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.™

III
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

IV
• 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

VI

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

VIII

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

4
Air Flow
Air inside the freezer section is cooled when it is drawn across the evaporator and circulated through
the freezer compartment.
Cold freezer air is also drawn into the refrigerator compartment and circulated to remove heat.
Refrigerator Air
Supply Duct
Evaporator Fan
Assembly
Freezer Air
Supply Grille
Freezer Return Air
Through Bottom of
Freezer Floor
Evaporator
Fig. 3
Condenser Fan
Condenser
Compressor

5
Defrost System
Automatic defrost after every eight hours of compressor run time is accomplished by utilizing a defrost
timer thermostat in the control box, a defrost bi-metal thermostat attached to the outlet of the evapotator
and a radiant electric heater suspended beneath the evaporator. (Fig. 4)
The bi-metal thermostat is attached to the outlet side of the evaorator coil tubing (Fig. 7) and opens at
48°F to terminate the defrost heating. About 33 minutes from the start of the defrost cycle, the timer
restores operation to the compressor circuit. (Fig. 5) The bi-metal thermostat contacts close at 13°F,
enabling the defrost heater to operate during the next defrost cycle.
Retaining
Clip
Retaining
Clip
Defrost Heater
Evaporator
Bi-Metal
Thermostat
Fig.4
The defrost heater is suspended on the right side and across the bottom of the evaporator. The defrost
heater also provides warming to the defrost drain area to keep it clear during the defrost cycle.(Fig.6)
Fig.5
Fig.6
Fig.7
Defrost Timer

6
SECTION TWO
CONFIRMATION OF LEARNINGCONFIRMATION OF LEARNING
CONFIRMATION OF LEARNINGCONFIRMATION OF LEARNING
CONFIRMATION OF LEARNING
EXERCISESEXERCISES
EXERCISESEXERCISES
EXERCISES
In the blank to the left of the statement, place a Tif the statement is TRUE or an Fif the statement
is FALSE.
___1. This refrigerator/freezer is provided with a refrigerant heat loop that is foamed in place
around the freezer compartment door.
___ 2. Air flow from the freezer compartment to the refrigerator compartment is regulated through
a motorized air damper door.
___ 3. The defrost timer is located inside the freezer compartment control box.
___ 4. The defrost cycle is designed to occur after eight hours of compressor run-time.
___ 5. The defrost bi-metal thermostat is designed to open at 48°F and close at 13°F.
Label all of the components in the illustration below.

7
Fig. 17
Filter-Drier
Water Supply Valve
Mounting Bracket
Screws
Compressor
Mounting Bolts
Slide-Out
Tray
PULL
OUT
SECTION THREE
COMPONENT ACCESSCOMPONENT ACCESS
COMPONENT ACCESSCOMPONENT ACCESS
COMPONENT ACCESS
Accessing the components in the 25 cu. ft. Top-Mount Refrigerator/Freezer is generally quite similar to
other typical Whirlpool units.
Accessing the Component Compartment
Components located in the component compartment are assembled on a slide-out tray at the bottom of
the unit. The compressor, filter-drier, condenser, condenser fan and water supply valve are located in
this area. To gain access to these components the compartment, heat exchanger and condenser fan
covers must be removed and the tray slid out.
Fig. 8
1. Remove the six (6) hex-head screws
securing the condenser fan cover to the
cabinet. (Fig. 8-A)
2. Remove the six (6) screws securing the
two sections of the heat exchanger cover
to the back of the unit. (Fig. 8-B)
3. Remove the five (5) screws securing the
component compartment cover to the
cabinet. (Fig. 8-C)
4. Remove the two (2) screws securing the
water supply valve to the base rail. (Fig.
8) NOTE: If a water supply valve is mount-
ed on the bracket, it is not necessary to
disconnect the copper supply tubing or the
plastic supply tubing.
Fig. 9
5. Push the filter-drier out of its retaining bracket and gently move it out of the way. NOTE: Take
care not to kink any of the tubing connected to the filter-drier.
6. Remove the two (2) compressor mounting bolts securing the slide-out tray to the lower rear
cabinet rail. (Fig. 9)
7. Carefully slide the tray out from the unit. (Fig. 9) NOTE: The tray can only slide out a few
inches without kinking the tubing. To slide the tray completely out, the sealed system must be
purged and the tubing disconnected.
(B)
Hex-
Head
Screws
(C)
Hex-
Head
Screws
(A)
Hex-
Head
Screws
Condenser Fan
Cover
Compartment
Cover
Heat
Exchanger
Cover

8
Fig. 17
Accessing Component in the Freezer Section
The evaporator, automatic ice maker, and other associated components are all accessible inside the
freezer section.
Removing the Automatic Ice Maker
NOTE: If Ice-Maker needs replacing, use FSP Replacement
Ice Maker.
1. Remove the hex-head screw securing the bottom
bracket to the freezer liner.
2. Loosen the two (2) screws in the slotted brackets at
the top of the automatic ice maker three or four
turns. (These screws must be removed if the
evaporator cover is to be removed.) (Fig. 12)
3. Slide the automatic ice maker up and off the screws.
4. Disconnect the automatic ice maker wiring harness connector and remove the automatic ice
maker from the unit.
5. Remove the extension from the water inlet tube.
Servicing the Evaporator and Other Related Components
The evaporator, evaporator fan, defrost bi-metal and defrost heater are located behind the
evaporator cover.
1. Remove freezer shelf and two (2) screws securing each shelf bracket to the back wall of
the freezer compartment. (Fig. 13)
Accessing the Heat Exchanger and Wiring Harness
The heat exchanger and wiring harness are located under the metal cover on the back of the cabinet.
Remove the six (6) screws securing the cover to the back of the cabinet. (Fig. 10 & 11)
Fig. 12
LOOSEN
THESE SCREWS
Screws
Heat
Exchanger
Wiring
Harness
Fig. 10 Fig. 11
Heat
Exchanger
Cover
REMOVE
THIS SCREW

9
2. Remove the automatic ice maker (if present) or slide the ice cube tray shelf forward to release
it from the (3) stand-off screws securing it to the freezer compartment ceiling.
3. Remove screw securing the rear of the light lens.
4. Remove the two (2) screws securing the freezer ceiling air duct to the top of the freezer
compartment.
5. Pull the air duct down from the freezer compartment ceiling. Take care not to break the five (5)
clips securing the front of the air duct to the ceiling. (Fig. 14)
6. Disconnect the electrical wire to the light switch and light socket and remove the air duct. the
wiring harness will remain attached to a piece of insulating material, which can be moved out of
the way when removing the evaporator cover. (Fig. 15)
7. Remove the remaining screws securing the evaporator cover to the back wall of the freezer
compartment.
Fig. 13
Fig. 14
Fig. 15
Ice Cube Tray
Shelf
Freezer
Shelf
Screws (under lens)
Light Lens
Screw
5
Clips
Air Duct Light Fixture
Wires
Insulation

10
Screws
Fig. 16
Removing the Evaporator Fan Motor
The evaporator fan motor is mounted on a bracket that is attached to a shroud mounted to the back
wall of the freezer section. (Fig. 16)
1. Remove freezer back panels.
2. Remove the two screws mounting the sheet metal cover plate to the bottom of the fan shroud.
3. Remove the two screws mounting the top of the fan shroud to the cabinet.
4. Lay the fan motor and the shroud over and remove wiring.
5. Remove the two screws mounting the bracket
to the motor.
Servicing the Evaporator, Defrost Bi-metal and Defrost Heater
The evaporator, defrost bi-metal and defrost heater are serviceable parts on these units.
Removing the Defrost Bi-metal
1. Remove the freezer back panel.
2. Unclip the thermostat from evaporator coil outlet tube and remove thermostat. (Fig. 17)
3. Cut either the red and blue leads or the blue and gray leads depending on which thermostat to
be removed.
4. When installing a replacement defrost bi-metal, use wire nuts to reconnect the pigtail wires of
the defrost bi-metal to the bare wire harness leads.
Screw Screw
Bi-Metal
Thermostat
Fig.17
Center
Support
Bracket
Cover Plate
Fan Shroud
Center
Support
Bracket

11
Removing the Defrost Heater Element
NOTE: Using this procedure will require the use of a ¼” magnetic nut driver when
removing and installing the three (3) screws securing the evaporator heat
shield. A dropped screw will fall into the condensate drain trough and
possibly be lost into the condensate drain.
1. Remove the freezer back panel.
2. Remove the two (2) screws securing the
cover plate to the bottom of the fan shroud.
(Fig. 18)
3. Remove the center support bracket.
4. Remove the drain tube heat sink. (Fig. 19)
5. Disconnect the wire leads to the heater element.
6. Carefully remove the styorfoam air blocks
from each side of the evaporator. (Fig. 20)
7. Carefully remove the three screws securing
the heat shield to the back wall. (Fig. 20)
8. Carefully lift the evaporator and heat shield
assembly up over the rear lip of the freezer
floor and pull it away from the back wall.
The evaporator can now be detached from
the heat shield hangers and clips.
Screws
Center
Support
Bracket
Fan Shroud
Cover
Plate Fig.18
Fig. 19
Evaporator
Tubing
Heater
Rod
Heat
Sink
Condensate
Drain
Fig. 20
Heat
Shield
Screw
Heat
Shield
Screw
Air
Block
Air
Block
Drain
Trough Drain

12
Accessing Components in the Refrigerator Section
Accessing the Control Box
The control box is located at the front of the refrigerator section and is secured to the refrigerator
compartment ceiling. The control box contains:
• The cold air damper control
• The defrost timer
• Freezer temperature control thermostat
• The switch for the refrigerator compartment lights
• Mullion moisture control switch
1. Remove the two (2) Phillips-head screws securing the front of the control box to the ceiling to
the refrigerator section.
2. Remove the two (2) Phillips-head screws hidden inside the standoffs at the back of the control
box.
3. Move the temperature controls toward the center of the control box to prevent the control racks
from interfering with the removal of the control box.
4. Lower the control box down. Carefully pull the freezer temperature-sensing tube from the hole
in the divider between the freezer and refrigerator compartments.
5. Unplug the six-pin wiring harness connector block and the violet and blue wire connectors.
The control box can now be removed from the refrigerator compartment. (Fig. 22)
Retaining Clip
Defrost Heater
Evaporator
Retaining Clip
Fig. 21
9. remove the two (2) clips securing the
heater to the evaporator bottom and slide
the heater down until it disengages from
the evaporator. (Fig. 21)
Fig. 22
Wiring
Harness
Connector
Violet & Blue Wire Connectors
Air
Damper
Air
Damper
Control
Defrost
Timer
Thermostat
Light
Switch
Mullion Heater
Switch

13
Removing the Damper Control
1. Remove the control box from the unit.
2. Unclip the damper control from the two mounting posts and slide it up and off the posts.
NOTE: Before installing a service replacement damper, rotate the control shaft full
counterclockwise. Install the rack slide in the far right position to synchronize
the damper setting properly.
Removing the Freezer Temperature Control
1. Remove the control box from the unit. (Fig. 22 - page 12)
2. Unclip the freezer temperature control from the mounting post and lift it off.
3. Remove the gasket material and electrical wiring tape securing the temperature -sensing tube
to the control box and unclip the tubing from the stud.
NOTE: Before installing a service replacement freezer temperature control, rotate the
control shaft fully counterclockwise. Install the rack slide to the far right position
to synchronize the thermostat setting properly.
When reassembly the control box, make sure the temperature-sensing tube is
clipped in placing and taped to the control box stud. Slide the insulating cap
over the tube and onto the post to seal the hole in the divider between the
freezer and refrigerator compartments.
Removing the Defrost Timer
1. Remove the control box from the unit.(Fig. 22 - page 12)
2. Unclip the timer from the mounting post.
3. Unplug the the wiring harness connector from the timer terminals.
Removing the Light Switch
1. Remove the control box from the unit.(Fig. 22 - page 12)
2. Snap the switch out of its mounting hole in the control box.
3. Unplug the wire connectors from the switch terminals.
Removing the Exterior Cabinet Moisture Switch
1. Remove the control box from the unit.(Fig. 22 - page 12)
2. Remove the plastic insultation from the switch.
3. Unclip the switch from between the mounting posts.
4. Unplug the wires from the switch terminals.