KitchenAid KAR-13 User manual

TECHNICAL EDUCATION
JOB AID 4317309
KAR-13
OUTDOOR AUTOMATIC
ICE MAKER
Model KUIO15NNLS

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WHIRLPOOL CORPORATION assumes no responsibility for any repairs made
on our products by anyone other than Authorized ervice Technicians.
FORWARD
This KitchenAid Job Aid, “Outdoor Automatic Ice Maker,” (Part No. 4317309), provides the
technician with information on the installation, operation, and service of the Outdoor Automatic Ice
Maker. It is to be used as a training Job Aid and ervice Manual. For specific information on the
model being serviced, refer to the “Use and Care Guide,” or “Wiring Diagram” provided with the
ice maker.
The Wiring Diagram and trip Circuits 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 detailed information that will enable the service technician to
properly diagnose malfunctions and repair the KitchenAid Outdoor Automatic Ice Maker.
The objectives of this Job Aid are to:
• Understand and follow proper safety precautions.
• uccessfully troubleshoot and diagnose malfunctions.
• uccessfully perform necessary repairs.
• uccessfully return the ice maker to its proper operational status.
Copyright © 2003, Whirlpool Corporation, Benton Harbor, MI 49022

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TABLE OF CONTENTS Pa e
GENERAL............................................................................................................................... 1-1
afety First......................................................................................................................... 1-1
KitchenAid Model & erial Number Designations.............................................................. 1-3
Model & erial Number Label And Wiring Diagram Locations .......................................... 1-4
pecifications..................................................................................................................... 1-5
Outdoor Ice Maker Warranty ............................................................................................. 1-6
INSTALLATION INFORMATION ........................................................................................... 2-1
Electrical upply Requirements ......................................................................................... 2-1
Water upply And Drain Connections ............................................................................... 2-2
THEORY OF OPERATION ..................................................................................................... 3-1
The Controls ...................................................................................................................... 3-1
Water And Refrigerant Circuit ............................................................................................ 3-2
COMPONENT ACCESS ......................................................................................................... 4-1
Component Locations ........................................................................................................ 4-1
Removing The Water Inlet Valve ....................................................................................... 4-2
Removing The Evaporator ................................................................................................. 4-3
Removing The Water Recirculation Pump......................................................................... 4-4
Removing The Evaporator Thermistor............................................................................... 4-8
Removing The Bin Thermostat ........................................................................................ 4-10
Removing The Hot Gas Valve And olenoid ................................................................... 4-12
Removing The Master witch, Recirculation Pump Motor Capacitor,
And Electronic Control Board ....................................................................................... 4-14
Removing The Condenser Fan Motor ............................................................................. 4-16
Removing The Condenser ............................................................................................... 4-18
Removing The Compressor ............................................................................................. 4-20
Removing The Door, Door Gasket, And Top Cover ........................................................ 4-22
COMPONENT TESTING ........................................................................................................ 5-1
Water Inlet Valve olenoid ................................................................................................ 5-1
Water Recirculation Pump ................................................................................................. 5-1
Evaporator Thermistor ....................................................................................................... 5-2
Bin Thermostat .................................................................................................................. 5-2
Hot Gas Valve olenoid..................................................................................................... 5-3
Master witch .................................................................................................................... 5-3
Recirculation Pump Motor Capacitor ................................................................................. 5-4
Condenser Fan Motor ........................................................................................................ 5-4
Compressor, Overload, & Relay ........................................................................................ 5-5

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Pa e
DIAGNOSIS & TROUBLESHOOTING ................................................................................... 6-1
Timing Chart ...................................................................................................................... 6-1
Troubleshooting Chart ....................................................................................................... 6-2
WIRING DIAGRAM & STRIP CIRCUITS ............................................................................... 7-1
Wiring Diagram .................................................................................................................. 7-1
trip Circuits ...................................................................................................................... 7-2
TECH TIPS ............................................................................................................................. 8-1
Cleaning The Ice Maker..................................................................................................... 8-1
Routine Cleaning ......................................................................................................... 8-1
Cleaning The pray Assembly .................................................................................... 8-2

1-1
Electrical Shock Hazard
Plug into a grounded 3-prong outlet.
Do not remove ground prong.
Do not use an adapter.
Do not use an extension cord.
Failure to ollow these instructions can
result in death, ire, or electrical shock.
Electrical Shock Hazard
Disconnect power be ore servicing.
Replace all parts and panels be ore
operating.
Failure to do so can result in death or
electrical shock.
GENERAL
SAFETY FIRST
Your sa ety and the sa ety o 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
“DA GER” or “WAR I G.” These words mean:
DANGER
WARNING
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.
You can be killed or seriously injured i you don’t
immediately ollow instructions.
You can be killed or seriously injured i you don’t
ollow instructions.
ELECTRICAL POWER SUPPLY &
GROUNDING REQUIREMENTS
WARNING
WARNING

1-2
Electrical Shock Hazard
Connect green ground wire to ground
screw.
Failure to do so can result in death or
electrical shock.
WARNING
IMPORTANT
Electrostatic Discharge (ESD)
Sensitive Electronics
ESD problems are present everywhere.
ESD may damage or weaken the elec-
tronic control assembly. The new control
assembly may appear to work well a ter
repair is inished, but ailure may occur at
a later date due to ESD stress.
• Use an antistatic wrist strap. Connect the
wrist strap to the green ground connec-
tion point, or to an unpainted metal sur-
face in the appliance.
- OR -
• Touch your finger repeatedly to a green
ground connection point, or to an un-
painted metal surface in the appliance.
• Before removing the part from its pack-
age, touch the antistatic bag to a green
ground connection point, or to an un-
painted metal surface in the appliance.
• Avoid touching electronic parts, or termi-
nal contacts. Handle the electronic con-
trol assembly by the edges only.
• When repackaging the failed electronic
control assembly in an antistatic bag,
observe the previous instructions.

1-3
KITCHENAID MODEL & SERIAL NUMBER DESIGNATIONS
MODEL NUMBER
SERIAL NUMBER
SERIAL NUMBER EH P 04 54321
DIVISION RESPONSIBILITY
E = EVA SVILLE, I / SOURCED
YEAR OF PRODUCTION
P = 2003, R = 2004
WEEK OF PRODUCTION
04 = 4th WEEK
PRODUCT SEQUENCE NUMBER
MODEL NUMBER K UI O 15 NN L S 0
I TER ATIO AL SALES I D.
OR MARKETI G CHA EL
IF PRESE T
PRODUCT GROUP
K = KITCHE AID
PRODUCT IDENTIFICATION
UI = U DERCOU TER ICE MAKER
MERCHANDISING SCHEME
O = OUTDOOR
CAPACITY / SIZE / SERIES / CONFIGURATION
15 = 15" WIDE
FEATURES
= O -PUMP, O -REVERSIBLE DOOR
YEAR OF INTRODUCTION
L = 2002
COLOR CODE
S = STAI LESS STEEL
ENGINEERING CHANGE (NUMERIC)

1-4
Wiring Diagram Location
(On Rear O Front Panel)
MODEL & SERIAL NUMBER LABEL
AND WIRING DIAGRAM LOCATIONS
The Model/Serial umber label and Wiring Diagram locations are shown below.
Model & Serial Number Label Location

1-5
SPECIFICATIONS
Ice Shape ............................................................................................................. Top Hat
Ice Production Per Cycle........................................................ 24 pcs, 0.595 Ibs. (0.27 kg)
Storage Capacity (Approximate) ............................................................. 28 Ibs. (12.7 kg)
Bin Control Setting ...................................................................................22 Ibs. (10.0 kg)
Exterior Dimensions (W x D x H) ...................14.9″ x 22.6″ x 33.5″ (378 x 575 x 850mm)
Exterior Finish ....................................... Stainless Steel, Plastic, Galvanized Steel (Rear)
et Weight ..................................................................................................88 Ibs. (40 kg)
Cube Control System .......................................................Thermistor & Electronic Control
Harvesting Control System ............................................................. Hot Gas & Thermistor
Ice Making Water Control...................................................................... Electronic Control
Bin Control System ......................................................................................... Thermostat
Refrigerant .............................................................................................................. R134a
Ambient Temperature .................................................................................... 45 To 100°F
Water Supply Pressure ............................................................................... 7 To113 PSIG
AC Power Supply .........................................................................104 To 127 VAC, 60 Hz
Amperage....................................................... 3.4A (5 Minute Freeze @ 104°F/WT 80°F)
Minimum Circuit Capacity ................................................................................... 15 Amps
Maximum Fuse Size............................................................................................ 15 Amps
Ice Production Per 24 Hr. (Approximate) ...........................................................................
Electrical Consumption
Freeze Cycle TimeHarvest Cycle Time
Water Consumption (Per 24 Hrs.)
50/10 70/21 90/32
70/21 222 Watts 228 Watts 235 Watts
80/27 227 Watts 237 Watts 242 Watts
90/32 228 Watts 244 Watts 250 Watts
100/38 237 Watts 246 Watts 255 Watts
Ambient
Temp (°F/°C)
Water Temperature
(
°F/°C
)
50/10 70/21 90/32
70/21 44 Gal. 38 Gal. 33 Gal.
80/27 39 Gal. 31 Gal. 27 Gal.
90/32 38 Gal. 24 Gal. 20 Gal.
100/38 31 Gal. 23 Gal. 16 Gal.
Ambient
Temp (°F/°C)
Water Temperature
(
°F/°C
)
50/10 70/21 90/32
70/21 3.1 min. 2.0 min. 2.0 min.
80/27 3.0 min. 2.0 min. 2.0 min.
90/32 3.0 min. 2.4 min. 2.0 min.
100/38 3.0 min. 2.0 min. 2.1 min.
Ambient
Temp (°F/°C)
Water Temperature
(
°F/°C
)
50/10 70/21 90/32
70/21 16 min. 19 min. 23 min.
80/27 18 min. 21 min. 26 min.
90/32 19 min. 24 min. 29 min.
100/38 25 min. 29 min. 33 min.
Ambient
Temp (°F/°C)
Water Temperature
(
°F/°C
)
50/10 70/21 90/32
70/21 51 lbs. (23 kg) 46 lbs. (21 kg) 43 lbs. (19 kg)
80/27 47 lbs. (22 kg) 40 lbs. (18 kg) 38 lbs. (17 kg)
90/32 46 lbs. (21 kg) 35 lbs. (16 kg) 32 lbs. (14 kg)
100/38 40 lbs. (18 kg) 34 lbs. (15 kg) 29 lbs. (13 kg)
Water Temperature (°F/°C)
Ambient
Temp (°F/°C)

1-6
OUTDOOR ICE MAKER WARRANTY

2-1
INSTALLATION INFORMATION
ELECTRICAL SUPPLY REQUIREMENTS
Before you move the ice maker into its final
location, it is important to make sure you have
the proper electrical connection:
Electrical Shock Ha ard
Plug into a grounded 3 prong outlet.
Do not remove ground prong.
Do not use an adapter.
Do not use an extension cord.
Failure to follow these instructions can
result in death, fire, or electrical shock.
WARNING
• A 115 Volt, 60 Hz, A only 15 ampere electrical
supply, properly grounded in accordance
with the National Electrical ode and local
codes and ordinances, is required.
• It is recommended that a separate circuit,
serving only the ice maker, be provided. Use
a receptacle which cannot be turned off by a
switch or pull chain.
Recommended Grounding Method
For personal safety, this appliance must be
grounded. This appliance is equipped with a
power supply cord having a 3-prong grounding
plug. To minimize possible shock hazard, the
cord must be plugged into a mating, 3- prong,
grounding-type wall receptacle, grounded in
accordance with the National Electrical ode
and local codes and ordinances. If a mating
wall receptacle is not available, it is the per-
sonal responsibility of the customer to have a
properly grounded, 3-prong wall receptacle
installed by a qualified electrician.

2-2
WATER SUPPLY AND DRAIN CONNECTIONS
CAUTION: To prevent damage to the freezer
mechanism, do not operate this ice maker
when the water supply is OFF, or if the pres-
sure is below 10 PSIG (0.7 bar), the recom-
mended water pressure. Stop the ice maker
until proper water pressure is resumed.
• The water supply inlet is 1/2-14 NPT and
must only be connected to a potable water
supply.
• A water supply line shut-off valve and drain
valve must be installed.
• Water supply pressure should be a minimum
of 10 PSIG (0.7 bar), and a maximum of 113
PSIG (7.5 bar). If the pressure exceeds 113
PSIG (7.5 bar), use a pressure reducing
valve.
Ice Maker
Shutoff Valve
Bin Drain Outlet
Hose 5/8" I.D.
1/4" Fall-Per-Foot
To Approved Floor Drain
Drain Valve (Air or O2 For
Long Term Storage)
• The drain outlet hose is 5/8″ (16mm) I.D. and
internally connected with a 2/3″ (17mm) O.D.
drain outlet.
• The drain must be 1/4″ fall-per-foot (2 cm
fall-per-meter) on horizontal runs for opti-
mum flow.
• Keep a 2 vertical inch (5 vertical cm) air gap
or more between the drain pipe end and the
sink.
• The drain pipe must be used to prevent a
backflow into the storage bin.
• This ice maker should be installed in accor-
dance with applicable national, state,
and local regulations.
Vent
Water Supply Inlet = 1/2-14 NPT

3-1
THEORY OF OPERATION
THE CONTROLS
ICE MAKING CONTROL
The freeze and harvest cycles are controlled
by a thermistor and an electronic control.
The electronic controller uses a thermistor that
is attached to the top of the evaporator to
monitor the evaporator temperature. When the
thermistor signals 28°F (–2°C , the control
begins to count down 10 minutes. The elec-
tronic control then switches the contacts of
relays X1 and X2, which stops the pump and
fan motors, and engerizes the hot gas and
water valves. This completes the freeze cycle,
and starts the harvest cycle.
HARVEST CONTROL
The ice cubes formed inside the ice making
cells are released by hot gas warming the
evaporator. When a small portion of the ice
melts on the ice making cells interior, the ice
drops down the ice guide into the storage bin.
When the evaporator is warmed further (to
approximately 45°F / 7°C , the thermistor sen-
ses the temperature rise, and the electronic
controller begins to count down 50 seconds.
The controller then switches the contacts of the
relays, which starts the pump and fan motors,
and de-energizes the hot gas and water valves.
This completes the harvest cycle, and starts
the freeze cycle. The harvest and freeze cycles
will continue until the bin is full of ice and the bin
thermostat is satisfied.
No Adjustment.
Controls Are Sealed.
If Seals Are Broken,
Replace Control.
At low temperature conditions where the har-
vest cycle exceeds 3 minutes, the water valve
will de-energize after 3 minutes.
At the initial start, or after a power failure, the
ice maker will begin in the harvest cycle, be-
cause the compressor is under a “no load”
condition (hot gas valve is energized . During
this time, any ice that is present on the evapo-
rator will be removed.
In the initial cycle at startup, or after shutdown
for bin control, water is supplied for 80 sec-
onds. The water valve de-energizes approxi-
mately 30 seconds after the freeze cycle starts.
NO ADJUSTMENT
The thermistor and electronic control are fac-
tory adjusted to produce constant ice all year,
and are not affected by changes in the ambient
and water temperatures. No adjustment is re-
quired for any frequency 50/60Hz or ambient
temperature from 45 to 100°F.

3-2
WATER AND REFRIGERANT CIRCUIT

4-1
COMPONENT LOCATIONS
This section instructs you on how to service each component inside the Outdoor Automatic Ice
Maker. The components and their locations are shown below.
COMPONENT ACCESS
Evaporator Thermistor
Water Inlet Valve
Bin Thermostat
On Rear Panel)
Condenser
Compressor
Hot Gas Valve
Behind Compressor)
Evaporator
BOTTOM FRONT OF UNIT
TOP OF UNIT
Master Switch
Condenser Fan Motor
Electronic Control Board
Water Recirculation Pump
Recirculation Pump
Motor Capacitor

4-2
REMOVING THE WATER INLET VALVE
Electrical S ock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in deat or
electrical s ock.
WARNING
1. Unplug ice maker or disconnect power.
2. Turn off the water supply to the ice maker.
3. Move the ice maker to gain access to the
rear of the unit.
4. Disconnect the drain outlet hose from the
ice maker.
5. Disconnect the water inlet line from the ice
maker.
6. Remove the ice from the storage bin.
7. Remove the ice maker door and the top
cover see page 4-22 for the procedures).
8. Remove the two screws from the water
inlet valve.
9. Disconnect the two wires from the water
inlet valve solenoid terminals.
REASSEMBLY NOTES:
• When you reconnect the inlet fill tube to the
water inlet valve, be sure to position it, as
shown in the photo above.
• When you reinstall the water inlet valve and
inlet fill tube in the ice maker, be sure to fit
the tube inside the molded retainer, as shown
at the top of the page.
10. Lift the water inlet valve, release the inlet
fill tube from the molded retainer, and
remove them from the ice maker.
11. Remove the clamp from the inlet fill tube
and remove the tube from the water inlet
valve.
Inlet Fill Tube In Retainer
Clamp
Solenoid Wires
Water Inlet
Valve
Screws

4-3
REMOVING THE EVAPORATOR
Electrical S ock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in deat or
electrical s ock.
WARNING
1. Unplug ice maker or disconnect power.
2. Turn off the water supply to the ice maker.
3. Move the ice maker to gain access to the
rear of the unit.
4. Disconnect the drain outlet hose from the
ice maker.
5. Disconnect the water inlet line from the ice
maker.
6. Open the ice maker door.
7. Remove the ice from the storage bin.
8. Remove the top cover see page 4-22 for
the procedure).
Evaporator
Screw 1 of 4)
9. Remove the four screws from the evapo-
rator.
10. Remove the water inlet valve solenoid
wires from the terminals and move them
out of the way.
11. Remove the evaporator thermistor screw
and remove the thermistor from the evapo-
rator. NOTE: You will need to replace the
thermistor and rebond it to the new evapo-
rator using the sealant provided with the
new thermistor.
12. Protect the area surrounding the two
evaporator joints.
13. Access the sealed system and discharge
the refrigerant into an approved recovery
system.
14. Unbraze the two evaporator joints from
the sealed system and remove the evapo-
rator.
Evaporator Joints
Evaporator Thermistor
Water Inlet Valve

4-4
REMOVING THE WATER RECIRCULATION PUMP
Electrical S ock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in deat or
electrical s ock.
WARNING
1. Unplug ice maker or disconnect power.
2. Turn off the water supply to the ice maker.
3. Move the ice maker to gain access to the
rear of the unit.
4. Disconnect the drain outlet hose from the
ice maker.
5. Disconnect the water inlet line from the ice
maker.
6. Open the ice maker door.
7. Remove the ice from the storage bin.
8. Remove the top cover see page 4-22 for
the procedure).
9. Remove the ice scoop from its holder.
10. Remove the hex screws from the holder
and remove the holder from the unit.
Holder
Ice Scoop
13. Push out on the left and right locking tabs
and pull the water reservoir out of the unit.
11. Squeeze the locking tabs on the tube clip
and remove the tube from the water reser-
voir.
12. Pull the other end of the tube off the water
recirculation pump.
Push Locking Tab Out On Each Side)
Reservoir
90° Tube Clip

4-5
14. Remove the screw from the right side of
the water recirculation pump cover. Grasp
the drain hose at the bottom of the cover,
then pull down and forward, and remove
the cover from the unit.
15. Remove the six screws from the rear chan-
nel cover and remove the cover from the
ice maker.
Water Recirculation
Pump Cover
Screw
Rear
Channel
Cover
Screw 1 0f 6)
19. Remove the four evaporator screws and
the four ice making housing screws.
Ice Making Housing
Screw 1 of 4)
Drain Hose
Evaporator Screw 1 of 4)
16. Disconnect the recirculation pump 3-wire
connector.
17. Cut the indicated wire tie.
18. Remove the green ground wire screw.
Ground Screw
Cut Wire Tie
3-Wire Connector
Continued on t e next page.

4-6
20. Lift the rear of the evaporator and the front
of the ice making component housing,
then slide the housing under the evapora-
tor toward the front of the unit until the
housing clears the evaporator.
21. Rotate the ice making component housing
so you can easily access the recirculation
pump mounting screws.
Ice Making Component Housing
Evaporator
22. Use a 9/32″ socket or a phillips screw-
driver, and remove the recirculation pump
mounting screws.
23. Disconnect the end of the water inlet fill
tube from the recirculation pump and re-
move the pump.
3 Pump Screws
Rotate Housing Over Evaporator
Water Recirculation Pump
Water Inlet Fill Tube