KitchenAid Job Aid 4322312 User manual

I
TECHNICAL EDUCATION
JOB AID 4322312
KAR-8
G-MODEL
25 cu. ft. TOP-MOUNT
REFRIGERATOR/FREEZER

II
INTRODUCTION
This Job Aid, 1998 "G" Model, 25 cu. ft. TOP-MOUNT REFRIGERATOR/FREEZERS, (Part No.
4322312) provides specific information for the installation, service and repair of 1998 "G" Model 25 cu.
ft. Top Mount Refrigerator/Freezers.
1998 "G" Model, 25 cu. ft. T0P-MOUNT REFRIGERATOR/FREEZERS has been compiled to provide
the most recent information on design, features, troubleshooting, service and repair procedures.
Whirlpool-required sweep charge procedures are to be strictly adhered to when repairing the sealed
system. For a complete explanation of those procedures, refer to the Job Aid, SWEEP CHARGE
PROCEDURES FOR THE 90's, (Part No. 4321717) and its companion video (Part No. 4321718.)
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 1998 "G" Model 25 cu. ft. Top-Mount Refrigerator/Freezers.
The objectives of the Job Aid are:
The service technician will -
• Understand proper safety precautions.
• Follow proper refrigerant recovery procedures.
• Successfully troubleshoot and diagnose malfunctions.
• Successfully perform necessary repairs.
• Successfully return the refrigerator/freezer to proper operational status.
TO THE INSTRUCTOR/INDEPENDENT STUDENT
At the end of certain sections of this Job Aid you will find a "Confirmation of Learning Exercise." A
pencil will be necessary to complete these exercises. Certain exercises may require that service
procedures be performed if an appropriate appliance is available.
Inc.Inc.
Inc.Inc.
Inc.
For the way it's made.™

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TABLE OF CONTENTS
INTRODUCTION ..................................................................................... II
TABLE OF CONTENTS ......................................................................... III
SAFETY ......................................................................................................... IV
R134a REFRIGERANT SERVICE INFORMATION ......................................... V
SECTION ONE
INSTALLATION CONSIDERATIONSINSTALLATION CONSIDERATIONS
INSTALLATION CONSIDERATIONSINSTALLATION CONSIDERATIONS
INSTALLATION CONSIDERATIONS ..............................................
..............................................
....................... 1
SECTION TWO
THEORY OF OPERATIONTHEORY OF OPERATION
THEORY OF OPERATIONTHEORY OF OPERATION
THEORY OF OPERATION
Temperature Control....................................................................................3
Refrigerant Flow ..........................................................................................3
Air Flow .........................................................................................................4
Defrost System .............................................................................................5
SECTION THREE
COMPONENT ACCESSCOMPONENT ACCESS
COMPONENT ACCESSCOMPONENT ACCESS
COMPONENT ACCESS
Accessing the Component Compartment .................................................7
Accessing the Heat Exchanger and Wiring Harness ................................8
Accessing Components in the Freezer Compartment .............................8
Accessing Component in the Refrigerator Compartment .....................12
SECTION FOUR
DIAGNOSIS AND TROUBLESHOOTINGDIAGNOSIS AND TROUBLESHOOTING
DIAGNOSIS AND TROUBLESHOOTINGDIAGNOSIS AND TROUBLESHOOTING
DIAGNOSIS AND TROUBLESHOOTING
Troubleshooting Guide ..............................................................................15
Diagnostic Information ..............................................................................17
SECTION FIVE
TECH TIPSTECH TIPS
TECH TIPSTECH TIPS
TECH TIPS
Typical External Sweat Patterns ...............................................................19
Wiring Harness Schematic ........................................................................20
Wiring Diagram ..........................................................................................21
Strip Circuits ..............................................................................................22
Serial and Model Number Designators ....................................................24
KitchenAid Warranty ..................................................................................25

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• The power cord must be plugged into a 3-prong, grounding-type
wall receptacle, grounded in accordance with the National Electrical
Code, ANSI/NFPA 70 - latest edition and local codes and
ordinances.
• It is the personal responsibility of the consumer to have a proper
3-prong wall receptacle installed by a qualified electrician.
• DO NOT, UNDER ANY CIRCUMSTANCES, REMOVE THE
POWER CORD GROUNDING PRONG.
• A separate adequately fused and grounded circuit should be
available for this appliance.
• Do not remove any grounding wires
from individual components while
servicing, unless the component is
to be removed and replaced. It is
extremely important to replace all
grounding wires when components
are replaced.
SAFETY
To avoid the risk of electrical shock,
property damage, personal injury or death:
! WARNING
Grounding Type
Wall Receptacle
Power Supply Cord
with 3-Prong
Grounding Plug
! WARNING
ELECTRIC SHOCK HAZARD
Disconnect the electrical power before servicing any components .
Failure to do so can result in death or electrical shock.
! WARNING
PERSONAL INJURY HAZARD
This unit has several sharp edges in areas where you will be working to
remove components for service. Wear protective gloves where sharp
edges are present.

V
R134a REFRIGERANT
Service Information
This product uses R134a refrigerant. This refrigerant requires synthetic Ester oil in the compressor.
This cooling system does not tolerate contamination from any of the following:
• Other Refrigerants
• Moisture
• Petroleum-based Lubricants
• Silicone Lubricants
• Cleaning Compounds
• Rust Inhibitors
• Leak Detection Dyes
• Any Other Type of Additive
As a result the following precautions should be observed:
• Use equipment dedicated to R134a sealed system service only.
• Do not leave a replacement compressor open to the atmosphere for more than 10 minutes.
• Always replace the filter-drier when performing any repairs on the sealed system.
•USE ONLY R134a REFRIGERANT FOR BACKFLUSHING AND SWEEP PROCEDURES.
• If the rubber plugs on the service replacement compressor appear to have been tampered
with or removed, DO NOT USE THE COMPRESSOR. Get another one.
• The filter-drier MUST be cut from the sealed system. Never unbraze the filter-drier from
system tubing. Applying heat will drive moisture back into the sealed system.
SEE SWEEP CHARGE PROCEDURES FOR THE 90's,
Part No. 4321717 FOR COMPLETE INSTRUCTIONS ON
SERVICING THE SEALED SYSTEM.
R134a
1,000 ppm
No effect
Can cause frostbite
Very slight irritation
Can cause frostbite
Can cause asphyxiation,
tachycardia and cardiac
arrhythmias.
Wear appropriate skin and
eye protection. Use adequate
ventilation.
Remove or Extinguish Ignition
or Combustible Sources.
Evacuate or Ventilate Area.
May decompose if contact is
made with flames and heating
elements. Container may
explode if heated due to
pressure rise. combustion
products are toxic.
The procedures / rules for R12
also apply to R134a.
Reclaim
HEALTH AND SAFETY HANDLING
Allowable Overall Exposure Limit
Vapor Exposure to Skin
Liquid Exposure to Skin
Vapor Exposure to Eyes
Liquid Exposure to Eyes
Above Minimum Exposure Limit
Safety and Handling
Spill Management
Fire and Explosion Hazards
Storage Conditions
Disposal Procedure

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VII
Section Three
True or False Statements:
1. ___
2. ___
3. ___
4. ___
5. ___
Section Two
True or False Statements:
1. ___
2. ___
3. ___
4. ___
5. ___
ANSWER SHEET
CONFIRMATION OF LEARNINGCONFIRMATION OF LEARNING
CONFIRMATION OF LEARNINGCONFIRMATION OF LEARNING
CONFIRMATION OF LEARNING
EXERCISESEXERCISES
EXERCISESEXERCISES
EXERCISES
T
F
FF
T
T
T
T
F
T
F
F
F
T
T
Section One
True or False Statements:
1. ___
2. ___
3. ___
4. ___
5. ___
Section One
Label the Components:
Evaporator
Condenser
Compressor
Filter Dryer
Process
Tube
Capillary Tube
Evaporator
Outlet
Condenser
Outlet
Heat
Loop

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IX

3
SECTION TWO
THEORY OF OPERATIONTHEORY OF OPERATION
THEORY OF OPERATIONTHEORY OF OPERATION
THEORY OF OPERATION
TEMPERATURE CONTROL
Freezer temperature is regulated by an air-sensing thermostat inside the control box located at the top
front of the refrigerator compartment. This thermostat actuates the compressor to circulate refrigerant
through the sealed system to remove heat from the freezer and refrigerator sections. The thermostat
should be set to maintain 0° - 5°F freezer food temperature.
Refrigerator temperature is regulated by an automatic air damper control. The air damper control is a
thermostat that manually actuates the air damper door. This control governs the amount of refrigerated
air entering the refrigerator compartment. The control should be set to maintain 38°F to 40°F fresh
food temperature.
Refrigerant Flow
Refrigerant is pumped from the compressor and passes through the condenser, the heat loop around
the freezer compartment opening, the filter drier, capillary tube, evaporator and the suction line back to
the compressor.
The heat loop is made of a continuous piece of copper tubing with no brazed joints.
Fig. 2
Evaporator
Condenser
Compressor
Filter Drier
Process
Tube
Capillary
Tube
Evaporator Outlet
Condenser
Outlet
Heat