Whirlpool 8178501A User guide

Page 1
CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS
R-101
JOB AID
Part No. 8178501A
FAST FILL
DISPENSER
SYSTEM
Page 2
FORWARD
This Whirlpool Job Aid, “Fast Fill Dispenser System” (Part No. 8178501A), provides the techni­cian with information on the operation and service of the Fast Fill Dispenser System. For specific information on the model being serviced, refer to the “Use and Care Guide,” or “Tech Sheet” provided with the refrigerator.
The Wiring Diagrams used in this Job Aid are typical and should be used for training purposes only. Always use the Wiring Diagram supplied with the product when servicing the unit.
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide information that will enable the service technician to properly diagnose malfunctions and repair the Fast Fill Dispenser System.
The objectives of this Job Aid are to:
• Understand and follow proper safety precautions.
• Successfully troubleshoot and diagnose malfunctions.
• Successfully perform necessary repairs.
• Successfully return the Fast Fill Dispenser System to its proper operational status.
WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on our products by anyone other than Authorized Service Technicians.
Copyright © 2005, Whirlpool Corporation, Benton Harbor, MI 49022
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TABLE OF CONTENTS
Page
GENERAL .............................................................................................................................. 1-1
Refrigerator Safety ............................................................................................................. 1-1
Model & Serial Number Designations ................................................................................ 1-2
Model & Serial Number Label Locations ............................................................................ 1-4
Whirlpool Refrigerator Warranty ......................................................................................... 1-5
KitchenAid Refrigerator Warranty ...................................................................................... 1-6
PRODUCT OPERATION ........................................................................................................ 2-1
Fast Fill Dispenser System Overview ................................................................................ 2-1
COMPONENT ACCESS ........................................................................................................ 3-1
Component Locations ........................................................................................................ 3-1
Removing The Water And Ice Dispenser Components ...................................................... 3-2
Removing The Freezer Door Dispenser Supply Harness And Water Tube ....................... 3-8
Removing The Smart Valve ............................................................................................. 3-10
Removing The Freezer Door .............................................................................................3-11
COMPONENT TESTING ........................................................................................................ 4-1
Ice Door Motor ................................................................................................................... 4-1
Water & Ice Pad Switches .................................................................................................. 4-1
IDI Motor ............................................................................................................................ 4-2
Smart Valve Coils ............................................................................................................... 4-2
DIAGNOSTICS & TROUBLESHOOTING ............................................................................. 5-1
Diagnostics ........................................................................................................................ 5-1
Troubleshooting ................................................................................................................. 5-5
Flowcharts ...................................................................................................................... 5-5
WIRING DIAGRAMS .............................................................................................................. 6-1
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— NOTES —
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GENERAL
DANGER
REFRIGERATOR SAFETY
Your safety and the safety of others is very important.
We have provided many important safety messages in this Job Aid and on the appliance. Always read and obey all safety messages.
This is the safety alert symbol. This symbol alerts you to hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word
“DANGER” or “WARNING.” These words mean:
You can be killed or seriously injured if you don’t immediately follow instructions.
You can be killed or seriously injured if you don’t follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed.
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MODEL & SERIAL NUMBER DESIGNATIONS
WHIRLPOOL MODEL NUMBER
MODEL NUMBER G S 6 N B E X R Q 00
PRODUCT GROUP
G = WHIRLPOOL GOLD
PRODUCT IDENTIFICATION S = SXS CONTOUR DOOR
F = FORMED DOOR
CAPACITY/CUBIC FOOT SIZE 6 = 26
MODEL SERIES N = FAST FILL
MODEL FEATURES
MODEL CODE
®
E = ENERGY STAR
DOOR SWING
X = SxS
YEAR OF INTRODUCTION
R = 2005
COLOR CODE
B = BLACK Q = WHITE ON WHITE S = STAINLESS STEEL Y =GREY/STAINLESS STEEL
ENGINEERING CHANGE DIGITS (00, 01, 02, 03, ETC.)
WHIRLPOOL SERIAL NUMBER
SERIAL NUMBER S S 21 12345
MANUFACTURING SITE
S = Fort Smith, AR
YEAR OF PRODUCTION S = 2005
WEEK OF PRODUCTION 21ST WEEK
PRODUCT SEQUENCE NUMBER
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KITCHENAID MODEL NUMBER
MODEL NUMBER K SR T 25 F R WH 00
PRODUCT GROUP
K = KITCHENAID
PRODUCT IDENTIFICATION SR = SxS
MERCHANDISING SCHEME/SERIES
T = CONTOURED DOORS F = FORMED DOORS N = FLAT DOORS
CAPACITY/CUBIC FOOT SIZE
MODEL FEATURES
YEAR OF INTRODUCTION
R = 2005
COLOR CODE
BL = BLACK WH = WHITE SS = STAINLESS STEEL
ENGINEERING CHANGE DIGITS (00, 01, 02, 03, ETC.)
KITCHENAID SERIAL NUMBER
SERIAL NUMBER S S 21 12345
MANUFACTURING SITE
S = Fort Smith, AR
YEAR OF PRODUCTION S = 2005
WEEK OF PRODUCTION 21ST WEEK
PRODUCT SEQUENCE NUMBER
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MODEL & SERIAL NUMBER LABEL LOCATIONS
WHIRLPOOL MODEL
Model & Serial Number Label
(Refrigerator Compartment)
KITCHENAID MODEL
Model & Serial Number Label
(Refrigerator Compartment)
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WHIRLPOOL REFRIGERATOR WARRANTY
ONE-YEAR FULL WARRANTY ON REFRIGERATOR
For one year from the date of purchase, when this refrigerator (excluding the water filter) is operated and main­tained according to instructions attached to or furnished with the product, Whirlpool Corporation or Whirlpool Canada LP will pay for FSP® replacement parts and repair labor costs to correct defects in materials or workman­ship. Service must be provided by a Whirlpool designated service company.
On models with a water filter: 30 day limited warranty on water filter. For 30 days from the date of purchase, when this filter is operated and maintained according to instructions attached to or furnished with the product, Whirlpool Corporation or Whirlpool Canada LP will pay for replacement parts to correct defects in materials and workman­ship.
SECOND THROUGH FIFTH YEAR FULL WARRANTY ON
SEALED REFRIGERATION SYSTEM PARTS AS LISTED
In the second through fifth years from the date of purchase, when this refrigerator is operated and maintained according to instructions attached to or furnished with the product, Whirlpool Corporation or Whirlpool Canada LP will pay for FSP® replacement parts and repair labor costs to correct defects in materials or workmanship in the sealed refrigeration system. These parts are: compressor, evaporator, condenser, dryer, and connecting tubing. Service must be provided by a Whirlpool designated service company.
Whirlpool Corporation or Whirlpool Canada LP will not pay for:
1. Service calls to correct the installation of your refrigerator, to instruct you how to use your refrigerator, to replace house fuses or correct house wiring or plumbing, to replace light bulbs, or replacement water filters other than as noted above.
2. Repairs when your refrigerator is used in other than normal, single-family household use.
3. Pickup and delivery. Your refrigerator is designed to be repaired in the home.
4. Damage resulting from accident, alteration, misuse, abuse, fire, flood, improper installation, acts of God, or use of products not approved by Whirlpool Corporation or Whirlpool Canada LP.
5. Any food loss due to product failure.
6. Repairs to parts or systems resulting from unauthorized modifications made to the appliance.
7. Replacement parts or repair labor costs for units operated outside the United States or Canada.
8. In Canada, travel or transportation expenses for customers who reside in remote areas.
WHIRLPOOL CORPORATION OR WHIRLPOOL CANADA LP SHALL NOT
BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES
Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so this exclusion or limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Outside the 50 United States and Canada, this warranty does not apply. Contact your authorized Whirlpool dealer to determine if another warranty applies.
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KITCHENAID REFRIGERATOR WARRANTY
ONE-YEAR LIMITED WARRANTY
For one year from the date of purchase, when this refrigerator (excluding the water filter) is operated and main­tained according to instructions attached to or furnished with the product, KitchenAid or KitchenAid Canada will pay for factory specified parts and repair labor costs to correct defects in materials or workmanship. Service must be provided by a KitchenAid designated service company.
On models with a water filter: 30 day limited warranty on water filter. For 30 days from the date of purchase, when this filter is operated and maintained according to instructions attached to or furnished with the product, Kitch­enAid or KitchenAid Canada will pay for replacement parts to correct defects in materials and workmanship.
SECOND THROUGH FIFTH YEAR FULL WARRANTY ON
CAVITY LINER AND SEALED REFRIGERATION SYSTEM PARTS AS LISTED
In the second through fifth years from the date of purchase, when this refrigerator is operated and maintained according to instructions attached to or furnished with the product, KitchenAid or KitchenAid Canada will pay for replacement or repair of the refrigerator/freezer cavity liner (including labor costs) if the part cracks due to defec­tive materials or workmanship. Service must be provided by a KitchenAid designated service company.
Also, in the second through fifth years from the date of purchase, KitchenAid or KitchenAid Canada will pay for factory specified replacement parts and repair labor costs to correct defects in materials or workmanship in the sealed refrigeration system. These parts are: compressor, evaporator, condenser, dryer, and connecting tubing. Service must be performed by a KitchenAid designated service company.
SIXTH THROUGH TENTH YEAR LIMITED WARRANTY ON
SEALED REFRIGERATION SYSTEM PARTS AS LISTED
In the sixth through tenth years from date of purchase, when this refrigerator is operated and maintained accord­ing to instructions attached to or furnished with the product, KitchenAid or KitchenAid Canada will pay for factory specified replacement parts to correct defects in materials or workmanship in the sealed refrigeration system. These parts are: compressor, evaporator, condenser, dryer, and connecting tubing.
KitchenAid or KitchenAid Canada will not pay for:
1. Service calls to correct the installation of your refrigerator, to instruct you how to use your refrigerator, to replace house fuses or correct house wiring or plumbing, to replace light bulbs, or replacement water filters other than as noted above.
2. Repairs when your refrigerator is used in other than normal, single-family household use.
3. Pickup and delivery. Your refrigerator is designed to be repaired in the home.
4. Damage resulting from accident, alteration, misuse, abuse, fire, flood, improper installation, acts of God, or use of products not approved by KitchenAid or KitchenAid Canada.
5. Any food loss due to product failure.
6. Repairs to parts or systems resulting from unauthorized modifications made to the appliance.
7. Replacement parts or repair labor costs for units operated outside the United States or Canada.
8. In Canada, travel or transportation expenses for customers who reside in remote areas.
9. Any labor costs during the limited warranty periods.
Disclaimer Of Implied Warranties; Limitation Of Remedies
Implied warranties, including to the extent applicable warranties of merchantability, or fitness for a particular purpose, are excluded to the extent legally permissible. Any implied warranties that may be imposed by law are limited to one year, or the shortest period allowed by law. Some states and provinces do not allow limitations or exclusions on how long an implied warranty of merchantability or fitness lasts, so the above limitations or exclu­sions may not apply to you.
If this product fails to work as warranted, customer’s sole and exclusive remedy shall be repair or replacement ac­cording to the terms of this limited warranty.
KitchenAid and KitchenAid Canada do not assume any responsibility for incidental or consequential damages.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Outside the 50 United States and Canada, this warranty does not apply. Contact your authorized KitchenAid dealer to determine if another warranty applies.
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PRODUCT OPERATION
FAST FILL DISPENSER SYSTEM OVERVIEW
FUNCTIONS AND FEATURES
The primary functions of the Fast Fill Dispenser System are:
• Ice dispensing (cubed and crushed)
• Water dispensing (normal fill with feed­back and measured fill)
• Water filter indicator
• Dispenser lighting (auto night light)
• Lockout
• Dispenser housing heater operation and power for the ice door. Power (14 volts DC) for a heated ice door is available and may be used as a service fix.
• Monitoring water valve flowmeter to measure water flow to ice maker and dispenser
• Showroom floor mode
• Service Mode Diagnostics
Components
There are three control boards in the Fast Fill Dispenser System. The user interface (touch­pad), and the core control are located in the dispenser area of the freezer door. The smart valve control is part of the valve and is located in the unit compartment.
Dispenser Area
The core control is attached to the dispenser housing and controls the dispenser motor, ice door motor, dispenser housing and ice door heaters. The core control also monitors the condition of the freezer door switch and provides the 14 volt DC power supply for the user interface and smart valve. Water and ice can not be dispensed while the freezer door is open.
The user interface provides customer input to the system based on input from the keypad. The user interface drives all the LED indicators and the audio beeper. The user interface pow­ers the white LED lighting and sets the proper amount of lighting during the auto night mode using the photo sensor on the user interface keypad.
The ice and water pad switches are connected electrically to the user interface.
Unit Compartment
The smart valve is mounted to the cabinet. In addition to the dispenser and ice maker water solenoids, it contains a small electronic board and a water flow sensor. The smart valve is used to measure the amount of water for the dispenser and the ice maker.
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Ice Dispenser Motor
Ice Door And Housing Heaters
All Fast Fill Dispenser System models will have IDI, (In-Door Ice). A bridge rectifier on the core control will rectify 120 volts AC to 120 volts DC for the ice dispenser motor. Changing polarity will reverse the motor to change from crush to cube modes. Clockwise (CW) rotation is crush and counterclockwise (CCW) is cube mode.
Ice Door Motor
The ice door is opened and closed by a DC mo­tor driven by a 12 volt DC square wave. When ice dispensing begins, the motor is driven in the CCW direction for approximately one second to open the door. When ice dispensing ends, there is a delay of 10 seconds to allow all ice to clear before the motor is driven CW to close the door. No switches are used to determine the position of the door motor. To ensure the ice door is not left open, a request is made to fully open and then close the door one hour after ice has been dispensed. If a cube had temporarily jammed open the door, this will ensure it does not stay open indefinitely. A re­quest to fully open and then close the door is also made immediately when power is applied or restored to the refrigerator.
The housing heater is a 120 volt AC, 2.25 watt heater. Service doors for refrigerators with stainless steel door skins will have additional zone heaters to reduce moisture and will be
4.25 watts. A 14 volt DC, 1 watt, heated service ice door will be available. It is powered from P3 on the core board.
Smart Valve
The smart valve is responsible for water dis­pensing and filling the ice maker. It also monitors total water volume used and accumulated time for the water filter indication. It drives the ice maker valve solenoid and the water dispenser valve solenoid.
120 volts AC will always be present at P1-4 and P1-5 on the smart valve. P1-1 is the AC input from the ice maker to start an ice maker fill request. 120 volts AC for any length of time, signals the valve to fill the ice maker. The valve fills the ice maker by volume, not by time. 14 volts DC will always be present at P2-1 and P2-3.
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OPERATION Water Dispensing
NORMAL FILL
Normal fill is when the customer presses the fill pad or holds the fill button. While water is being dispensed, the flowmeter will measure the water dispensed and display the amount on the user interface.
The following sequence occurs:
1. The user interface supplies 5 volts DC to one side of the water pad switch.
2. The water pad switch is pushed closed.
3. The user interface receives back the 5 volts DC.
4. The user interface signals the core control on P1-2.
5. The core control outputs a data signal to the smart valve.
6. The smart valve then energizes the water valve solenoid with 120 volts AC, and us­ing the flowmeter, sends a signal for the amount of water dispensed, to the user interface display.
MEASURED FILL
Measured fill is where the user interface com­mands the smart valve to dispense a specific amount of water. The water is measured by the flowmeter in the smart valve. The unit of measure may be changed as desired at any time that you are not dispensing water. Options are ounces, liters and cups. The user interface water switch may be used to start, pause or resume measured fill.
The following sequence occurs:
1. The units of measure are selected.
2. The volume of water requested is en­tered.
3. The water keypad is pressed or the water dispenser activation pad is held closed.
4. The user interface receives the signal.
5. The user interface signals the smart valve.
6. The smart valve then energizes the water valve solenoid with 120 volts AC, and us­ing the flowmeter, sends a signal for the amount of water as it is dispensed, to the user interface display. When the proper volume has been reached, the smart valve control de-energizes the water valve so­lenoid.
Ice maker Fill
Using the flowmeter, the valve will fill the ap­propriate volume of water when requested by the ice maker, 4.4 ounces (130 ml) of water for 8 cube ice makers, and 2.9 ounces (86 ml) of water for 5 cube ice makers. It is important to note that because the ice maker is not time­filled, it may take more or less time than the
7.5 seconds to fill. After receiving the 120 volt
AC signal from the ice maker, the smart valve will fill the ice maker.
The flowmeter is used for both the ice maker and the water dispenser with the water dis­penser having priority over the ice maker fill. If the water dispenser is operated during an ice maker fill, the ice maker fill will be paused until the dispenser operation has been completed. The smart valve will hold the partial ice maker fill volume in memory, and completes the fill when the flowmeter is available.
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Ice Dispensing
IDI ice dispensing is the same as in Side-By­Side IDI electronic dispensers, with the addition of an ice door that is powered open and closed by an electric motor. When the dispenser pad is depressed, the user interface commands the core control to dispense ice, based on the cube/crushed keypad selection.
The core control directs 120 volts AC through the PTC in the IDI motor, and back to the core control. The core control rectifies the 120 volts AC, and 120 volts DC is sent back out on the BR/WH and RD/WH wires. The polarity de­termines the direction that the motor will run. RD/WH wires will be positive for crushed ice, and will run clockwise. The BR/WH wires will be positive for cubed ice, and will run coun­terclockwise.
The following sequence occurs:
1. The ice pad switch is pushed closed.
2. The user interface receives the signal.
3. The user interface signals the core control on P1-2 which direction to run the auger.
4. The core control outputs the square wave to the ice door motor for approximately 1 second, and at the same time, the IDI motor is energized on P2-1 and P2-2 with 120 volts DC.
5. When dispensing has stopped, the ice door will remain open for 10 seconds, and then power is applied for approximately 1 second to close the door.
Operation Defaults
Low water pressure: If the water pressure falls
below 5 psi, or if the flowmeter fails, the fast fill dispenser system will assume the pressure to be at 60 psi, and will default to a timed fill. The accuracy of the fill will depend on the amount of pressure that is above or below 60 psi. For example, if the actual water pressure is 5 psi, the water volume dispensed will be low.
During low water pressure default, the ice maker will fill for 7.5 seconds.
Dispenser fill timeout: If water is dispensed continuously for 5 minutes by the customer, or if a water pad switch fails closed, power will be interrupted to the valve. Normal operation will resume when the closed switch is released.
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COMPONENT ACCESS
This section instructs you on how to service the Fast Fill Dispenser System in the Side-By-Side Refrigerator. The components and their locations are shown below.
COMPONENT LOCATIONS
Dispenser Cover Assembly
User Interface & Board
Dispenser Light Assembly
Ice Pad Switch
Water Pad Switch
Unit Compartment
Dispenser
Ice Door Motor
Water Tube
Water Nozzle
IDI Motor
Core Board
Dispenser Supply Harness
3-1
Smart Valve
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REMOVING THE WATER AND ICE DISPENSER COMPONENTS
4. Pull out at the bottom, lift up on the dis­penser cover assembly, and remove the assembly from the refrigerator door.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
NOTE: The water and ice dispenser compo-
nents are listed as follows:
Ice Door Motor
Core Board
Pad Switches
User Interface Board
User Interface (touchpad)
Dispenser Light Assembly
IDI Motor
Water Dispenser Nozzle
5. Disconnect the dispenser cover 3-wire connector from the user interface board, and the ground wire connector from the ground wire harness.
Water & Ice
Dispenser Cover
1. Unplug refrigerator or disconnect power.
2. Pull the dispenser drip tray out as far as it will go, then press down to release the catch, pull the tray out all the way and remove it from the dispenser.
3. Remove the two screws from the dispenser cover assembly.
Dispenser Cover Screws
Press To Release
Dispenser Drip Tray
3-Wire Connector
On Interface Board
Ground Wire
Connector
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Page 17
6. To remove the ice door motor:
P
u
l
l
O
u
t
a) Remove the two screws from the ice
door assembly, and remove the as­sembly from its housing.
b) Disconnect the motor wire connector
from the core board at P5.
Clip
Motor Wires
Water Tube
Clip
Screws
Ice Door Motor
Ice Door
Assembly
Motor P5
Core Board
c) Push down on the blue quick disconnect
locking ring, and pull the water tube from the fitting (see the top right photo).
d) Release the two clips, and pull the
nozzle & ice guide out just far enough to remove the motor wires and connec­tor, then remove the ice door assembly from the dispenser.
Nozzle & Ice Guide
Quick-Disconnect
e) Remove the two screws from the motor
and remove the motor from the ice door assembly housing.
Ice Door Motor Screws
Ice Door Motor
Continued on the next page.
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7. To remove the core board:
8. To remove an ice or water pad switch:
a) Remove the wire connectors from P1,
P2, P3, P5, P6, and P7.
b) Unclip the tabs at the top of the board,
and remove the shield and board from the dispenser housing. NOTE: If the tabs become damaged, secure the board with two screws at the indicated top corner locations.
Core Board
Screw Hole
Screw Hole
a) With the back of the dispenser cover
assembly facing up, press the release tab in on the wire connector, and pull the connector off the user interface board pins.
Water & Ice Pad
Switch Connectors
Water
Back Of Dispenser
Cover Assembly
Ice
b) Press in on the release button, and slide
the pad switch clips off the dispenser cover assembly.
P6
P7
P5
Board Orientation Notch
Core Board Tabs
P1
P2
P3
Release Buttons
Slide Pad Switch Up
To Disengage Clips
c) Remove the pad switch assembly.
Pad Switch
Assembly
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9. To remove the user interface board:
a) With the back of the dispenser cover
assembly facing up, disconnect the ice and water pad switch connectors.
b) Disconnect the user interface ribbon
cables from the user interface board. To do this, lift the locking tabs, and pull the cables out of the connectors.
c) Remove the four screws from the user
interface board, and remove the board and its cover from the dispenser cover assembly.
b) Carefully lift one of the corners of the
user interface, and peel it off the dis­penser cover assembly.
User Interface
Lift Locking Tabs
Water & Ice Pad
Switch Connectors
User Interface
Board Cover
Board Screws
Lift Ribbon
Cable
User Interface Board
10. To remove the user interface:
a) Remove the user interface board (see
step 9).
11. To remove the dispenser light (LED)
assembly:
a) With the back of the dispenser cover
assembly facing up, disconnect the wire connector from the user interface board.
b) Push out on either of the two tabs, and
pull the light assembly off the dispenser cover assembly.
Pull Out Dispenser Light Assembly
Push Out Tab
Back Of
Dispenser Cover
Assembly With Board
Removed
Connector
Dispenser Light Assembly
Continued on the next page.
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12. To remove the IDI motor:
a) Open the freezer door. b) Press in on the release button and re-
move the ice bin from the door shelf.
e) Remove the boot from the top of the
IDI motor.
f) Disconnect the motor connector from
the IDI motor.
g) Unclip the wires from the retainers under
the IDI motor housing.
h) Remove the three screws from the IDI
motor housing and remove the motor and housing from the dispenser.
Boot
Screws
Ice Bin Release Button
c) Remove the two screws from the hex
drive shaft coupling holder and remove the coupling assembly.
Shaft Coupling Holder Screws
d) Lift the spring and hex drive shaft up
and out of the door.
IDI Motor
Screw
Connector
Wire Retainers
i) Remove the four screws from the IDI
motor and remove the motor from the housing.
IDI Motor
Screw (1 of 4)
Spring
Hex Drive Shaft
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Page 21
13. To remove the water dispenser nozzle:
a) Push down on the blue quick-discon-
nect locking ring, and pull the water tube from the fitting.
b) Pull out on the locking clip and remove
it from around the quick-disconnect.
Water Tube
Locking Clip
Quick-Disconnect
c) Remove the cover from the water nozzle
housing.
d) Unclip the water nozzle and remove it
from the housing.
Water Nozzle
Water Nozzle
Housing Cover
Housing Clip
Housing
Water Nozzle
Housing Cover
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REMOVING THE FREEZER DOOR
DISPENSER SUPPLY HARNESS AND WATER TUBE
b) Remove the dispenser cover assembly
(see page 3-2 for the procedure).
c) Disconnect harness connectors P1 and
P7 from the core board.
d) Disconnect the ground wire screw.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
1. Unplug refrigerator or disconnect power.
2. Open the refrigerator and freezer doors and remove the bottom grille.
Bottom Grille
3. To remove the freezer door dispenser
supply harness:
Ground Wire Screw
P7
Harness Channel Opening
Core Board
P1
e) Grasp the ends of the harness wires
firmly and pull the harness up and out of the channel opening in the freezer door.
a) Using a screwdriver, pry out on the
harness connector locking tab, and disconnect the harness connector from the main harness.
Harness Connector
Pull Harness Out
Of Channel Opening
4. To remove the dispenser water tube:
a) Turn off the water supply to the refrig-
erator.
b) Place a towel or a small container to
catch any water when you disconnect the water supply tubing under the freezer door hinge.
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Page 23
c) Push down on the blue quick-discon-
nect locking ring, and pull the dispenser water tube from the fitting. Allow any water to drain into the container or onto the towel.
Quick-Disconnect
d) Push down on the blue quick-discon-
nect locking ring, and pull the water tube from the fitting.
Water Tube & Nozzle Quick- Disconnect
Dispenser Water Tube
e) Pull the water tube out of the freezer
door channel and remove the tube.
Pull Water Tube Out Through Opening
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Page 24
REMOVING THE SMART VALVE
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
5. Remove the two screws from the smart valve bracket, and remove the assembly from the side of the refrigerator.
1. Unplug refrigerator or disconnect power.
2. Turn off the water supply to the refrigera­tor.
3. Pull the refrigerator away from the wall so that you can access the rear of the unit.
4. Remove the screws from the unit access cover and remove the cover.
Unit Access Cover
Smart Valve Screws
6. Place a towel or a small container to catch any water when you disconnect the water supply tubing.
7. Push down on the quick-disconnect locking rings, and pull the water inlet, ice maker, and dispenser outlet water tubes from the fittings.
8. Disconnect the smart valve wire connec­tors from the smart valve and remove the smart valve assembly.
Ice Maker Tube
Smart Valve
Wire Connectors
3-10
Dispenser
Outlet Tube
Water Inlet Tube
Page 25
REMOVING THE FREEZER DOOR
7. Using a screwdriver, pry out on the harness connector locking tab, and disconnect the harness connector from the unit.
8. Place a towel or a small container under the freezer door hinge to catch any water in the tubing when it is disconnected.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
NOTE: The freezer door is shown being re-
moved in the following procedure. Except for the wiring and water tubing disconnects, the refrigerator door is removed in the same man­ner.
1. Unplug refrigerator or disconnect power.
2. Turn off the water supply to the refrigerator.
3. Open the refrigerator and freezer doors and remove the bottom grille.
9. Push down on the blue quick-disconnect locking ring, and pull the door water tube out of the fitting. Allow any water to drain into the container or onto the towel.
Harness Connector
Door Water Tube & Quick-Disconnect
10. Remove the screw from the top hinge cover and remove the cover.
Harness & Tubing Disconnects
Bottom Grille
4. Close the refrigerator door.
5. Remove the contents from the freezer door shelves.
6. Close the freezer door.
Top Hinge Cover & Screw
Continued on the next page.
3-11
Page 26
NOTE: Support the freezer door so that it does
not fall in the next step.
11. With the freezer door closed, remove the three screws from the top hinge, and re­move the hinge. IMPORTANT: DO NOT remove the tap plate retainer screw inside the center hinge cutout.
Remove 3 Hinge Screws
Do Not Remove Tap Plate Retainer Screw
12. Partially open the freezer door and lift it off the bottom hinge pin. Guide the wires and tubing through the hinge opening, and remove the door.
Lift Door Off Bottom Hinge Pin
Remove Wires
& Tubing
3-12
Page 27
COMPONENT TESTING
Before testing any of the components, perform the following checks:
The most common cause for control failure
is corrosion on connectors. Therefore, dis­connecting and reconnecting wires will be necessary throughout test procedures.
All tests/checks should be made with a VOM
or DVM having a sensitivity of 20,000 ohms­per-volt DC, or greater.
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
ICE DOOR MOTOR
Check all connections before replacing com-
ponents, looking for broken or loose wires, failed terminals, or wires not pressed into connectors far enough.
Resistance checks must be made with power
cord unplugged from outlet, and with wiring harness or connectors disconnected.
WATER & ICE PAD SWITCHES
3 2 1
6 5 4
Refer to page 3-2 for the procedure for access­ing the ice door motor.
1. Unplug refrigerator or disconnect power.
2. Disconnect the motor connector at P5 on the core board.
3. Set the ohmmeter to the R x 1 scale.
4. Touch the ohmmeter test leads to the fol­lowing motor connector pins:
Pin 1 to pin 2,3,5,or 6 = 45 to 55 Ω
Refer to page 3-2 for the procedure for access­ing the water & ice pad switches.
1. Unplug refrigerator or disconnect power.
2. Disconnect the water and ice pad switch connector from the user interface board.
3. Set the ohmmeter to the R x 1 scale.
4. Touch the ohmmeter test leads to the pad switch connector pins and press the pad. The meter should indicate less than 175 Ω.
4-1
Page 28
Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical
shock.
IDI MOTOR SMART VALVE COILS
Ice Maker Coil (Red)
Cover
5 4 3 2 1
Dispenser Coil (Green)
Refer to page 3-2 for the procedure for access­ing the IDI motor.
1. Unplug refrigerator or disconnect power.
2. Disconnect the IDI motor connector.
3. Set the ohmmeter to the R x 1 scale.
4. Touch the ohmmeter test leads to the fol­lowing motor connector pins:
Pins 1 and 2 = 10 to 15 Ω Pins 4 and 5 = 220 to 270 Ω
Refer to page 3-10 for the procedure for ac­cessing the smart valve.
1. Unplug refrigerator or disconnect power.
2. Unsnap and remove the cover from the smart valve housing.
3. Set the ohmmeter to the R x 10 scale.
4. Touch the ohmmeter test leads to either coil connector. The meter should indicate between 240 and 280 Ω.
4-2
Page 29
DIAGNOSTICS & TROUBLESHOOTING
UI DISPLAY DIGITS
1234
5
DIAGNOSTICS
Use the following procedure to enter the diag­nostics mode:
1. Make sure that the unit is not in the “lock­out” mode (the lockout LED will be off).
2. Press and hold the CUBED and LIGHT buttons for about 3 seconds until the unit beeps, then release both buttons.
3. Diagnostics will begin with step 0. NOTE: Each step displays the step number in dig­its 4 and 5 (see below) of the user interface display, and the step result, using the first three digits (1 - 3).
4. Each step must be manually advanced by pressing the LOCKOUT button to move to the next step in the sequence, or back up to the previous step by pressing the FILTER RESET button.
5. All buttons and pads are inoperative, ex­cept for those described in the actions for each step.
6. The diagnostics charts shown on the fol­lowing pages describe each component that is tested.
7. If communication is lost with the dispenser core control board, steps 10 - 14 will display “- - -” on digits 1 - 3.
8. If communication is lost with the smart valve control, steps 15 - 20 will display “- - -” on digits 1 - 3.
9. The diagnostics mode ends automatically after the steps are complete, or 20 minutes have elapsed (whichever comes first). The diagnostics mode may be manually exited by pressing the LIGHT button during any step, or in the case that electrical power is cycled. Following the exit of the diagnos­tics mode, the controls will resume normal operation.
5-1
Page 30
WHIRLPOOL MODELS
5-2
Page 31
KITCHENAID MODELS
5-3
Page 32
MODULAR ICE MAKER & ICE LEVEL DETECTOR MODELS
5-4
Page 33
TROUBLESHOOTING
Flowcharts
The flowcharts on the following pages are intended to be used with the Diagnostics Charts. If a problem occurs during the diagnostics tests, refer to the flowcharts to help locate and correct it. The flowcharts cover the following problems:
1. Ice Cannot Be Dispensed (Water Dispenser Is Operating Normally) - Page 5-6.
2. Both Ice And Water Cannot Be Dispensed - Page 5-7.
3. Ice Maker Does Not Produce Ice (Water Dispenser Is Operating Normally) - Page 5-8.
4. Ice Maker Does Not Produce Enough Ice - Page 5-8.
5. Water Cannot Be Dispensed (Ice Maker Is Operating Normally) - Page 5-9.
6. Measured Fill Is Not Accurate - Page 5-10.
7. Water Dispenser Fill Is Too Slow - Page 5-10.
8. Dispenser Lighting Does Not Operate - Page 5-11.
9. Dispenser Lighting Does Not Operate Correctly In The “Auto” Mode - Page 5-11.
10. Dispenser Lighting Does Not Turn Off - Page 5-11.
11. User Interface Keypad Buttons Do Not Operate Correctly - Page 5-12.
12. User Interface Display Indicators Do Not Operate Correctly - Page 5-12.
13. Moisture Present In Dispenser Area - Page 5-13.
5-5
Page 34
Perform
resistance check on ice
door motor.
Is reading correct?
Perform
resistance check on
ice pad (see page 4-1).
Is reading correct?
Perform
resistance check on
IDI motor (see pg 4-2).
Is reading correct?
Replace user
interface board.
1. ICE CANNOT BE DISPENSED (WATER DISPENSER IS OPERATING NORMALLY)
A. Ice Dispenser Door Does Not Open
• Before starting the diagnostics, make sure that there is nothing blocking the ice door.
• Make sure that connector P5 is properly seated with the core board connector, and all wires are tight.
Test Passes: Ice
pad is recognized.
Test Fails: Ice pad
is not recognized.
Door opens.
Status is correct.
Door does not open.
Status is correct.
Exit diagnostics. Check
for normal operation.
Part Passes: Replace
user interface board.
Go to diagnostics on page 5-1,
then to step #5 on page 5-2
or 5-3 and press the ice pad.
Go to diagnostics on page 5-1,
then to step #5 on page 5-2
or 5-3 and press the ice pad.
Part Fails: Replace
ice pad.
Door does not open.
Status is not correct.
Go to diagnostic step #14.
Replace core control board.
Replace ice door motor.
B. In-Door Ice Motor Does Not Operate
• Confirm that connector P2 is properly seated with the core board connector, and all wires are tight.
• Confirm that the IDI motor connector and terminals are tight.
Test Passes: Ice
pad is recognized.
Test Fails: Ice pad
is not recognized.
Replace IDI motor.
Replace core
control board.
START
START
YES
NO
Perform
resistance check on
ice pad (see pg 4-1).
Is reading correct?
Replace ice pad.
Replace user
interface board.
YES
NO
YES
NO
YES
NO
5-6
Page 35
Display reads “0.”
Repair or replace
freezer door switch.
Repair open circuit in LB/BK
wire between freezer door switch
and core control board.
Display reads “1.”
START
2. BOTH ICE AND WATER CANNOT BE DISPENSED
Perform
resistance check on
freezer door switch.
Is reading correct?
Replace smart
valve.
Repair open
RD/YL & BK/YL
wire between smart valve and
core control board.
Replace core
control board.
Replace filter.
Repair water
supply.
YES
NO
YES
NO
Check
for correct water
supply to refrigerator.
Is
supply correct?
Check
the grill filter.
Does water dispense
with filter removed?
Check
smart valve for
14 vdc across RD/YL &
BK/YL wires. Is
reading correct?
Check
core control board
across RD/YL & BK/YL
wires. Is reading
correct?
YES
NO
YES
NO
YES
NO
Go to diagnostics on page 5-1,
then to step #12 on page 5-2 or
5-3 and close the freezer door.
5-7
Page 36
4. ICE MAKER DOES NOT PRODUCE ENOUGH ICE
• Verify freezer temperature is 5°F or colder, and that the airflow is not blocked.
• Make sure that the ice maker is receiving the proper amount of water (8 cubes = 4.4 oz. (130 cc) of water).
• Look for high ice usage by customer.
• At 0°F, 80 to 106 cubes of ice in a 24-hour period is normal.
Initiate a forced harvest
(see ice maker tech sheet).
Unplug refrigerator,
or disconnect power for
30 seconds, then
restore power.
Initiate a forced harvest
(see ice maker tech sheet).
Ice maker bimetal
is open.
Check ice maker,
heater, & module.
YES
YES
NO
NO
Ice maker harvests
and fills.
Ice maker harvests
but does not fill.
Ice maker harvests
and fills.
Proceed to flow
chart test 2.
Ice maker will
not operate.
Jumper BK to BK/WH with
an insulated wire at the
optics receiver board.
Replace bimetal or
ice maker.
Repair or replace
ice maker.
Replace smart
valve.
Repair fill tube.
Unit operates
normally.
Repair or replace
optics
Repair or replace
optics
Repair or replace
ice maker.
3. ICE MAKER DOES NOT PRODUCE ICE (WATER DISPENSER IS OPERATING NORMALLY)
• Verify freezer temperature is 5°F or colder. Ice production will be slow from 10°F to 15°F, and will stop at around 18°F.
• Ice maker should be in the “park” (2:00) position.
* Voltage will be present on the tan wire of the ice maker for 7 to 8 seconds during harvest just before it reaches the “park” position. This
voltage is in series with the mold heater, and will be between 80 and 105 volts ac. The voltage on the tan wire signals the valve to fill the ice
maker. Line voltage must always be present across the BK & WH wires at the valve. 14 vdc must always be present across the RD/YL and
BK/YL wires on the valves.
START
Check the IDI
optics (see ice maker
tech sheet). Did the
optics test pass?
Check for ice in
ice maker mold. Is ice
present?
Check the water
dispenser operation.
Does it operate normally?
YES
NO
YES
NO
YES
NO
YES
NO
Initiate a
forced harvest
(see ice maker tech
sheet). Does ice
maker operate?
Check
water line
between smart valve
and ice maker for kinks or
blockage. Fill tube is
clear?
Check
for normal
conditions, as shown in
the footnote*. Are
conditions normal?
5-8
Page 37
Replace user
interface board.
5. WATER CANNOT BE DISPENSED (ICE MAKER IS OPERATING NORMALLY)
• Prior to following the diagnostics routine, make sure that no plumbing leaks exist
by checking the connections listed in section “Measured Fill Is Not Accurate.”
Check water pad connection
on dispenser user
interface board.
Replace water pad.
Replace user
interface board.
Press the water pad and
then the water button to
test for water dispense.
Replace touchpad.
Unit operates normally.
Replace user
interface board.
Unit is operating normally.
Unit is operating normally.
Replace smart valve.
Replace core
control board.
Plug in or reseat
the connector.
Water cannot be
dispensed by
water pad only.
Water cannot be
dispensed by
water button only.
Water cannot be
dispensed by
water pad & button.
Go to diagnostics on
page 5-1, then to step #5
on page 5-2 or 5-3 and
press water button.
Go to diagnostics on
page 5-1, then to step
#10 on page 5-2 or 5-3.
Go to diagnostics step #5
and press water button.
Digits 2 & 3 display
“34” when water
button is pressed.
Digits 2 & 3 do not
display “34” when
water button is pressed.
Digits 1, 2, & 3 display
decimal number for
software version.
Digits 1, 2, & 3 display
decimal number for
software version.
Check ribbon cable
connections P4 and P5
on user interface board.
Tighten connections.
Digits 2 & 3 display
“34” when water
button is pressed.
Digits 2 & 3 do not
display “34” when
water button is pressed.
Digits 1, 2, & 3
display “–”.
Digits 1, 2, & 3
display “–”.
Digits 1, 2, & 3 display
decimal number for
software version.
Digits 1, 2, & 3
display “–”.
Digits 1, 2, & 3 display
decimal number for
software version.
Digits 1, 2, & 3
display “–”.
Check the P6 and P7 connectors on the core
control board, and make sure that the
connector and all the wires are secure.
Also check the P1 connector at the user
interface board, and make sure that the
connector and all of the wires are secure.
Check the P1 and P2 connectors and make
sure that all the wires are secure.
Go to diagnostics
step #15.
Repeat diagnostics
step #15.
Repeat flow chart
procedure from START.
Repeat diagnostics
step #10.
Go to
diagnostics on
page 5-1, then to step
#5 on page 5-2 or 5-3.
Is water pad
recognized?
Perform
resistance
check on water pad
(see pg 4-1).
Is reading correct?
Is the unit operating?
START
YES
NO
YES
NO
YES
NO
5-9
Page 38
Spigot
Door Elbow Joint
Outlet
Filter
Customer
Connection
Smart Valve
Ice Maker Fill Outlet
Smart Valve Inlet
Smart Valve
Water Dispenser Outlet
Inlet
Water Tank
Ice Maker
6. MEASURED FILL IS NOT ACCURATE
Consistent measured fill inaccuracies are often due to the smart valve mechanics, low incoming
water pressure, or water plumbing leaks. Make sure that no leaks occur in the following locations:
• Door Spigot
• Door Elbow Joint
• Water Tank
• Smart Valve Water Dispenser Outlet
• Smart Valve Ice Maker Fill Outlet
• Smart Valve Inlet
• Customer Connection
• Filter Inlet & Outlet
If no leaks are found, replace the smart valve.
7. WATER DISPENSER FILL IS TOO SLOW
• Verify proper refrigerator water supply.
• Water filter is blocked, or incorrect filter is being used (dispense water with water filter removed to test).
• Check for kinked water tubing.
5-10
Page 39
Disconnect the dispenser
lighting assembly connector P6
on the user interface board.
Measure the voltage
across the terminals.
12 to 14 vdc is present
across the terminals.
12 to 14 vdc is not present
across the terminals.
Replace the dispenser
lighting assembly.
Replace user
interface board.
Replace user
interface board.
Go to diagnostics on page 5-1,
then to step #6 on page 5-2 or 5-3.
Go to diagnostics on page 5-1,
then to step #1 on page 5-2 or 5-3.
Unit operates normally.
Unit operates normally.
Replace user
interface board.
Test passes.
Test fails.
Press the light button
to exit diagnostics.
Go to diagnostics
step #7.
Replace user
interface touchpad.
8. DISPENSER LIGHTING DOES NOT OPERATE
• Use this diagnostics procedure in the event that the dispenser night light never turns on.
9. DISPENSER LIGHTING DOES NOT OPERATE CORRECTLY IN THE “AUTO” MODE
• Use this diagnostics procedure in the event that the dispenser lighting does not operate correctly when set for AUTO
(i.e. lighting should get brighter with more ambient light, and dimmer with less ambient light).
10. DISPENSER LIGHTING DOES NOT TURN OFF
• Make sure that the user interface board ribbon connectors are properly seated on the board.
YES
NO
YES
NO
Does lighting increase
and decrease?
Check for normal
operation.
Does lighting turn off?
START
START
START
5-11
Page 40
Test passes.
Test fails.
Test fails. Some or all
indicators do not turn on.
Test passes. All
indicators turn on.
Replace user
interface board.
Replace user
interface touchpad.
Seat the connectors until
unit operates properly.
11. USER INTERFACE KEYPAD BUTTONS DO NOT OPERATE CORRECTLY
• Use this diagnostics procedure when pressing a button gets no response or no audible beep.
If an audible beep does occur, but a button gets no response, then there is most likely a wiring problem, or a control board failure.
If the failure exists with regards to a water dispense, or measured fill, then refer to the section “Water Cannot Be Dispensed.”
• Make sure that the ribbon connection at the user interface board connectors P4 and P5 are seated correctly.
YES
NO
Replace user
interface board.
Reseat connectors &
retest.
Replace user interface
touchpad.
Unit operates properly.
12. USER INTERFACE DISPLAY INDICATORS DO NOT OPERATE CORRECTLY
• Includes fragmented digits on display, or LED indicators that do not operate.
• If the user interface display is completely blank, make sure that power is applied to the refrigerator. Disconnect user interface
connector P1, and measure the voltage across the RD/YL and BK/YL wires from the core control board. If 14 vdc is not present,
replace the core control board.
• Make sure that the ribbon cables at P4 and P5 on the user interface board are properly connected.
Are the ribbon
connectors loose?
Check ribbon
cables at P4 & P5 for
proper connection. Are the
ribbon connectors
secure?
Check for the original
problem.
Does it still exist?
YES
NO
YES
NO
START
START
Go to diagnostics on
page 5-1, then to step #0 on
page 5-2 or 5-3.
Go to diagnostics on
page 5-1, then to step #5 on
page 5-2 or 5-3.
5-12
Page 41
Digit 3 displays “1”
(heater is on).
13. MOISTURE PRESENT IN DISPENSER AREA
• The following diagnostics procedure examines a moisture-related issue that may be caused by the dispenser
housing heater not operating correctly.
• Make sure that the ice door closes fully each time it is used.
Some condensation will be normal
during high humidity conditions,
especially on the ice door.
Replace core
control board.
Replace freezer
door assembly.
Unit operates.
Press Ice Mode/Cubed button
until digit 3 displays “1”.
Digit 3 displays “0”
(heater is off).
YES
NO
Remove
connector at
core control board P3,
and measure resistance
across heater leads.
Is
resistance present?
120 vac is present on
core control board P3 connector.
YES
NO
START
Go to diagnostics on
page 5-1, then to step #8 on
page 5-2 or 5-3.
5-13
Page 42
— NOTES —
5-14
Page 43
WIRING DIAGRAM 1
Color Code:
See A On “Wiring Diagram 2”
See B On “Wiring Diagram 2”
WIRING DIAGRAMS
WHIRLPOOL MODELS
6-1
Page 44
WIRING DIAGRAM 2
A
B
6-2
Page 45
SCHEMATIC DIAGRAM 1
Color Code:
6-3
Page 46
SCHEMATIC DIAGRAM 2
6-4
Page 47
WIRING DIAGRAM 1
See A On “Wiring Diagram 2”
See B On “Wiring Diagram 2”
Color Code:
KITCHENAID MODELS
6-5
Page 48
WIRING DIAGRAM 2
A
B
6-6
Page 49
SCHEMATIC DIAGRAM 1
Color Code:
6-7
Page 50
SCHEMATIC DIAGRAM 2
6-8
Page 51
PRODUCT SPECIFICATIONS
AND
WARRANTY INFORMATION SOURCES
IN THE UNITED STATES:
FOR PRODUCT SPECIFICATIONS AND WARANTY INFORMATION CALL:
FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737
FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL:
THE TECHNICAL ASSISTANCE LINE: 1-800-253-2870
HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN
AUTHORIZED SERVICER
FOR LITERATURE ORDERS:
PHONE: 1-800-851-4605
FOR TECHNICAL INFORMATION AND SERVICE POINTERS:
www.servicematters.com
IN CANADA:
FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL:
1-800-461-5681
FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL:
THE TECHNICAL ASSISTANCE LINE: 1-800-488-4791
HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN
AUTHORIZED SERVICER
Page 52
CORPORATION
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