21
5-1 DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on Page 5-4. LED is flashing at 1 second intervals indicating a 5 minute “harvest” mode. LED is flashing 2 pulses repeated. Hold in the freezer light switch. Wait 5 minutes and use 2002 Design Optics Mode on Page 5-4. Proceed to Original Design Optics Mode on Page 5-2. Yes Yes No No OPTICS DIAGNOSTICS MODE Diagnostics are used to determine whether the optics circuits are operating properly. If the optics circuits are malfunctioning, the ice maker will not operate. The optics system consists of an emitter board and a receiver board. The emitter board trans- mits a beam of infrared light that is detected by the receiver. If the beam of light is inter- rupted, the ice maker will not operate. The optics system can have one of two types of optics board designs installed: the original design, or the 2002 design. Use the following flow chart to determine which of the board designs are installed. Once this is determined, you will be directed to perform the appropriate optics diagnostics procedure. FLOW CHART TO DETERMINE OPTICS BOARD DESIGN

DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

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Page 1: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-1

DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS

Close the freezer door for a minimum

of 1 minute.

Open the freezer door.

Proceed to 2002Design Optics

Mode on Page 5-4.

LED is flashing at 1 secondintervals indicating a 5 minute

“harvest” mode.

LED is flashing 2 pulses repeated.

Hold in the freezer light switch.

Wait 5 minutes anduse 2002 Design Optics

Mode on Page 5-4.

Proceed to Original Design Optics

Mode on Page 5-2.

Yes

Yes

No

No

OPTICS DIAGNOSTICS MODEDiagnostics are used to determine whether theoptics circuits are operating properly. If theoptics circuits are malfunctioning, the ice makerwill not operate.

The optics system consists of an emitter boardand a receiver board. The emitter board trans-mits a beam of infrared light that is detectedby the receiver. If the beam of light is inter-rupted, the ice maker will not operate.

The optics system can have one of two typesof optics board designs installed: the originaldesign, or the 2002 design.

Use the following flow chart to determine whichof the board designs are installed. Once this isdetermined, you will be directed to perform theappropriate optics diagnostics procedure.

FLOW CHART TODETERMINE OPTICSBOARD DESIGN

Page 2: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-2

3. Make sure the ice maker manual shutoffslide is in the “ON” (open) position on theinfrared receiver module.

4. Close the freezer door for a minimum of 10seconds.

5. Open the freezer door and activate thefreezer door switch 3 times. NOTE: Thisstep must be completed within 10 sec-onds of opening the freezer door.

6. Close the freezer door within 20 secondsof completing step 5.

7. Wait for a minimum of 5 seconds, and amaximum of 50 seconds, then open thefreezer door and view the status LED onthe infrared receiver module for the errorcode. NOTE: You will have 60 seconds toopen the freezer door, and 2 seconds fromthen to view the LED output code.

U-ShapedCutout

Infrared Emitter Beam

IceLevel

Freezer DoorLight Switch

If you observe two LED pulses (flashes), per-form the following steps.

1. Open the freezer door and remove the icebin from the door.

2. Make sure the ice maker manual shutoffslide is in the “on” (open) position.

3. Tape the spring-loaded emitter door to theemitter cover in the “down” position.

4. Close the freezer door for at least 10seconds.

Manual Shutoff Infrared Receiver Slide Sensor

OPTICS DIAGNOSTICS FORORIGINAL DESIGN BOARDSKIT #4388635 SUBS TO #4389102EMITTER—PART #2198585RECEIVER—PART #2198586To initiate an optics check, perform the follow-ing steps:

1. Open the freezer door.

2. Remove enough ice from the ice bin sothat the ice level is at least one inch belowthe U-shaped cutouts in the bin.

Status LED

Page 3: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-3

5. Open the freezer door and actuate thefreezer door switch 3 times. NOTE: Thisstep must be completed within 10 sec-onds of opening the freezer door.

6. Close the freezer door within 20 secondsof completing step 5.

7. Wait for a minimum of 5 seconds, and amaximum of 50 seconds, then open thefreezer door, and view the status LED onthe infrared receiver module for the errorcode. NOTE: You will have 60 seconds toopen the freezer door, and 2 seconds fromthen to view the LED output code.

If the LED still flashes twice, there could bedirt or frost on the optics, something could beblocking the infrared beam path, or the opticsmay be defective. Clean the optic elements andrepeat the previous test.

If the LED does not flash, the ice maker mayhave been in a harvest, preventing the diag-nostics from being performed. Look at the icemaker to make sure the ejector is at the homeposition. If it is, wait 3 minutes, and try runningtest again. If the LED still does not flash, theoptics boards may be defective.

Page 4: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-4

Manual Shutoff Slide

Infrared ReceiverSensor

OPTICS DIAGNOSTICS FOR2002 DESIGN BOARDSKIT #4389102EMITTER—PART #2220398RECEIVER—PART #2220402To initiate an optics check, perform the follow-ing steps:

1. Open the freezer door.

2. View the status LED. It should flash twice,pause for 1 second, and repeat the cyclefor as long as the door is open.

NOTES:

• If the LED is not flashing, the ice makermay be in the 5 minute “harvest” mode.If so, push in on the freezer door switchwith your finger, and observe the LED.It should begin to flash at 1 second in-tervals, and continue to flash for as longas you hold the door switch.

• If the LED does not flash, as describedabove, the original style optics boardsmay be installed. Perform the steps,shown in Chart A, on page 5-6.

3. Check the ice maker manual shutoff slideand make sure that it is in the “ON” (open)position on the infrared receiver module.

EmitterModule

4. Close the flapper door on the emitter mod-ule so that the infrared beam has a clearpath to the receiver board.

Door Shown In TheOpen Position

5. Make sure that the door switch is notpushed in, and view the status LED. Withthe flapper door on the emitter moduleheld closed, and the ice maker not in the 5minute “harvest” mode, the status LEDshould be on steady. This indicates thatthe optics circuits are operating properly.If the status LED continues to flash, referto the “Troubleshooting Chart” on page5-9.

Status LED

Page 5: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-5

3. Slide the ice maker out of the mountingrails and leave the wiring harness con-nected.

4. Jumper the thermostat, as shown below.

5. Connect power to the unit.

6. Remount the ice maker, making sure thatthe water fill tube is inside the fill cup.

7. Make sure there is a clear path across thebin for the infrared beam to travel to thereceiver sensor.

8. Close the freezer door and wait 5 secondsto allow the optics relay to close.

9. Open the freezer door and you will see theejector bar moving. Remove the thermo-stat jumper prior to the ejector bladesreaching the 10:00 position, or else youwill not see the water fill. The mold shouldbe warm due to the heater operation.

10. Disconnect the power immediately afterthe water fill.

11. With the freezer door closed, reconnectthe power.

12. Wait for a minimum of 5 seconds, and amaximum of 50 seconds, then open thefreezer door, and view the status LED forthe output codes, as shown in Chart C, onpage 5-7.

NOTE: The optics must be working properlyto test the ice maker. If the optics test fails,you will not be able to force a harvest and checkthe ice maker. Refer to the TroubleshootingChart on page 5-10 for additional servicing in-formation.

IMPORTANT: If the freezer temperature isnot cold enough to allow the ice maker bi-metal to close, a jumper must be installedon the ice maker at test points T and H, andthe test rerun.

1. Run an optics check as described in theprevious section.

2. Disconnect power to the unit.

Electrical Shock Hazard

Voltage is present during these tests.

WARNINGCOMPONENT DIAGNOSTICS MODE

Motor Jumper (Points T and H)

Page 6: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-6

— Chart B —

Diagnostics Chart For 2002 Design Optics Boards

— Chart A —

Diagnostics Chart For Original Design Optics Boards

STEP # STATUS LED POSSIBLE CAUSES ACTION

1. Open the freezer door (make sure that the freezer door has been closed for a minimum of 10 seconds prior to opening the door).

2. Activate the door switch 3 times. Push the button in completely for 1 second each time.

3. Close the freezer door for a minimum of 5 seconds for a maximum of 50 seconds.

4. Open the freezer door and immediately view the diagnostics “status” LED.

2 pulses, repeated once, indicates the optics are blocked, or defective. Clear the optics path, and repeat the “Optics Diagnostics Procedure.” Replace both boards, if necessary.

A steady light that is ON for 5 seconds indicates that both of the optics boards are good. Continue with the “Component Diagnostics Mode.”

If there is no light, unplug the refrigerator for 5 seconds, and repeat the test. If there is still no light, replace both optics boards.

OPTICS DIAGNOSTICS PROCEDURE FOR ORIGINAL DESIGN BOARDS

OPTICS DIAGNOSTICS MODE CHARTSNOTES:

1. Optics Diagnostics will not respond:

• For 5 minutes after the ice maker begins a “harvest” cycle. To reset the control, wait untilthe ice maker “parks,” then unplug the refrigerator for 5 seconds, and repeat the test.

• While the control board is running self-checks. Reset the control, as above.2. The ice maker control must be in the “ON” position.

3. The ice bin must be on the door and the ice level below the notched openings.

STEP # STATUS LED POSSIBLE CAUSES ACTION

The optics are faulty. Go to Step 2.

Faulty Status LED, or original style boards are installed.

Replace the receiver and emitter boards, or perform the steps in Chart A.

LED is on steadily. The Optics are working properly. Close the freezer door.

OPTICS DIAGNOSTICS PROCEDURE FOR 2002 DESIGN BOARDS

1. Open the freezer door.

No lamp.

Go to Step 2.

Ice maker is in the “harvest” mode. The harvest mode consists of a five (5) minute period that starts when the bimetal closes, and the ice maker begins to run.

Two (2) pulses followed by a one (1)second delay (repeated).

The flapper door on the emitter is blocking the beam.

2. Press in the emitter flapper door to unblock the optics beam.

To confirm, press in and hold the freezer door switch. If in the “harvest” mode, the Status LED will flash once every second.

Replace the emitter and receiver boards.The Optics are faulty.Two (2) pulses followed by a one (1) second delay (repeated).

Page 7: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-7

— Chart C —Component Diagnostics Mode

For Original & 2002 Design Boards

COMPONENT DIAGNOSTICS MODE CHART

5. Close the freezer door to align the optics and a harvest cycle will begin in 5 seconds.

1. Disconnect the power supply.2. Slide the ice maker out and remove the cover.3. Jumper holes “T” and “H” to bypass the bimetal and start a harvest.4. Reconnect the power supply.

Status LED Output Codes

4 PULSES, repeated once, indicates the relay is defective. Replace both the emitter and receiver boards.

6. Open the freezer door and observe the ice maker. A “harvest” should be in progress.NOTE: If holes “T” and “H” are properly jumpered and the ice maker will not run, stop the test, and check the ice maker. 7. Remove the jumper before the fingers reach 10:00. Reinstall the ice maker, or be prepared to catch the water fill during step 8.8. Disconnect power immediately after the water fill.

STEADY LIGHT for 5 seconds indicates the relay and optics are okay, and the receiver senses the ice maker.NO LIGHT: Unplug the refrigerator for 5 seconds, and repeat the test.

3 PULSES, repeated once, indicates the optics and relay are okay, but the ice maker is not being sensed, or will not operate. If this happens:

COMPONENT DIAGNOSTICS MODE (RUN OPTICS DIAGNOSTICS PROCEDURE FIRST)

• Check the bail arm switch to make sure it is On.

9. With the freezer door closed, reconnect the power supply.

• Check the ice maker circuit and the connections back to the receiver board and neutral. • Check the ice maker components.

2 PULSES, repeated once, indicates the optics are blocked, or defective. Clear the optics path, and repeat the “Optics Diagnostics Procedure.” Replace both boards, if necessary.

10. Wait 5 seconds, to a maximum of 50 seconds, then open the freezer door, and watch the Status LED for one of the following codes.

Page 8: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-8

TES

TR

ESU

LTPO

SSIB

LE C

AUSE

CORR

ECTI

VE A

CTIO

N

Ice

mak

er s

lide

cont

rol t

urne

d O

FF (c

lose

d).

Mov

e ic

e m

aker

slid

e co

ntro

l to

ON

(ope

n).

Dirt

on

optic

s.

Cle

an d

irt fr

om o

ptic

s.M

isalig

ned

ice b

in.

Rea

lign

ice

bin

cuto

uts

with

opt

ics

path

. Ic

e in

bin

blo

ckin

g op

tics

path

. R

emov

e en

ough

ice

from

bin

to c

lear

pat

h.

Fros

t on

optic

s le

nses

. C

lean

fros

t fro

m le

nses

. Ic

e bi

n no

t clo

sing

optic

s em

itter

door

pro

perly

. Ta

pe e

mitt

er d

oor c

lose

d an

d re

test

. If o

ptic

s te

sts

ok

ay, t

he ic

e bi

n an

d/or

its

mou

ntin

g ar

e at

faul

t.Fr

eeze

r doo

r not

com

plet

ely

clos

ed d

urin

g

O

ptic

s Te

st.

Clo

se fr

eeze

r doo

r and

rete

st.

Faile

d op

t ics.

Rep

lace

em

it ter

and

rece

iver

boa

rds

and

rete

st.

Ice

mak

er is

in “h

arve

st” c

ycle

. W

ait 5

min

utes

unt

il “h

arve

st” c

ycle

is c

ompl

ete

and

rete

st.

LED

was

not

vie

wed

with

in 2

sec

onds

of

op

enin

g fre

ezer

doo

r. R

etes

t and

vie

w L

ED w

ithin

2 s

econ

ds o

f ope

ning

free

zer

door

. Fr

eeze

r doo

r was

not

clo

sed

for a

min

imum

of

5 se

cond

s be

fore

sta

rt ing

test

. C

lose

free

zer d

oor,

wai

t for

at l

east

5 s

econ

ds, a

nd re

test

.

Inco

rrect

wiri

ng a

t em

it ter

or

rece

iver

boa

rd.

Cor

rect

wiri

ng a

nd r

etes

t .

Opt

ics

perfo

rmin

g se

lf-te

sts

(will

not

pe

rform

dia

gnos

t ic te

sts

durin

g th

is t i

me)

. M

ake

sure

ice

mak

er is

“par

ked.

” Unp

lug

refri

gera

tor f

or

5

seco

nds

to re

set o

ptic

s co

ntro

l and

rete

st.

LED

is d

efec

t ive.

Rep

lace

em

it ter

and

rece

iver

boa

rds

and

rete

st.

5 se

cond

LED

on

stea

dy.

Ice

mak

er c

ontro

l circ

uit i

s fu

nctio

ning

nor

mal

ly.

Non

e re

quire

d.

No L

ED p

ulse

s.

2 LE

D p

ulse

s, re

peat

ed.

Opt

ics

Dia

gnos

tic M

ode

(opt

ics

test

onl

y)

TR

OU

BL

ES

HO

OT

ING

CH

AR

T A

Ori

gin

al O

pti

cs D

esig

n

Page 9: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-9

TR

OU

BL

ES

HO

OT

ING

CH

AR

T B

2002

Op

tics

Des

ign

TES

TR

ESU

LTPO

SSIB

LE C

AUSE

CORR

ECTI

VE A

CTIO

N2

LED

pul

ses,

repe

ated

.Ic

e m

aker

slid

e co

ntro

l tur

ned

OFF

(clo

sed)

.M

ove

ice

mak

er s

lide

cont

rol t

o O

N (o

pen)

.D

irt o

n op

tics.

C

lean

dirt

from

opt

ics.

Fros

t on

optic

s le

nses

. C

lean

fros

t fro

m le

nses

. Fl

appe

r doo

r is

open

and

is b

lock

ing

the

emitt

er b

eam

.H

old

the

emitt

er d

oor c

lose

d, a

nd th

e st

atus

LED

sho

uld

be

on s

tead

y.

Faile

d op

tics.

Rep

lace

em

itter

and

rece

iver

boa

rds

and

rete

st.

No L

ED p

ulse

s.

Ice

mak

er is

in 5

min

ute

“har

vest

” cyc

le.

To v

erify

, pre

ss in

on

door

sw

itch.

Sta

tus

LED

sho

uld

flash

at

1 s

econ

d in

terv

als.

Inco

rrect

wiri

ng a

t em

it ter

or

rece

iver

boa

rd.

Cor

rect

wiri

ng a

nd r

etes

t .

Opt

ics

perfo

rmin

g se

lf-te

sts

(will

not

pe

rform

dia

gnos

t ic te

sts

durin

g th

is t i

me)

. M

ake

sure

ice

mak

er is

“par

ked.

” Unp

lug

refri

gera

tor f

or

5

seco

nds

to re

set o

ptic

s co

ntro

l and

rete

st.

LED

is d

efec

t ive.

Rep

lace

em

it ter

and

rece

iver

boa

rds

and

rete

st.

5 se

cond

LED

on

stea

dy.

Flap

per d

oor i

s he

ld c

lose

d.N

orm

al w

ith f l

appe

r doo

r clo

sed.

Opt

ics

Dia

gnos

tic M

ode

(opt

ics

test

onl

y)

Page 10: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-10

TR

OU

BL

ES

HO

OT

ING

CH

AR

T C

Co

mp

on

ent

Dia

gn

ost

ics

Mo

de

TES

TR

ESU

LTPO

SSIB

LE C

AUSE

CORR

ECTI

VE A

CTIO

N4

LED

pul

ses,

repe

ated

onc

e.

Def

ectiv

e em

itter

rel

ay.

Rep

lace

em

itter

and

rece

iver

boa

rds

and

rete

st.

Ice

mak

er in

“hom

e” p

ositio

n an

d bi

met

al is

ope

n.

Inst

all j

umpe

r in

ice

mak

er h

oles

“T” a

nd “H

” and

rete

st.

Ice

mak

er b

ail a

rm s

witc

h in

OFF

pos

ition.

Ba

il ar

m n

ot u

sed

in th

ese

mod

els

but s

witc

h m

ust b

e O

N.

Ice

mak

er is

unp

lugg

ed.

Plug

in ic

e m

aker

and

rete

st.

Ther

mal

fuse

in ic

e m

aker

har

ness

is o

pen.

Rep

lace

ice

mak

er h

arne

ss a

nd re

test

.In

corre

ct w

iring

at e

mitt

er o

r rec

eive

r boa

rd.

Cor

rect

wiri

ng a

nd r

etes

t. Pr

oble

m w

ith ic

e m

aker

.Se

e "Ic

e M

aker

Che

cks.

”2

LED

pulse

s.

Opt

ics

boar

ds d

efec

tive.

Rep

lace

em

itter

and

rece

iver

boa

rds

and

rete

st.

5 se

cond

LED

on

stea

dy.

Ice

mak

er c

ontro

l circ

uit i

s fu

nctio

ning

nor

mal

ly.

Non

e re

quire

d.

No L

ED p

ulse

s.

Opt

ics

perfo

rmin

g se

lf-te

sts

(will

not

per

form

di

agno

stic

test

s du

ring

this

t im

e).

Mak

e su

re ic

e m

aker

is “p

arke

d.” U

nplu

g re

frige

rato

r for

5 se

cond

s to

rese

t opt

ics

cont

rol a

nd re

test

.

Opt

ics

chec

k no

t run

bef

ore

test

ing

ice

mak

er.

Run

opt

ics

test

and

rech

eck

ice

mak

er.

Free

zer

door

not

clo

sed

afte

r O

ptic

s te

st.

Clo

se fr

eeze

r doo

r to

star

t har

vest

. O

ptic

s pa

th n

ot c

lear

. C

lear

opt

ics

path

. O

ptic

s te

st fa

ilure

. R

epla

ce e

mit t

er a

nd re

ceiv

er b

oard

s an

d re

test

. Ic

e m

aker

is u

nplu

gged

. Pl

ug ic

e m

aker

in.

Ther

mal

fuse

in ic

e m

aker

har

ness

is o

pen.

Repl

ace

ice m

aker

har

ness

.W

iring

har

ness

or d

oor s

witc

h pr

oble

m.

Che

ck c

ontin

uity

in w

iring

har

ness

and

doo

r sw

itch.

Ejec

tor b

ar d

oes

not m

ove.

Mot

or h

as fa

iled.

Re

plac

e ice

mak

er m

odul

e.

Ther

mos

tat j

umpe

r not

mak

ing

cont

act .

Rep

ositi

on ju

mpe

r. H

eate

r has

faile

d.Re

plac

e ice

mak

er.

Ther

mos

tat j

umpe

r was

lef t

inst

alle

d p

ast 1

1:00

po

sit io

n.

Rem

ove

jum

per b

y 10

:00

posi

tion

of e

ject

or b

ar.

Wat

er v

alve

is u

nplu

gged

. C

onne

ct h

arne

ss to

val

ve.

Cus

tom

er’s

wat

er s

uppl

y is

pro

blem

.C

heck

for p

rope

r wat

er s

uppl

y.

Froz

en w

ater

f ill

tube

.

Def

rost

the

wat

er f i

ll tu

be a

nd c

heck

for s

eepi

ng v

alve

. W

ater

val

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Page 11: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-11

TROUBLESHOOTING THE MOTOR

NOTE: Refer to the “Motor Failure ModesChart” at the bottom of the page.

1. Motor does not hum or rotate.a)1, 2, 3, 5, 6.b)Make sure refrigerator is plugged in.c) Make sure freezer door is completely

closed.d)Make sure selection button is in UN-

LOCK position.e)Wait 1 minute after an ice jam occurs

for motor’s surge protector to automati-cally reset.

f) Disconnect/reconnect the 6-pin harnessto the motor 3 - 5 times to remove anyoxidation buildup on the connector pins.

g)Check power in the circuit (see “Check-ing The Switch Pack on page 5-14 ).

2. Motor hums but does not rotate.

a)Clear ice jam in ice bin.b)Possible broken gear inside motor as-

sembly.

3. Motor starts but heats rapidly.a)2, 3, 5.

4. Motor runs too hot after extended opera-tion.a)3, 4, 6, 9.

5. Reduction in power—motor overheats.a)2, 5, 6.

6. High no-load speed (30 RPM is nominal).a)2

7. Excessive noise (mechanical).a)2, 7, 8.

8. Jerky operation—severe vibration.a)2.

1. Open circuit in connection to line (e. g. house fuse is blownor motor is defective).

2. Defective motor.

3. Overloaded motor (mechanical failure in load).

4. Ventilation blocked.

5. Wrong connection to motor.

6. Improper or low line voltage.

7. Poor alignment between motor and load (e. g. loose motormounting).

8. Amplified motor noise due to mounting conditions.

9. High ambient temperature.

Motor Failure Modes Chart

Electrical Shock Hazard

Disconnect power before servicing.

Replace all panels before operating.

Failure to do so can result in death orelectrical shock.

WARNING

Page 12: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-12

CHECKING THE MOTORTo check voltages* at the motor for crushedor cubed ice operation:

1. Open the freezer door and remove the icebucket from the door.

2. Tape the door switch closed.

NOTE: When you are instructed to make areading at the motor connector, press the tipsof the red and black test leads into the indi-cated harness connector slots so they touchthe bare metal wire connectors. Reach aroundthe front of the door and press the ice dispenserlever to activate the dispenser switch.

* Voltage readings may vary, depending on the supplyvoltage, and the type of test equipment being used.

Press The IceDispenser Lever

Door Switch Taped Closed

Pin 1

Press Tips IntoConnector SlotsAgainst Bare WireTerminals To CheckVoltages

Motor HarnessConnector

Test Leads

Electrical Shock Hazard

Voltage is present during these tests.

WARNING

Page 13: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-13

Motor Connector

Pin 1

7

6

5

4

3

2

1

+115 VDC

–115 VDC

Neutral

L1 (115 VAC)

Motor (115 VDC)

Motor (115 VDC)

To Switch Pack (OR/BU)

To Switch Pack (PK/BK)

From Switch Pack (RD/WH)

From Switch Pack (BR/WH)

(WH)

(BU)

No ConnectionWire Harness Pinouts

3. Press the Unlocked button on the ice andwater dispenser front panel.

4. Touch the AC meter test leads to wireharness pins 3 and 5, then press the icedispenser lever. The meter should read115 VAC.

5. Touch the DC meter’s black test lead towire harness pin 6, and the red test lead topin 7, then press the ice dispenser lever.The meter should read +115 VDC ±10%.

6. Press the Crushed ice button on the iceand water dispenser front panel.

7. Touch the DC meter’s black test lead towire harness pin 1, and the red test lead topin 2, then press the ice dispenser lever.The meter should read +115 VDC ±10%.

8. Press the Cube ice button on the ice andwater dispenser front panel.

9. Touch the DC meter’s red test lead to wireharness pin 1, and the black test lead topin 2, then press the ice dispenser lever.The meter should read +115 VDC ±10%.

10. Remove the tape from the door switch.

Page 14: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-14

L1 ToLight

L1(115 VAC)

L1(115 VAC)

L1 To Paddle/Dispenser Switch

& DC Motor

To Motor (115 VDC)

Pin 2

To Motor (115 VDC)

Pin 1

115 VDCFrom Motor

115 VDCFrom Motor

YL/BK

BR/WH BR/WH

RD/WH RD/WH

OR/BUPK/BKBU/BK

BU/BK

GY

CHECKING THE SWITCH PACKTo check voltages at the switch pack:

NOTE: All of the wires must be connected tothe pins on the switch pack to obtain the fol-lowing readings, including the wire to the pinbeing measured. Also, the freezer door lightswitch must be in the closed (taped down)position before performing any voltage checks.When measuring a voltage, lift the wire con-nector partially off the switch terminal, andtouch the meter test lead probe to the terminal(see below).

Switch Pack Pinouts

1. To check the Light On and Light Offswitches, press the Light button on the iceand water dispenser front panel, and thedispenser housing light should turn on. Ifthe light does not turn on:

a)Check switch pack pins BU/BK and YL/BK using an AC voltmeter. The metershould read 115 VAC if the switch isopen, or 0 VAC if the switch is closed.

b)Disconnect the BU/BK and YL/BK wiresfrom the Light switch terminals. Checkthe switch continuity with an ohmme-ter. The continuity should change whenthe Light switch is pressed on and off.

2. The Locked/Unlocked switch allows ACvoltage to be sent to the motor through theice dispenser lever switch when it is in theUnlocked position. If the Unlocked switchis defective, the dispenser lever will notoperate the motor. To check the switch:

a)Check pins BU/BK and GY using an ACvoltmeter. The meter should read 115VAC if the switch is open, (Locked), or0 VAC if the switch is closed (Un-locked).

b)Disconnect the BU/BK and GY wiresfrom the Lock/Unlocked switch termi-nals. Check the switch continuity withan ohmmeter. The continuity shouldchange when the switch is changedfrom Locked to Unlocked.

Electrical Shock Hazard

Voltage is present during these tests.

WARNING

Page 15: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-15

3. To check to make sure that DC voltage isbeing supplied to the switch pack:

a)Press the Unlocked button.b)Touch the DC voltmeter’s black test lead

to PK/BK and the red test lead to OR/BU, then press the ice dispenser lever.The meter should read +115 VDC±10%.

4. To check the Crushed and Cube iceswitches:

a)Press the Unlocked and the Crushedbuttons on the ice and water dispenserfront panel.

b)Touch the DC voltmeter’s black test leadto BR/WH and the red test lead to RD/WH, then press the ice dispenser lever.The meter should read +115 VDC±10%.

c) Press the Unlocked and the Cube but-tons on the ice and water dispenserfront panel.

Continuity Tests

Refer to the chart below to perform the ice dis-penser switch pack continuity tests. All of thetests are performed with power disconnectedfrom the unit, and the wires disconnected fromthe terminals of the switch under test.

d)Touch the DC voltmeter’s black test leadto RD/WH and the red test lead to BR/WH, then press the ice dispenser lever.The meter should read +115 VDC±10%.

Electrical Shock Hazard

Disconnect power before servicing.

Replace all panels before operating.

Failure to do so can result in death orelectrical shock.

WARNING

Switch Pack Setup Continuity Readings

Light Interlock Switch With Switch Closed Terminal BK to BU/BKIce Dispenser “Unlock” Selected Terminal BU/BK to GYIce Lever Switch With Dispenser Pushed In Terminal GY to BUDispenser Light Switch With Light On Selected Terminal BU/BK to YL/BKCrushed Ice Selected Terminals OR/BU to RD/WH

& PK/BK to BR/WHCubed Ice Selected Terminals OR/BU to BR/WH

& PK/BK to RD/WH

Page 16: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

5-16

Wire TerminalSlot

WireRetainer

Tab

MotorConnector

Screwdriver

2. To install a wire terminal, position theterminal with the slot facing the retainertab, and slide it into the connector. Pressdown on the retainer tab to lock it in place.

SERVICING THE HARNESS &MOTOR CONNECTORBoth the motor connector and the wire harnessare serviceable. To remove a wire from themotor connector:

1. Use a small screwdriver or knife and liftthe wire retainer tab far enough to slidethe wire terminal out of the connector.

Electrical Shock Hazard

Disconnect power before servicing.

Replace all panels before operating.

Failure to do so can result in death orelectrical shock.

WARNING

Page 17: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

6-1

WHIRLPOOL WIRING DIAGRAM

ICE DISPENSERMOTOR (SEE NOTE 2)

NOTES:1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position.2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the

positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. The BR/WH and RD/WH wiresswitch polarity, depending on the crushed/cubed switch position, (see the following table).

BR/WH RD/WHCrushed – +

Cubed + –

WIRING DIAGRAMS & STRIP CIRCUITS

Page 18: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

6-2

KITCHENAID WIRING DIAGRAM

NOTES:1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position.2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the

positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. The BR/WH and RD/WH wiresswitch polarity, depending on the crushed/cubed switch position, (see the following table).

BR/WH RD/WHCrushed – +

Cubed + –

ICE DISPENSERMOTOR (SEE NOTE 2)

Page 19: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

6-3

CUBED MODE

STRIP CIRCUITS

CRUSHED MODE

Voltage RectifierBridge Converts

115 VAC to 115 VDC

MotorCW

Rotation

L1

N

LightInterlockSwitch

Dispenser LockSwitch

Crushed IceSelection

Ice LeverSwitch

+

BK

BU/BK GY BU

OR/BU

PK/BK BR/WH

RD/WH

Voltage RectifierBridge Converts

115 VAC to 115 VDC

MotorCCW

Rotation

L1

N

LightInterlockSwitch

Dispenser LockSwitch

Cubed IceSelection

Ice LeverSwitch

+

BK

BU/BK GY BU

OR/BU

PK/BK

BR/WH

RD/WH

Page 20: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

7-1

CONFIRMATION OF LEARNING EXERCISES1. Trace the circuit for the crushed ice operation by closing the necessary switches. Refer to the

Wiring Diagram NOTES at the bottom of the page.

NOTES:1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position.2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the

positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. The BR/WH and RD/WH wiresswitch polarity, depending on the crushed/cubed switch position, (see the following table).

BR/WH RD/WHCrushed – +

Cubed + –

ICE DISPENSERMOTOR (SEE NOTE 2)

L1To Light Switch

N

Page 21: DIAGNOSTICS & TROUBLESHOOTINGDIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS Close the freezer door for a minimum of 1 minute. Open the freezer door. Proceed to 2002 Design Optics Mode on

7-2

NOTES:1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position.2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the

positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. The BR/WH and RD/WH wiresswitch polarity, depending on the crushed/cubed switch position, (see the following table).

2. Trace the circuit for the cubed ice operation by closing the necessary switches. Refer to theWiring Diagram NOTES at the bottom of the page.

BR/WH RD/WHCrushed – +

Cubed + –

ICE DISPENSERMOTOR (SEE NOTE 2)

L1To Light Switch

N