make sure that the clips are level from side to
side and from front to rear at each corner.
4. Install the shelves with the smaller wires running
from front to back.
TRAY
SLIDE
NOTE: SHELF SUPPORT
STANDARDS ARE
SHOWN OUTSIDE
FOR CLARITY
Tray Slide Installation
SHELF
SUPPORT
STANDARD
SER.2
2-3
Installation Section 2
THIS PAGE INTENTIONALLY LEFT BLANK
2-4
Section 3 Start-Up
Section 3
Start Up
Electrical Requirements
All cord-connected units should be plugged into a
grounded and properly sized electrical outlet with
appropriate overcurrent protection. Refer to the
drawing below for electrical plug configurations.
5-20P 5-15P
SER.4
5-20P and 5-15P Electrical Plug Configurations
All permanently connected (hard-wired) units are
fitted with a power junction box and 6” pigtail wires
for power connection.
Connect one end of the power line to the pigtail from
the cabinet junction box. Connect the other end to a
properly sized electrical source.
As a rule, the power lines must be enclosed inside a
conduit secured to the power junction boxes on both
ends.
CAUTION
Power installation must be in compliance with the
National Electrical Code and all applicable local
and state codes.
WARNING
Never use an extension cord.
Never alter the power cord or plug supplied with
the cabinet.
After the power source has been connected, turn on
the main power switch. The switch is located on the
cabinet top, behind the front panel.
3-1
Start-Up Section 3
Electrical Specifications
REACH-IN
REFRIGERATORS
Full Door
Half Door
Glass Door
Model Voltage/ Phase/Cycles Total
Amps
KR-1 115/60/1 9.9 15 amp 5-15P
230/50/1 ** ** **
KR-2 115/60/1 10.4 15 amp 5-15P
230/50/1 ** ** **
KR-3 *115 & 208-230/60/1
230/50/1 ** ** **
KR-101 115/60/1 9.9 15 amp 5-15P
230/50/1 ** ** **
KR-102 115/60/1 10.4 15 amp 5-15P
230/50/1 ** ** **
KR-103 *115 & 208-230/60/1
230/50/1 ** ** **
KR-1GD 115/60/1 14.7 20 amp 5-20P
230/50/1 ** ** **
KR-2GD 115/60/1 16.0 20 amp 5-20P
230/50/1 ** ** **
KR-3GD *115 & 208-230/60/1
230/50/1 ** ** **
Minimum
circuit amps
15.1
Minimum
circuit amps
15.1
Minimum
circuit amps
15.3
Maximum
Fuse Size
20 amp Hard-Wired
20 amp Hard-Wired
20 amp Hard-Wired
ANSI Electrical
Plug Configuration
REACH-IN
FREEZER
Full Door
Half Door
Model Voltage/ Phase/Cycles Total
Amps
KF-1 115/60/1 12.4 20 amp 5-15P
230/50/1 ** ** **
KF-2 115/60/1 16 20 a m p 5-20-P
230/50/1 ** ** **
KF-3 *115 & 208-230/60/1
230/50/1 ** ** **
KF-101 115/60/1 12.4 20amp 5-15P
230/50/1 ** ** **
KF-201 208/230/60/1 16 20 amp 5-20-P
230/50/1 ** ** **
KF-301 *115 & 208-230/60/1
230/50/1 ** ** **
Minimum
circuit amps
15.8
Minimum
circuit amps
15.8
Maximum
Fuse Size
20 amp Hard-Wired
20 amp Hard-Wired
ANSI Electrical
Plug Configuration
* 4 wire dual voltage required: 115 Volt for the lights and fans, 208-230 Volt for the compressor.
** Data not available at time of printing.
3-2
Section 3 Start-Up
Condensate Water Removal
(Refrigerators and Freezers)
Manitowoc cabinets are equipped with a condensate
vaporizer system. This system uses energy-saving hot
gas supplied by the refrigeration system lines. No
drain connection is required.
Defrost Systems
GENERAL
Refrigerator coils operate at temperatures below
freezing (32°F). During compressor “off” time, the
evaporator fan continues to circulate 38°F refrigerator
compartment air through the evaporator coil. This air
circulation raises the coil temperature above the
freezing point, melting any frost that may have
accumulated.
The run-off water is drained into the vaporizer pan
and is evaporated by the hot gas refrigeration line
during compressor “on” time.
24 HOUR
DIAL
2 HOUR
DIAL
SV1080
Defrost Time Clock
Important
Set the defrost timer to defrost the reach-in during
the lowest usage periods.
Freezer coils are defrosted electrically at userdetermined times.
NOTE: A freezer’s evaporator fans do not run
immediately upon start-up or during and immediately
following the defrost cycles. The fans start when the
coil temperature falls below freezing. This prevents
the fans from blowing moisture or heated air on the
stored products.
DEFROST SETTINGS
The defrost timer is factory preset to defrost the
evaporator coil each day at 2:00 AM, 8:00 AM,
2:00 PM, and 8:00 PM.
If you wish to change the defrost times, remove the
pins from the outer dial and re-insert them into the
desired time slots. (Refer to drawing.)
CAUTION
Leave at least one hole between adjacent pins.
SETTING TIME OF DAY
The defrost timer must be set to “real time” after the
power is turned on, or after a power failure.
To set the time:
1. Grasp the knob in the center of the inner dial.
2. Turn it counterclockwise to rotate the outer dial.
3. Line up the current time of day on the outer dial
with the pointer.
ADJUSTING DEFROST DURATION
The defrost cycle is terminated by a temperaturesensing switch located on the suction line, adjacent to
the evaporator coil.
The defrost duration is factory-set. Normally, no
adjustment is required. For a longer defrost time,
press down on the inner dial pointer and rotate the
pointer until the desired time lines up.
Important
The coil defrosts only until the temperature-sensing
switch terminates the cycle, regardless of the
defrost duration that is set.
3-3
Start-Up Section 3
Temperature Control
REFRIGERATORS AND FREEZERS
The temperature controls are factory-set to maintain
an average temperature of 38°F (3°C) in refrigerators,
and an average temperature of 0°F (18°C) in freezers.
The temperature variance is 6-8 F (2°-4°C) degrees.
A freezer should run between -2°F to +4°F (3°C to 15°C). A refrigerator should run between +35° to
+42°F (1°C to 5°C).
For a different cabinet temperature setting, turn the
temperature control knob, located behind the front
cabinet louver.
CAUTION
Setting the temperature control to the coldest
setting may cause the coil and/or air ducts to freeze
and ice up. This will eventually result in a warmer
cabinet temperature.
If ice accumulation occurs and the temperature is
lower than the guidelines, turn the control knob to
a warmer setting.
Loading Shelves
For maximum operating efficiency, load the shelves
with space between the stored items. This allows air
to circulate properly.
CAUTION
Do not store more than 250 pounds of product on
any shelf and no more than 800 pounds of product
per cabinet.
CAUTION
Store products with high acid content (such as
lettuce, other fresh vegetables or fruits, salad
dressings, etc.) in closed containers. This will
prevent corrosion on the evaporator coil and other
metal parts in the air distribution system.
Important
Uncovered food will dehydrate much more rapidly
than covered food. For best food quality, always
store in covered container.
CAUTION
Allow the reach-in to reach proper operating
temperature before filling it with product. Do not
place hot or steaming foods in the cabinet.
3-4
Section 4 Cleaning
Section 4
Cleaning
Exterior
Clean cabinet exterior surfaces with a solution of
mild soap and water. To minimize streaking, follow
with a fresh water rinse.
If stainless steel becomes discolored, scrub only in
the direction of the finished grain.
For high shine, see your kitchen equipment dealer for
a high-quality stainless steel polish.
CAUTION
Do not use steel wool, caustic soap, or abrasive
cleaners, as these may damage the metal finish.
Alcohol-based cleaners may damage the nylon
door cams.
Interior
Clean cabinet interior surfaces with warm water and
baking soda, applied with a cloth or sponge.
The shelves and shelf support standards can be
removed without special tools to facilitate cleaning.
Wash door gaskets weekly with a mild soap and
water solution, followed by a fresh water rinse.
While cleaning, check the door gaskets for proper
sealing. Adjust if needed.
CAUTION
Never use cleaners that are not approved for use
where food may come into contact with cabinet
interior surfaces.
CAUTION
Do not use steel wool, caustic soap, or abrasive
cleaners, as these may damage the metal finish.
4-1
Cleaning Section 4
Cleaning the Condenser Coil
CONDENSER CLEANING PROCEDURE
WARNING
Disconnect electric power before cleaning.
A dirty condenser restricts airflow, resulting in
excessively high operating temperatures. This reduces
efficiency and shortens component life.
The washable aluminum filter is designed to catch
dust, dirt, lint and grease. This helps keep the
condenser clean. For efficient operation, it is very
important to clean the condenser coil surface and
keep it free of dust, dirt, and lint.
The condition of the air filter and condenser coil
should be checked monthly.
CAUTION
Failure to clean and maintain the condenser coil
properly will result in reduced air circulation
through the condenser fins. This will cause
reduced efficiency, high operating pressures, and
possible shortened compressor life.
Use this procedure to clean the condenser monthly:
1. Remove and clean the filter with a mild soap and
water solution.
2. Clean the outside of the condenser with a soft
brush or a vacuum with a brush attachment. Clean
from top to bottom not side to side. Be careful not
to bend the condenser fins.
3. Shine a flashlight through the condenser to check
for dirt between the fins. If dirt remains:
A. Blow compressed air through the condenser
from the inside. Be careful not to bend the fan
blades.
B. Use a commercial condenser coil cleaner.
Follow the directions and cautions supplied
with the cleaner.
Repeat step 3 until all dirt is removed.
After cleaning, straighten any bent condenser fins
with a fin comb.
WARNING
Condenser fins are sharp. Use care when working
around them.
FIN COMB
CONDENSER
COMB
DOWN
ONLY
Using a Fin Comb
WARNING
Disconnect electric power before cleaning.
CLEANING THE FAN BLADES AND MOTOR
If necessary, clean the fan blades and motor with a
soft cloth. If it is necessary to wash the fan blades,
cover the fan motor to prevent moisture damage.
4-2
Section 5 Adjustments and Calibrations
Section 5
Adjustments and Calibrations
Adjustments
Cabinet doors may require some adjustment after a
period of usage, depending upon the frequency of
door openings. This is normal. Follow the appropriate
procedure below:
SOLID DOOR ADJUSTMENT
1. Remove the metal hinge covers that conceal the
three hinge mounting screws. Gently pry it off
with a flat-bladed screwdriver.
HINGE
MOUNTING
SCREWS
DOOR
HINGE
GLASS DOOR ADJUSTMENT
To adjust the spring tension:
1. Locate the adjustment bushing on the hinges. This
bushing is on top of the hinge for right-hand
doors and on the bottom for left-hand doors.
2. Insert a small nail (1/8”) into a hole in the
adjustment bushing. Wind the bushing clockwise
until the pin can be removed from the bushing.
INSERT A
SMALL NAIL
TURN
CLOCKWISE
HINGE
COVER
E-3044-B
Hinge/Hinge Cover
2. Loosen the three hinge mounting screws
approximately two rotations, using a Phillips
screwdriver.
3. While a second person firmly pushes the door
closed to the front face of the cabinet, re-tighten
the screws.
4. Re-install the hinge covers.
ADJUSTMENT
BUSHING
Hinge Adjustment
3. Continue winding the bushing clockwise until the
desired tension is achieved.
4. Re-insert the bushing pin.
CAUTION
Do not over-tighten the hinge spring.
Adjusting the hinge adjustment bushings one hole
at a time is recommended.
5-1
Adjustments and Calibrations Section 5
Thermometer Calibration
Occasionally, the rigors of shipping and installation
can shift the thermometer out of proper adjustment.
If the accuracy of the thermometer is in question,
place another thermometer inside the cabinet at
approximately mid-height and compare the readings.
If the thermometer requires adjustment, follow the
procedure below.
1. Gently pry off the clear thermometer cover lens
with a small flat-bladed screwdriver.
2. While carefully holding the dial indicator needle
with one hand, turn the slotted center pivot with a
flat-bladed screwdriver. Turn clockwise to
decrease the reading and counterclockwise to
increase the reading.
3. Replace the clear thermometer cover lens by
pressing it into place around the perimeter.
5-2
Section 6 Before Requesting Service
Section 6
Before Requesting Service
Troubleshooting Guide
Before requesting any service on your Manitowoc
cabinet, please check the following points.
Disconnect electric power before performing any
This guide is not comprehensive; it is intended as a
service.
reference for solutions to common problems.
Symptom Possible Cause Corrective Action
Cabinet not running Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker.
Power cord unplugged. Plug in power cord.
Thermostat set too high. Set thermostat to lower temperature.
Main power switch turned off. Turn main power switch on.
Cabinet in defrost cycle. (Freezer models) Wait for defrost cycle to finish.
Condensing unit runs
for long periods or
continuously Prolonged door openings or door(s) ajar. Make sure door(s) are closed when not in
Cabinet temperature Thermostat set too high. Set thermostat to lower temperature.
is too high Poor air circulation in cabinet. Re-arrange product to allow proper air
Cabinet is noisy Loose part(s). Locate and tighten loose part(s).
Refrigerator is freezing
product
Compressor will not Dirty condenser coil. Clean the condenser coil.
start - hums and trips
on overload
protector
Excessive amount of warm product
placed in cabinet.
Door gasket(s) not sealing properly. Check gasket condition. Adjust door or
Dirty condenser coil. Clean the condenser coil.
Evaporator coil iced over. Turn unit off and allow coil to defrost.
Exterior thermometer is out of calibration. Re-calibrate thermometer.
Excessive amount of warm product
placed in cabinet.
Prolonged door openings or door(s) ajar. Make sure door(s) are closed when not in
Dirty condenser coil. Clean the condenser coil.
Evaporator coil iced over. Turn unit off and allow coil to defrost.
Tubing vibration. Insure tubing is free from contact with
Thermostat is set too low. Set thermostat to higher temperature.
Not enough cabinet clearance for
proper refrigeration system operation.
Low voltage to cabinet. Check and correct incoming voltage to
Allow adequate time for product to cool
down.
use. Avoid prolonged door openings.
replace gasket if necessary.
Make sure thermostat is not set too cold.
Also, check gasket condition.
circulation.
Allow adequate time for product to cool
down.
use. Avoid prolonged door openings.
Make sure thermostat is not set too cold.
Also, check gasket condition.
other tubing or components.
Move cabinet or make other
adjustments to gain proper cabinet
clearances.
cabinet.
WARNING
6-1
Before Requesting Service Section 6
THIS PAGE INTENTIONALLY LEFT BLANK
6-2
Section 7 Electrical Specifications
Section 7
Electrical Specifications
Main Power Switch
Function
Switches power to the reach-in on and off.
Specifications
Double pole single throw (DPST)
Check Procedures
1. Check for proper line voltage (+/– 10%).
2. Inspect the switch for proper wiring.
3. Inspect the terminals for clean, tight
connections.
4. Check across the switch terminals with a
voltmeter. Replace the switch if you do not
obtain the results below:
Switch Position Voltage
On 0
Off Line
Temperature Control (Thermostat)
Function
Opens and closes to start and stop the compressor
and condenser fan(s) to maintain a constant cabinet
temperature.
Specifications
Constant differential
Range 0°± 2°F (-17.8° ± -16.7°C) / 5°± 2°F (-15° ±
-16.7°C)
Check Procedures
If the reach-in continues to run in the cooling cycle:
1. Turn the temperature control to the warmest
setting.
2. Hook a voltmeter across the temperature control
terminal leads.
3. If the voltmeter reads line voltage, the control
has opened and is functioning normally. If the
control fails to open, replace it.
If the reach in does not run:
1. Disconnect electrical power supply.
2. Turn the temperature control to the coldest
setting.
3. Isolate the temperature control and hook an
ohmmeter across the terminals.
4. If the ohmmeter registers continuity, the control
is good.
7-1
Electrical Specifications Section 7
Light Switch
Function
Turns the interior cabinet light on as the reach-in
door is opened.
Specifications
Single pole push button switch.
Check Procedures
1. Check for proper line voltage (± 10%).
2. Inspect the switch for proper wiring.
3. Inspect the terminals for clean, tight
connections.
4. Check across the switch terminals with a
voltmeter. Replace the switch if you do not
obtain the results below:
Door
Position
Closed 0 Line
Open Line 0
N.O.
Contacts
N.C.
Contacts
Defrost Termination/Fan Delay Switch
Function
Terminates the defrost cycle and delays the start of
the evaporator fan(s) after defrost.
Specifications
Thermodisc
Open Temperature 55±60°F (12.8±15.6°C)
Close Temperature 35±60°F (1.7±15.6°C)
Check Procedures
1. Hook a voltmeter across the N.O. terminals. If,
during the defrost cycle, the bimetal disc does
not open when the evaporator reaches the
specified temperature, replace the thermostat.
2. Hook a voltmeter across the N.C. terminals. If,
after the defrost cycle, the bimeter disc does not
close when the evaporator coil reaches the
specified temperature, replace the thermostat.
7-2
Section 7 Electrical Specifications
Defrost Timer
Function
Initiates the defrost cycle at preset times to prevent
evaporator frost buildup.
Specifications
Paragon 8145-00
See page 5-3 for defrost timer adjustment.
Check Procedures
1. Inspect the terminals for clean, tight
connections.
2. Verify that correct line voltage is at terminals X
and 3.
Voltage at
Terminals X and 3
If 24-hour dial is not
Correct
None Restore line voltage
3. Hook a voltmeter across the switch terminals.
Verify the readings below. If you do not get
these readings, replace the defrost timer.
Cycle Terminals Expected Reading
2 and 4 0 volts–closed
Cooling
Start of
Defrost
3 and N 0 volts–closed
3 and 1 Line volts - open
2 and 4 Line volts – open
3 and N Line volts - open
3 and 1 0 volts - closed
turning, replace automatic
Action
defrost time clock
Defrost Heater Element
Function
Defrosts the evaporator coil.
Coil Heater Specifications
Model
°°°°F/°°°°C
20/-6.7
45/7.2
70/21.1 230 3.5 800 64-67
1/-17.2
2/-16.7
14/-10
18/-7.8
36/2.2 230 4.8 1100 45-49
Check Procedures
1. Turn off the electric power to the reach-in
freezer.
2. Disconnect the leads to the defrost heater and
check across with an ohmmeter. See
specifications (above) for ohm values.
Results of Check Action
Continuity and ohm
value within
specifications
No continuity Replace the element
Ohm value not within
specifications
Volt Amp Watt Ohm
115
115
115
230
115
115
7.0
7.0
9.6
8.5
5.2
5.2
800
800
1100
1950
600
600
Element is OK
Replace the element
14-18
14-18
8-12
26-30
20-24
20-24
7-3
Electrical Specifications Section 7
Anti-Condensate Door Heaters
Drain Pan Heater Element
Function
Warms the drain pan to allow moisture to drain
Specifications
Model
°°°°F/°°°°C
20/-6.7
45/7.2
70/21.1 230 1.73 400 130-135
Check Procedures
1. Turn off the electric power to the reach-in
freezer.
2. Disconnect the leads to the defrost heater and
check across with an ohmmeter. See
specifications (above) for ohm values.
Volt Amp Watt Ohm
115
115
3.5
3.5
400
400
30-34
30-34
Function
Prevents condensation (sweating) on the cabinet and
door surfaces.
Specifications
Heater Type Ohm Reading
(total)
Refrigerator
Full Door(s)
Refrigerator
Half Doors
Freezer
Full Door(s)
Freezer
Half Doors
Check Procedures
1. Turn off the electric power to the reach-in.
2.5 Watts
per foot
1.6 Watts
per foot
5.0 Watts
per foot
3.7 Watts
per foot
30
Ohm
20
Ohm
14
Ohm
50
Ohm
Result of check Action
Continuity and ohm value
within specifications
No continuity Replace the element
Ohm value not within
specifications
See page 9-6 for replacement procedures
Element is OK
Replace the element
2. Disconnect the mullion heater leads. Check
with an ohmmeter. See specifications (above)
for ohm values.
Results of Check Action
Continuity and ohm
value within
specifications
No Continuity Replace the heater
Ohm value not within
specifications
See page 9-16 for replacement procedure.
Heater is OK
Replace the heater
7-4
Section 7 Electrical Specifications
Compressor Overload Protector
Function
Shuts down the compressor if an overcurrent
condition exists.
Check Procedures
WARNING
Disconnect the electric power to the freezer
before proceeding with the following steps.
Check the continuity of the external overload
protector.
1. Disconnect the wires from the overload
protector from other components.
2. Check the continuity of the overload protector.
Results of check Action
Continuity Overload protector is OK
Allow the compressor to
No continuity
No continuity at
room temperature
reach room temperature and
check again
Replace
Start Relay
Function
A relay used to disconnect the start winding.
Check Procedures
1. Disconnect the wires from the start relay. If the
relay must be moved, keep it upright.
2. Check the continuity at the contact terminals.
Results of check Action
Continuity Replace the relay
No continuity Relay is OK
3. Check continuity at the relay coil terminals.
Refer to the wiring diagram for terminal
identification.
Results of check Action
Continuity Relay is OK
No continuity Replace the relay
7-5
Electrical Specifications Section 7
Compressor Windings
Function
Draws current during the running cycle.
Check Procedures
NOTE: The compressor must be at room
temperature.
1. Disconnect the wires from the compressor
terminals.
2. Check the resistance between terminals C and
R:
Results of check Action
Resistance See step 5
1. Verify external
No resistance
overload is closed.
2. Run winding is open;
replace compressor.
4. Check the resistance between terminal C and the
compressor shell:
Results of check Action
Compressor is grounded;
Resistance
No resistance
5. Check the resistance of the windings. The
resistance reading between terminals S and R
should equal the readings between terminals C
and R, and terminals C and S added together:
replace compressor
Compressor is not
grounded - OK
S to R = C to R + C to S
3. Check the resistance between terminals C and S:
Results of check Action
Resistance See step 5
No resistance
Start winding is opened;
replace compressor.
7-6
Section 7 Electrical Specifications
1-2-3 Door Refrigerator
KR-1 KR-2 KR-3 KR-101 KR-201 KR-301
115/60/1
7-7
Electrical Specifications Section 7
1-2 Door Freezer
KF-1 KF-2 KF-101 KF-201
115/60/1
7-8
Section 7 Electrical Specifications
3 Door Freezer
KF-3 KF-301
208-230/60/1
7-9
Electrical Specifications Section 7
1 Door Glass Door Refrigerator
KR-1GD
115/60/1
7-10
Section 7 Electrical Specifications
2 Door Glass Door Refrigerator
KR-2GD
115/60/1
7-11
Electrical Specifications Section 7
3 Door Glass Door Refrigerator
KR-3GD
208-230/60/1
7-12
Section 8 Refrigeration
Section 8
Refrigeration
Charging Specifications
BASE
MODEL
KR-1
KR-101
KR-1GD
KF-1
KF-101
KR-2
KR-201
KR-2GD
KF-2
KF-201
KR-3
KR-301
KR-3GD
KF-3
KF-301
Ambient
Temperature
°°°°F/°°°°C
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
70/21.1
100/37.8
Average
Interior
Temperature
38 F
3.3°C
38 F
3.3°C
38 F
3.3°C
0 F
-17.8 C
0 F
-17.8 C
38 F
3.3°C
38 F
3.3°C
38 F
3.3°C
0 F
-17.8 C
0 F
-17.8 C
38 F
3.3°C
38 F
3.3°C
38 F
3.3°C
0 F
-17.8 C
0 F
-17.8 C
Suction
Pressure
50 PSI 195 PSI
50 PSI 195 PSI
50 PSI 195 PSI
20 PSI 185 PSI
20 PSI 185 PSI
50 PSI 195 PSI
50 PSI 195 PSI
50 PSI 195 PSI
20 PSI 185 PSI
20 PSI 185 PSI
50 PSI 195 PSI
50 PSI 195 PSI
50 PSI 195 PSI
20 PSI 185 PSI
20 PSI 185 PSI
Discharge
Pressure
295 PSI
295 PSI
295 PSI
286 PSI
286 PSI
295 PSI
295 PSI
295 PSI
286 PSI
286 PSI
295 PSI
295 PSI
295 PSI
286 PSI
286 PSI
Compressor
Size (H.P.)
.33 16
.33 16
.50 18
.50 27
.50 27
.33 12
.33 12
.50 24
.75 33
.75 33
.50 17
.50 17
.75 35
1.00 42
1.00 42
Charge
oz.
grams
454 g
454 g
510 g
765 g
765 g
340 g
340 g
680 g
936 g
936 g
482 g
482 g
992 g
1191 g
1191 g
Refrigerant
Type
R-22
R-22
R-22
R-404A
R-404A
R-22
R-22
R-22
R-404A
R-404A
R-22
R-22
R-22
R-404A
R-404A
8-1
Refrigeration Section 8
Refrigerant Recovery / Evacuation & Recharging
Do not purge refrigerant to the atmosphere. Capture
refrigerant using recovery equipment by specific
manufacturer’s recommendations.
IMPORTANT
We assume no responsibility for the use of
contaminated refrigerant. Damage resulting from
the use of contaminated refrigerant is the sole
responsibility of the servicing company.
CONNECTIONS
1. Suction side of the compressor through the
suction service valve.
2. Discharge side of the compressor through the
discharge service valve.
SELF-CONTAINED RECOVERY/EVACUATION
1. Place the main ON/OFF toggle switch in the
OFF position.
2. Install manifold gauges, charging cylinder/scale,
and recovery unit or two-stage vacuum pump.
3. Open (backseat) the high and low side Reach-In
service valves.
4. Perform recovery or evacuation:
a) Recovery: Operate the recovery unit as
directed by the manufacturer’s instructions.
b) Evacuation prior to recharging:
Pull the system down to 250 microns. Then,
allow the pump to run for an additional halfhour. Turn off the pump and perform a standing
vacuum leak check.
NOTE: Check for leaks using halide or electronic
leak detector after charging the Reach-In.
Figure 7.1
Continued next page…
8-2
Section 8 Refrigeration
Charging Procedures
IMPORTANT
The charge is critical on all Reach-In units. Use a
scale or a charging cylinder to ensure the proper
charge is installed.
1. Be sure the Main ON/OFF toggle switch is in
the OFF position.
2. Close the vacuum pump valve, the low side
service valve, and the low side manifold gauge
valve.
3. Open the high side manifold gauge valve and
the high side service valve.
4. Open the charging cylinder and add the proper
refrigerant charge (shown on nameplate)
through the discharge service valve.
5. Let the system “settle” for 2 to 3 minutes.
6. Place the main ON/OFF toggle switch in the ON
position.
7. Close the high side valve on the manifold gauge
set. Add any remaining vapor charge through
the suction service valve (if necessary).
NOTE: Manifold gauges must be removed properly
to ensure that no refrigerant contamination or loss
occurs.
8. Make sure that all the vapor in the charging
hoses is drawn into the Reach-In before
disconnecting the charging hoses.
a) Run the Reach-In cooling mode.
b) Close the high side service valve at the
Reach-In.
c) Open the low side service valve at the
Reach-In.
d) Open the high and low side valves on the
manifold gauge set. Any refrigerant in the lines
will be pulled into the low side of the system.
e) Allow the pressures to equalize while the
Reach-In is running.
f) Close the low side service valve at the
Reach-In.
g) Remove the hoses from the Reach-In and
install the caps.
8-3
Refrigeration Section 8
System Contamination Clean-up
This section describes the basic requirements for
restoring contaminated systems to reliable service.
IMPORTANT
We assume no responsibility for the use of
contaminated refrigerant. Damage resulting from
the use of contaminated refrigerant is the sole
responsibility of the servicing company.
DETERMINING SEVERITY OF CONTAMINATION
Either moisture or residue generally causes system
contamination from compressor burnout entering
the refrigeration system.
Inspection of the refrigerant usually provides the
first indication of system contamination. Obvious
moisture or an acrid odor in the refrigerant indicates
contamination.
If either condition is found, or if contamination is
suspected, use a Total Test Kit from Totaline or a
similar diagnostic tool. Follow the manufacturer’s
directions. These devices sample refrigerant,
eliminating the need to take an oil sample.
If a refrigerant test kit indicates harmful levels of
contamination, or if a test kit is not available,
inspect the compressor oil.
1. Remove the refrigerant charge from the ReachIn.
2. Remove the compressor from the system.
3. Check the odor and appearance of the oil.
4. Inspect the suction and discharge lines at the
compressor for burnout deposits.
5. If no signs of contamination are present,
perform an acid oil test.
Check the chart below to determine the type of cleanup required.
Contamination/Clean-up Chart
Symptoms/Findings Required Cleanup Procedure
No Symptoms or suspicion of contamination Normal evacuation/recharging procedure
Moisture/Air Contamination symptoms
• Refrigeration system open to atmosphere for prolonged periods
• Refrigeration test kit and/or acid oil test shows contamination
• Leak in water-cooled condenser
• No burnout deposits in open compressor lines
Mild Compressor Burnout symptoms
• Oil appears clean but smells acrid
• Refrigeration test kit or acid oil test shows harmful acid content
• No burnout deposits in open compressor lines
Severe Compressor Burnout symptoms
• Oil is discolored and smells acrid
• Refrigeration test kit or acid oil test shows harmful acid content
• Burnout deposits found in the compressor and lines, and in other
components
Mild contamination clean-up procedure
Mild contamination clean-up procedure
Severe contamination clean-up procedure
8-4
Section 8 Refrigeration
MILD SYSTEM CONTAMINATION
CLEAN-UP PROCEDURE
1. Replace any failed components.
2. If the compressor is good, change the oil.
3. Replace the liquid line drier.
NOTE: If the contamination is from moisture, use
heat lamps during evacuation. Position them at the
compressor, condenser and evaporator prior to
evacuation.
IMPORTANT
Dry nitrogen is recommended for this procedure.
This will prevent CFC release.
4. Follow the normal evacuation procedure, except
replace the evacuation step with the following:
a) Pull vacuum to 1000 microns. Break the
vacuum with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 PSI.
b) Pull vacuum to 500 microns. Break the vacuum
with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 PSI.
c) Change the vacuum pump oil.
d) Pull vacuum to 250 microns. Run the vacuum
pump for ½ hour on self-contained models, 1
hour on remotes.
SEVERE SYSTEM CONTAMINATION
CLEAN-UP PROCEDURE
1. Remove the refrigerant charge.
2. Remove the compressor.
3. Remove the liquid line drier.
4. Replace the TXV.
5. Wipe away any burnout deposits from suction
and discharge lines at compressor.
6. Sweep through the open system with dry
nitrogen.
IMPORTANT
Refrigerant sweeps are not recommended, as they
release CFC’s into the atmosphere.
7. Install a new compressor and new start
components.
8. Install a suction line filter-drier (with acid and
moisture removal capability) of adequate size.
Place the filter drier as close to the compressor
as possible.
9. Install inlet and outlet access valves.
10. Install a new liquid line drier.
Continued next page…
NOTE: You may perform a standing vacuum test to
make a preliminary leak check. You should use an
electronic leak detector after system charging to be
sure there are no leaks.
5. Charge the system with the proper refrigerant to
the nameplate charge.
6. Operate the Reach-In unit.
8-5
Refrigeration Section 8
11. Follow the normal evacuation procedure, except
replace the evacuation step with the following:
FILTER DRIERS
a) Pull vacuum to 1000 microns. Break the
vacuum with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 PSI.
b) Change the vacuum pump oil.
c) Pull vacuum to 500 microns. Break the vacuum
with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 PSI.
d) Change the vacuum pump oil.
e) Pull vacuum to 250 microns. Run the vacuum
pump for ½ hour on self-contained models, 1
hour on remotes.
NOTE: You may perform a standing vacuum test to
make a preliminary leak check. You should use an
electronic leak detector after system charging to be
sure there are no leaks.
12. Charge the system with the proper refrigerant to
the nameplate charge.
13. Operate the Reach-In unit for one hour. Then
check the pressure drop across the suction line
filter-drier.
a) If the pressure drop is less than 1 PSI, the
filter-drier should be adequate for complete
clean up.
b) If the pressure drop exceeds 1 PSI, change
the suction line filter-drier and the liquid line
drier. Repeat steps 8 through 13 until the
pressure drop is acceptable.
14. Operate the Reach-In unit for 48-72 hours.
Then remove the suction line filter-drier and
change the liquid line drier.
15. Follow normal evacuation procedures.
The size of the filter-drier is important. Using an
improperly sized filter-drier will cause the Reach-In
unit to be improperly charged with refrigerant.
IMPORTANT
Driers are covered as a warranty part. Driers
must be replaced any time the system is opened
for repairs.
Refrigerant Re-Use Policy
We recommend the use of:
1. New Refrigerant
• Must be of original nameplate type.
2. Reclaimed Refrigerant
• Must be of original nameplate type.
3. Recovered or Recycled Refrigerant
• Must be recovered or recycled in accordance
with current local, state and federal laws.
• Must be from and re-used in the same
McCall product. Re-use of recovered or
recycled
refrigerant from other products is not
approved.
• Recovered refrigerant must come from a
“contaminant-free” system. To decide
whether the system is contaminant free,
consider:
a) Type(s) of previous failure(s)
b) Whether the system was cleaned,
evacuated and recharge properly
following failure(s)
c) Compressor motor burn outs and
improper past service, prevent
refrigerant re-use.
8-6
Section 9 Replacement Procedures
Section 9
Replacement Procedures
Evaporator Fan Motor
1 Section Refrigerators and Freezers
If Mounting Bracket Is Not Broken
1. Remove air distribution duct from the cabinet
interior ceiling (Figure 9.1).
3. Using a ¼” nut driver, remove the (2) motor
mounting screws and separate the motor from
the bracket (Figure 9.3).
Figure 9.1
2. Disconnect the (2) terminal connectors from the
motor (Figure 9.2).
Figure 9.2
Figure 9.3
4. Reverse steps 1-3 to replace motor.
5. Reconnect power and return to normal use.
NOTE: The evaporator-housing lid may be
removed to provide added lighting and visibility
(Figure 9.4).
Figure 9.4
9-1
Replacement Procedures Section 9
Evaporator Fan Motor
1 Section Refrigerators and Freezers
If Mounting Bracket Is Broken
1. Remove the air distribution duct from the
interior ceiling (Figure 9.5).
3. Using a ¼” nut driver, remove the (2) motor
mounting screws and separate the motor from
the bracket (Figure 9.7).
Figure 9.7
Figure 9.5
2. Disconnect the (2) terminal connectors from the
motor (Figure 9.6).
Figure 9.6
4. Remove the evaporator-housing lid, located on
the cabinet top. (Figure 9.8)
Figure 9.8
5. Remove the coil mounting screws and carefully
lift the coil, only enough to gain access to the
motor mounting screws (Figure 9.9).
Continued next page…
9-2
Section 9 Replacement Procedures
Figure 9.9
Figure 9.11
6. When the coil has been moved, remove the
evaporator drain pan by removing (4) mounting
screws.
7. Remove the bracket mounting screws and
replace bracket-motor assembly.
8. Reverse Steps 1-5 to complete motor
installation.
9. Reconnect power and return to normal use.
Light Switch
1. Remove the door by lifting straight up
(Figure 9.10). Carefully set the door aside.
3. Remove the (3) hinge mounting screws
and carefully pull the hinge flange from
the cabinet front.
4. Slide the light switch and switch retainer from
the hinge. Unplug the switch (Figure 9.12).
Figure 9.12
Figure 9.10
2. Pry off the TOP hinge cover on the cabinet
hinge flange with a flat blade screwdriver or flat
scraper (Figure 9.11).
5. Install the new switch into the hinge and replace
the door hinge onto the cabinet front. Install the
(3) mounting screws. Snug the screws but DO
NOT tighten fully.
6. Re-hang the door onto the hinges.
7. Make sure that the door is hanging plumb and
that the door operates properly.
8. Tighten the screws and replace the hinge cover.
9-3
Replacement Procedures Section 9
Evaporator Fan Motor
2 & 3 Section Refrigerators and Freezers
1. Remove the evaporator-housing lid, located on
the cabinet top, exposing the evaporator fan
motor (Figure 9.13).
Figure 9.13
3. Remove the fan bracket mounting screws.
Disconnect the wiring terminals from the motor.
Remove the defective motor and replace with
the new motor. Replace screws (Figure 9.15).
2. Remove the wiring box cover. Locate and
disconnect the fan motor wires (Figure 9.14).
Figure 9.14
Figure 9.15
4. Reconnect motor wires in wiring box. Check to
make sure that wire access hole through the
evaporator box is properly sealed and reseal if
necessary.
5. Replace wiring box cover.
6. Replace the evaporator-housing lid.
7. Reconnect power and return to normal use.
9-4
Section 9 Replacement Procedures
Temperature Control
Refrigerators & Freezers
1. Remove the front louvered hatch cover by
lifting straight up and pulling straight out.
2. Lay the hatch cover on top of the freezer
evaporator housing.
IMPORTANT
Do not disconnect the wires to the digital
thermometer display.
3. Remove the (6) screws from the
thermostat/wiring box front (Figure 9.16).
6. Remove the temperature control sensor from the
aluminum sleeve by pulling out slowly
(Figure 9.18). Remove the sensor from the
evaporator housing.
Figure 9.17
Figure 9.16
4. Remove the (2) mounting screws and the control
knob from the face of the control.
5. Remove the lid from the evaporator housing by
unlocking the (4) hold-down latches
(Figure 9.17).
Figure 9.18
7. Replace the temperature control and install
sensor.
8. Reset the temperature to setting #4 to #5 on
refrigerators and #5 to #6 on freezers.
9. Monitor temperature for final control
adjustments.
9-5
Replacement Procedures Section 9
Evaporator Drain Pan Heater Element
3. Remove coil mounting screws and lift coil up
WARNING
Disconnect the electric power to the freezer before
proceeding with the following steps.
1. Remove front louvered hatch cover by lifting up
and pulling straight out.
2. Remove the evaporator box cover lid
(Figure 9.19).
slowly, not to detach lines or wiring
(Figure 9.20).
Figure 9.20
Figure 9.19
4. Disconnect the heater wires located in the
wiring box (Figure 9.21) for 2 & 3 section
cabinets or wiring bundle (Figure 9.22) for 1
section cabinets.
Continued next page…
Figure 9.21
9-6
Section 9 Replacement Procedures
Heater Element
Heated Holding Cabinets
1. Turn off the main power to the cabinet.
2. Remove the right side blower panel by
removing the (13) screws.
NOTE: Blower motor wiring may be disconnected
to allow easier blower panel removal.
Figure 9.22
5. Replace drain pan heater and reconnect wiring.
6. Reposition evaporator coil and secure with
mounting screws.
7. Reposition the evaporator housing cover and
lock down latches.
8. Attach front louvered hatch cove, making sure
that the thermometer connections are fully
engaged.
9. Return to normal use.
3. Disconnect the wiring leads to the element by
loosening the nuts with a small wrench.
4. Replace the heater element.
5. Reverse steps 1-3 to re-install the wiring and
blower panel.
9-7
Replacement Procedures Section 9
Digital Thermometer Display and Probe
1. Remove the front louvered hatch cover by
lifting straight up and pulling straight out.
2. Unplug the thermometer probe from the back of
the digital display module.
3. Carefully pry the display module from the hatch
cover back with a flat blade screwdriver or
scraping tool (Figure 9.23).
4. Disconnect the (2) yellow wires from the probe
harness. Remove the probe from the interior
ceiling by loosening the mounting bracket screw
(Figure 9.24)
Figure 9.24
Figure 9.23
5. Remove the Permagum sealant from the cabinet
top where the probe wire penetrates the top.
Carefully pull the probe wire through the
cabinet top.
6. Feed the new probe wire through the top hole
and reattach the probe and bracket to the interior
ceiling.
7. Carefully, pull the wire taught and reseal the
cabinet top hole with the Permagum.
8. Peel the paper from the mounting tape on the
digital display module.
Continued next page…
9-8
Section 9 Replacement Procedures
9. Carefully align the module with the rectangle
cutout in the hatch cover. Press the module
firmly into place. (Figure 9.25)
Figure 9.25
10. Plug the probe wire terminal onto the back of
the display module, making sure that the plug
lines up with the pins on the module
(Figure 9.26)
11. Reconnect the (2) yellow wires from the
transformer with the gray leads on the probe.
12. Reinstall the hatch cover and secure any excess
wire with a wire tie.
13. Check operation and return to normal service.
Figure 9.26
9-9
Replacement Procedures Section 9
Digital Thermometer Transformer
WARNING
Disconnect the electric power to the freezer before
proceeding with the following steps.
1. Remove the front louvered hatch cover by
lifting straight up and pulling straight out.
2. Remove the (6) screws from the wiring box
front (Figure 9.27)
3. Disconnect the black and white wires on the
transformer from the power and neutral wires in
the wiring box. (Figure 9.28).
4. Disconnect the yellow wires on the transformer
from the (2) gray wires on the transformer probe
(Figure 9.28)
Figure 9.27
Figure 9.28
5. Remove the transformer from the evaporator
housing and replace with the new transformer.
6. Reconnect all wiring.
7. Replace the top louvered hatch cover.
8. Power up the freezer.
9. Return to normal operation.
9-10
Section 9 Replacement Procedures
Door Handle (solid doors)
1. Remove the foot from the door lock assembly
(Figure 9.29).
Figure 9.31
Figure 9.29
3. Remove out the two mounting screws and
remove the door handle (Figure 9.32).
2. Pry off gray plug button (located in the rear
center of the door) and a small section of the
door gasket nearest the lock assembly
(Figures 9.30 and 9.31).
Figure 9.30
Figure 9.32
4. Reverse steps 1-3 to install the new door handle.
9-11
Replacement Procedures Section 9
Door Handle (glass doors)
1. Pry or lift off a small section of door gasket
behind the door handle, exposing the (2) handle
mounting screws (Figure 9.33).
Figure 9.33
2. Remove the two mounting screws to release the
handle.
3. Replace door handle.
4. You may need a rubber mallet to re-install
gasket.
Door Hinge (solid doors)
1. Remove the door by lifting straight up
(Figure 9.34). Carefully set the door aside.
Figure 9.34
2. Pry off the hinge cover with a thin flat blade
screwdriver (Figure 9.35).
9-12
Figure 9.35
Continued next page…
Section 9 Replacement Procedures
3. Remove the (3) three hinge mounting screws
from each hinge on the cabinet front
(Figure 9.36). Replace the hinge and reattach
with the screws.
Figure 9.36
4. Remove the (3) three hinged mounting screws
from each flange on the door (Figure 9.37) and
replace hinge.
Door Gasket (solid doors)
1. Remove the old gasket by pulling the gasket
from the foamed in retainer in the door.
(See figure 9.38)
Figure 9.38
2. Starting the upper left corner of the door, place
the locking male lip into the retainer of the door.
Figure 9.37
5. Install the door and check operation
3. Firmly press into place until the gasket locks.
4. If necessary, gently tap into place with a rubber
mallet.
9-13
Replacement Procedures Section 9
Door Gasket (glass doors)
1. Remove the old gasket by pulling the gasket
from the foamed in retainer in the door.
(See figure 9.39)
Figure 9.39
2. Starting the upper left corner of the door, place
the locking male lip into the retainer of the door.
3. Firmly press into place until the gasket locks.
4. If necessary, gently tap into place with a rubber
mallet.
9-14
Section 9 Replacement Procedures
Vinyl Breaker Strips (door jambs)
WARNING
Disconnect the electric power to the freezer before
proceeding with the following steps.
1. Remove the flat vinyl breakers by gently prying
off with a flat-blade screwdriver. (Figure 9.40)
WARNING
Door heater wires lie directly behind the front edge
of the flat breaker strips. Take care not to damage
the wires.
3. Replace the breakers by starting each end into
the corner blocks and snapping into place.
4. Gently tap the breaker into place if necessary,
using a rubber mallet. (Figure 9.41)
Figure 9.41
Figure 9.40
2. Remove the corner blocks as necessary by
slipping the male tab from the flat breaker.
9-15
Replacement Procedures Section 9
Anti-Condensate Door Heater Wires
WARNING
Disconnect the electric power to the freezer before
proceeding with the following steps.
1. Remove the vinyl door breakers as described
previously.
2. Carefully, pull the heater wire connections from
the inside top corner.
3. Clip the connections, making sure to leave
enough wire length to reconnect the new heater
wire. (Figure 9.42)
Defrost Termination/Fan Delay Switch
WARNING
Disconnect the electric power to the freezer before
proceeding with the following steps.
1. Remove the evaporator-housing lid.
(Figure 9.43).
Figure 9.42
4. Remove the old heater wire.
5. Starting at the inside corner, carefully place the
new heater wire around the door perimeter,
fitting it into the space between the primary
breaker retainer and the metal cabinet face.
6. Connect each end of the heater wire to the leads
in the corner.
7. Replace the breaker strips as described
previously.
Figure 9.43
2. Locate the 3-wire defrost termination/ fan delay
switch, clamped to the suction line.
(Figure 9.44)
Figure 9.44
9-16
Continued next page…
Section 9 Replacement Procedures
3. Remove the wiring box cover on the front of the
evaporator housing on 2 & 3 section cabinets
(Figure 9.45). Wiring connections for 1 section
cabinets are located inside evaporator housing
(Figure 9.46)
Figure 9.45
4. Trace and disconnect the defrost termination /
fan delay switch from the wiring bundle. Reconnect the new switch.
5. Attach the new switch to the suction line.
6. Replace the evaporator-housing lid.
7. Connect the power and resume normal
operation.
NOTE: The evaporator fan will not restart until the
fan delay switch senses 32°F from the suction line.
Figure 9.46
9-17
Section 9 Replacement Procedures
THIS PAGE INTENTIONALLY LEFT BLANK
9-19
We reserve the right to make product
improvements at any time.
MANITOWOCââââ Koolaire
81 West Holly St.
Parsons TN. 38363
Phone: (887) 582-5086
Service Fax: (901) 847-5552
Web Site - www.manitowocice.com
Specifications and design are subject
to change without notice.
ã2000 Manitowocâ
Koolaire
Litho in USA
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