Kuppersbusch KE 470-2-2T User manual

GB
Fridge-Freezer Combination
Top Mount
KE 470-2-2T

Service Manual: H7-420-64-01-B
Responsible: D. Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Tel.: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 21.08.2000 45801 Gelsenkirchen

Service Manual KE 470-2-2T 3
For internal use only
Contents
1. Introduction ....................................................................................................................4
2. Components ...................................................................................................................6
2.1 Exchanging the temperature regulator .................................................................6
2.2 Defrost Timer ........................................................................................................7
2.3 No-Frost-System ................................................................................................10
2.4 Defrost Heater Replacement ..............................................................................11
2.5 Replacing The Defrost Thermostat ....................................................................11
2.6 Condenser Fan Motor ........................................................................................12
2.7 Freezer Fan Motor ..............................................................................................13
3. Cabinet and Related Components..............................................................................15
3.1 Food Liner ..........................................................................................................15
3.2 Freezer Shelves .................................................................................................15
3.3 Refrigerator Shelves ...........................................................................................15
3.4 Freezer Cold Control .......................................................................................... 17
3.5 Mounting Hardware ............................................................................................18
3.6 Defrost Water Drain System ...............................................................................18
3.7 Cabinet Doors and Associated Parts .................................................................19
3.8 Cabinet Wheels ..................................................................................................21
3.9 Front Wheel Assembly .......................................................................................21
3.10 Cabinet Levelling ................................................................................................ 21
3.11 Door Seal ...........................................................................................................22
3.12 Toe-in & Toe-out Adjustments ............................................................................22
3.13 Hinge Adjustments .............................................................................................23
3.14 Door Alignment ...................................................................................................23
3.15 Door Switch ........................................................................................................23
4. Servicing of Automatic Icemakers (optional) ...........................................................24
4.1 Servicing ............................................................................................................. 24
4.2 Test Procedures .................................................................................................25
4.3 Service Procedures ............................................................................................25
4.4 Accessing the Control Box .................................................................................26
4.5 Module Components ..........................................................................................27
4.6 Water Fill Adjustments .......................................................................................28
4.7 Water Problems ..................................................................................................29
4.8 Temperature Problems .......................................................................................29
4.9 Thermostat .........................................................................................................29
5. Installation.....................................................................................................................31
5.1 Harness ..............................................................................................................31
5.2 Levelling Ice Maker ............................................................................................32
5.3 Removing and Replacing Fill Cup ......................................................................32
5.4 Other Information ...............................................................................................33
5.5 Specifications .....................................................................................................33
6. Troubleshooting ..........................................................................................................34
7. Specification ................................................................................................................40
8. Wiring Diagrams...........................................................................................................41

4 Service Manual KE 470-2-2T
For internal use only
1. Introduction
This refrigeration service manual provides the information necessary to service Top Mount model
refrigerators.
Note: The KE 470-2-2T covered in this Service Manual uses R134a refrigerant.
Each part of this manual is divided into sections relating to a general group of components and each
section is subdivided into various parts describing a particular component or service procedure.
This service manual is a valuable service tool and care should be taken to keep it up to date by prompt
and proper filing of subsequent pages as they are issued.
The following model is covered in this service manual:
KE 470-2-2T
Top Mount Model
H x W x D 710 x 1,739 x 786 mm
incl. handle
Total capacity 464 l
Fridge area 332 l
Freezer area 132 l
Noise level 48 dB
Power consumption 0.19 kWh / 24 h per 100 litres
Energy efficiency class B
No-Frost-System Yes
No-Clean-Condenser Yes
Water inlet with Aquastop Optional
Freestanding unit on rollers Yes
Climazone technology Yes
Icemaker Optional

Service Manual KE 470-2-2T 5
For internal use only
General
The American style Fridge-Freezer Combination “Top Mount“ is the centrepiece of any kitchen. The high
quality of workmanship and finish, including stainless steel front, side and top panels, guarantee many
years of proud ownership.
The appliance is fitted with state of the art technology, such as:
♦No-Frost-System
♦No-Clean-Condenser
♦As the compressor is cooled from the front, both the front
and rear panels are flat, to allow flush fitting to a wall.
♦Water inlet with Aquastop
♦Self-closing doors with magnetic catches
♦Freestanding unit on rollers
♦Climazone technology
Freezer area
Refrigerator area
“Keep Fresh” zones
(for fruit, vegetables and cheese)

6 Service Manual KE 470-2-2T
For internal use only
2. Components
2.1 Exchanging the temperature regulator
1. Disconnect the appliance from the mains.
2. Open the fresh food door and remove any items on the top shelf.
3. Undo the front screw of the regulator housing.
Undo the rear screws, whilst holding the front section of the temperature regulator housing.
Then pull the housing downwards.
4. Undo the screws on the rear of the regulator housing. Push the regulator housing towards the
right and remove from its holder.
5. Disconnect the push-on connectors from the temperature regulator housing.
6. Take the temperature regulator housing out of the fridge-freezer and place it on a level work
surface.
7. Take the regulator out of the housing.
8. Pull the cables away from the clips on the temperature regulator housing.
9. Remove the regulator by applying pressure to the locking mechanism with your right thumb.
Turn and remove the regulator with your left hand.
10. To remove the heatsink, insert the blade of a screwdriver between the heatsink and the
regulator housing. Turn the screwdriver to release.
11. Fit the replacement housing in reverse order.
ScrewdriverHeatsink
Regulator housing

Service Manual KE 470-2-2T 7
For internal use only
2.2 Defrost Timer
The freezer evaporator defrosting system is actuated by an electric timer. The timer is mounted in the
control housing located in the fresh food compartment.
The timer control shaft is designed for screwdriver advancement. When manually setting the timer to
initiate defrosting, turn the control shaft clockwise until you establish the approximate location of the
defrost cycle. Then turn the shaft slowly, stopping as soon as you hear the first click. The diagram
illustrates the timer circuits in sequence.
Control housing
Defrost Timer
To advance defrost timer, turn
clockwise.

8 Service Manual KE 470-2-2T
For internal use only
1st Click – The timer turns off the compressor and freezer fan circuit for approximately 21 minutes, and
it energizes the defrost heater. Once the temperature of the defrost termination thermostat reaches
the cut-out point, the termination thermostat will open the circuit to the radiant heater. However, the
compressor circuit remains open for the duration of the defrost interval
2nd Click – The timer switches off the defrost circuit and starts the compressor, freezer fan, and the
condenser fan motor. The compressor and fan motors are now governed by the temperature control for
a period of approximately 8 hours of the compressor run time, after which a new defrost cycle begins.
.
Line (blue)
Timer
motor Defrost
thermostat
to compressor
(orange)
Defrost heater
Second click: Normal operation
Line
(white) yellow
Line (blue)
Line
(white) Timer
motor Defrost
thermostat
to compressor
(orange)
yellow
Defrost heater
First click: Defrost operation
N. 2 , yellow
N. 1, white
N. 4, orange
N. 3 , blue

Service Manual KE 470-2-2T 9
For internal use only
2.2.1 Checking the Defrost Timer
Disconnect all wires from the timer and attach ohmmeter probes to the terminals specified in the
accompanying chart. If no continuity is indicated, the timer is defective.
2.2.2 Timer Replacement
1. Disconnect the unit from the mains.
2. Open the fresh food door and remove any items on the top shelf.
3. Remove the front mounting screw in the temperature control housing.
4. Whilst holding the front of the temperature control housing, remove the rear mounting screw.
Lower the temperature control housing.
5. Disconnect the temperature control housing electrical quick disconnect.
6. Remove the temperature control housing from the refrigerator and place on a flat work surface.
7. Gently push the timer until it clears the two front locking tabs.
8. Rotate timer up toward back of housing.
9. Lift timer towards the front of the housing to clear the rear locking tab.
10. Disconnect the electrical connector from the timer.
11. Install the replacement timer in reverse order of removal.
To Test Turn Timer Knob
to Check between Terminals
Timer Motor Circuit Leave as is 1 + 3*
Defrost Circuit 1st Click 1 + 2
Compressor Circuit 2nd Click 1 + 4

10 Service Manual KE 470-2-2T
For internal use only
2.3 No-Frost-System
These models use a radiant heater to remove accumulated frost from the freezer evaporator and drain
through during a defrost cycle.
The defrost timer switches on the defrost heater every 8 hours (with reference to the actual run time of
the compressor). As soon as the temperature in the proximity of the thermostat reaches a value of
approx +3.3 °C , the thermostat interrupts the circuit to the defrost heater. The defrost heater is a spiral
wound resistance wire enclosed in a heat resistant glass tube.
An ohmmeter check will determine if all phases of the defrost cycle are functioning properly. The defrost
thermostat contacts open at approximately +3.3°C, and closes at approximately -9.4°C.
The defrost thermostat has a 240 K ohm resistor connected internally across the two terminals. This
resistor enables the defrost heater to be checked when the evaporator is -9.4°C, or higher.
An ohmmeter can be used to test the defrost heater and thermostat without disassembling the freezer
compartment even if the evaporator temperature is -9.4°C or higher. To check, proceed as follows:
1. Disconnect the unit from the mains.
2. Open the fresh food door and remove any items on the top shelf.
Remove the front mounting screw in the temperature control housing. Whilst holding the front of
housing, remove the rear mounting screw. Lower the control housing.
3. Disconnect the timer wire harness connector from the defrost timer.
4. Set the ohmmeter to 1 kOhm and connect the probes to the No. 2 and No. 3 terminals of the
disconnect plug.
5. The meter should read between 100 to 200 ohms. The resistance is not critical. The heater is
working if there is continuity between terminals No. 2 and No. 3. If there are no resistance
readings (open circuit) the defrost heater and thermostat must be checked separately.
NOTE: When using the meter, avoid touching the probes as this could result in a false reading and
misdiagnosis.
To test defrost heater and thermostat when the evaporator temp. is -9.4°C (or below) proceed as follows:
1. Switch on the watt meter.
2. Manually advance the defrost timer to the defrost cycle. See the defrost timer section for infor-
mation on manually advancing the timer.
3. The wattmeter should read between 1.8A ± 10% depending on the model (total wattage of the
timer motor and defrost heater). If the reading is 0 and 20mA is displayed, the defrost heater or
thermostat is defective. To further isolate the defective part, proceed to step 4.
4. Disconnect the unit from the watt meter.
blu
blu white
Defrost-thermostat
FOR DIAGNOSTIC CONTINUITY CHECK 240 K-OHMS
Radiant-heater
yellow
white
orange

Service Manual KE 470-2-2T 11
For internal use only
5. Follow step 2 and 3 of ”Testing the Heater and Thermostat” when the evaporator temperature is
-9.4°C, or higher.
6. If the meter reads approximately 240K ohms, the defrost thermostat is defective.
To use an ohmmeter, set the meter to 1k ohm. If the reading is approximately 100 to 200 ohms, the
defrost heater and thermostat are operative.
2.4 Defrost Heater Replacement
1. Disconnect the unit from the mains.
2. Remove the icemaker, if fitted.
3. Remove the evaporator cover by loosening the top 4 screws on each corner of the cover and
removing the bottom screws on each corner.
4. Tilt the top of the evaporator cover forward and disconnect the wire harness connector.
5. Remove the evaporator cover and fan motor assembly. It is very important that this part be
reinstalled in the same manner as it was originally.
6. Disconnect the defrost heater wire leads. Using long nose pliers, remove the defrost heater
retainer clips. (One on the right side of the heater and one on the left side).
7. Remove the heater and the shield.
Note the placement and orientation of the shield. It goes between the heater and the evaporator
cover.
8. Install the replacement heater in the reverse order of removal.
NOTE: When installing the replacement heater, do not touch the glass. Salt from fingertips
could cause damage.
2.5 Replacing The Defrost Thermostat
The defrost termination thermostat is located on the top right
side of the evaporator.
1. Follow the first five steps in replacing the
heater.
2. Disconnect the leads from the thermostat.
3. Remove the defrost thermostat and mounting clip. This
is done by releasing the mounting clip that is snapped
around the evaporator tubing.
4. Install the new defrost thermostat in the reverse order of
removal. Make sure the thermostat is located as per the
drawing.
Defrost thermostat 1/4“
minimum clearance between
the thermostat
and tube joint
Radiant heater clip
Radiant heater and shield Lower front and rear coil passes
Foam

12 Service Manual KE 470-2-2T
For internal use only
2.6 Condenser Fan Motor
The condenser fan motor is connected in parallel with the compressor. If the compressor runs but the
motor doesn’t, the motor is either defective or disconnected. If neither operates, check the cold control,
defrost timer, and the cabinet wiring.
2.6.1 To Check The Condenser Motor Direct
1. Disconnect the unit from the power source.
2. Remove the insulated cover from the rear of the cabinet.
3. Disconnect the condenser fan motor lead connector on the motor terminals.
To remove the lead connector from the condenser fan motor, grasp the connector with your
thumb inserted between the connector and the locking lever as shown. Pull the connector away
from the motor.
4. Attach a 230V test cable to the condenser motor and connect to the mains. If the motor fails to
operate, it is defective and must be replaced.
2.6.2 Condenser Fan Motor Replacement
1. Disconnect the unit from the power source and remove the insulated cover from the rear
of cabinet.
2. Disconnect the condenser fan motor lead connector on the motor terminals.
3. Remove the screws that mount the fan motor to the brackets.
4. Transfer the fan blade to the replacement motor, making sure it is installed in the same manner
as the original.
5. Install the fan motor leads and earth wire.
6. Install those parts previously removed. Test run the unit.

Service Manual KE 470-2-2T 13
For internal use only
2.7 Freezer Fan Motor
The freezer fan circulates the cooled air throughout the fresh food and freezer compartment. The fan
blade is made of polyethylene and is pushed onto the shaft. It is important when replacing the fan blade
that the hub of the fan blade faces outward towards the back of the freezer air tower. If the fan fails or
operates erratically, the reduced air circulation will result in poor cooling characteristics.
2.7.1 Freezer Fan Motor Diagnosis
1. Disconnect the unit from the power source.
2. Remove the icemaker, if fitted.
3. Remove the freezer shelving.
4. Remove the evaporator cover mounting screws.
5. Tilt the top of the evaporator cover forward and disconnect the wire harness connector.
6. Remove the evaporator cover and fan motor assembly and place it on a work surface.
7. Disconnect the evaporator fan motor leads. The wire leads are self-locking and it is important to
squeeze the clip before pulling the leads off the terminals. Connect the motor terminals to a
power cable and connect the cable to the mains.
8. If the motor fails to operate, it is defective and must be replaced.
Freezer air
tower

14 Service Manual KE 470-2-2T
For internal use only
2.7.2 Freezer Fan Motor Replacement
1. Follow steps 1 to 5 ”Checking the Freezer Fan Motor”.
2. Remove the freezer air tower from the cover by pressing the mounting tabs inward. Remove the
screws that secure the motor bracket assembly to the evaporator cover.
3. Remove the fan blade by pulling it off the shaft.
4. Remove the screws that secure the rear bracket to the front bracket. Remove the motor from
the rear mounting bracket.
5. Install the new motor in the rear mounting bracket. Mount the rear bracket to the front mounting
bracket.
6. Install the fan blade on the replacement in the same position as on the original motor shaft.
7. Install the motor and bracket assembly onto the evaporator cover.
8. Connect the wire leads and the earth wire to the motor.
9. Reassemble those parts previously removed and test the unit.
The fan blade is provided with a stop on the face of the hub. When the blade is positioned so the stop
rests against the end of the shaft, it is properly installed.

Service Manual KE 470-2-2T 15
For internal use only
3. Cabinet and Related Components
3.1 Food Liner
All food liners are made of a high impact polystyrene material which has a glossy surface. All models are
produced with foamed-in-place insulation.
3.2 Freezer Shelves
The freezer area is equipped with a full width adjustable freezer shelf. This shelf can be removed by lift-
ing the left end up about 1.5 cm and pulling the right end bars out of the sockets in the side wall. Reverse
the removal procedure to replace the shelf, making sure the left end bars are pressed completely into
the supports.
3.3 Refrigerator Shelves
Adjustablefreezer
shelf
Crispershelves

16 Service Manual KE 470-2-2T
For internal use only
3.3.1 Adjustable Cantilever Shelves
Glass or wire cantilever shelves may be available with your refrigerator. To remove a shelf, tilt front up
and lift the rear up a fraction of an inch and pull straight out. To lock the shelf into another position, tilt
the shelf with the front up. Insert hooks into desired shelf openings and let the shelf settle into place.
Make sure that the shelf is securely locked into position before loading it with food.
3.3.2 Cantilever Shelf Trim
The cantilever shelf trims are easily removed by placing the shelf on a flat work surface. Raise the front
of the shelf, grasp the right underside of the front trim, and pull towards you. Next, remove the glass from
the rear trim and remove trim.
Install the new rear trim on the glass. Place the shelf in a vertical position (shelf front up). Install the glass
and rear trim by applying a downward force on the rear metal shelf cross brace until it snaps securely
into place. Next, install the front trim on the glass and the front metal shelf cross brace.
3.3.3 Crisper Shelves
1. Remove cantilever shelves if needed to allow removal of crisper.
2. Remove crisper drawers by pulling out to the stop. Lift and pull again.
3. Carefully remove glass. The glass just lays on the shelf.
4. Lift crisper shelf and pull forward. Tilt to one side to remove from the refrigerator.
5. Reverse procedure to reinstall.

Service Manual KE 470-2-2T 17
For internal use only
3.4 Freezer Cold Control
The freezer control is located in the temperature control housing of the fresh food compartment. The
control knob is connected to a damper by an actuator arm and actuation tape. By turning the freezer
control knob toward a higher number you can reduce the flow of chilled air into the fresh food
compartment; thus lowering the temperature of the freezer compartment.
By turning towards a lower number, you increase the flow of chilled air into the fresh food compartment
and decrease the flow of the freezer compartment.
Replacing The Manual Freezer Damper Control
1. Disconnect the unit from the mains.
2. Open the fresh food door, then remove any food products on the top shelf.
3. Remove the front mounting screw in the temperature control housing.
4. While holding the front of the temperature control housing, remove the rear mounting screw,
and lower control housing.
5. Disconnect the temperature control housing electrical quick disconnect.
6. Remove the temperature control housing from the refrigerator and place on a flat work surface.
7. Lift the damper control up just enough so that you can turn the damper arm to separate from the
actuation tape.
8. Replace the damper control.
9. Assemble the parts by following the reverse order of removal.
Actuation tape
Actuator arm
Rear locking taps
Front locking taps
Control knob
set at N.1

18 Service Manual KE 470-2-2T
For internal use only
Replacing The Freezer Control Actuator Arm And Tape:
Do Steps 1-6, “Replacing the Manual Damper Control“
1. Lift up the actuator arm to disengage it from the control knob and front locking tabs.
2. Rotate actuator arm counterclockwise and lift it out to clear the rear locking tabs.
3. Remove the actuator arm from the actuation tape.
4. Install the replacement parts in the reverse order.
3.5 Mounting Hardware
Nylon Snap Nuts
Snap nuts are in places where a screw must mount in the liner.
To remove a snap nut, pry it loose with a small screwdriver or putty knife.
Install a snap nut by pressing the nut into the opening until it snaps into place.
3.6 Defrost Water Drain System
Defrost water collects in the evaporator drip tray and drains into a trough in the fresh food control
housing. Next, the water passes through a restricted opening and into a 90° elbow which joins to the
drain tube. (The restricted opening prevents foreign objects from blocking the drain system.) The drain
tube is located in the insulation cavity and drains the water into a pan located under the cabinet.
NOTE: A trap is incorporated with the drain tube to prevent warm air from entering into the
refrigerator.

Service Manual KE 470-2-2T 19
For internal use only
3.7 Cabinet Doors and Associated Parts
3.7.1 Paint Touch-Up
Painted areas of the cabinet doors that become scratched or marked can be touched up with enamel.
The original paint finish is a high solids polyester type.
Never use lacquer anywhere on the cabinet where it could come into contact with
the door seal.
Lacquer will damage the vinyl material in the seal.
3.7.2 Inner Door Liner Replacement
The polystyrene inner door liner and the door seal are mounted to the outer panel by screws placed
around the door flange. The inner door liner can be replaced without removing the door from the cabinet.
If it is necessary to remove the door liner, proceed as follows:
1. Turn the control to the ”OFF” position.
2. Open the freezer door and remove the screws from around the door flange.
3. Remove the door liner and transfer the seal to the replacement liner. Make sure the lip of the
seal will sandwich between the inner and outer door panel.
4. Position the replacement door liner and loosely install all the screws around the door flange.
5. Open and close the door several times to check the seal for proper alignment.
6. Carefully open the door by pulling on the middle of the door panel.
NOTE: Do not pull the door by the handle or the panel will shift out of alignment.
7. Tighten all corner screws.
8. Open and close the door several times. Recheck the door seal for proper alignment. If align-
ment is correct, tighten the remaining screws.
Tighten the screws until they are just snug, then turn clockwise another one-half turn.
NOTE: Do not attempt to twist the door panel after all screws have been tightened.
9. Transfer the shelves and the trim to the replacement liner.
3.7.3 Outer Door Panel Replacement
Upper door
NOTE: Remove all food from the freezer door.
1. Turn the control to the ”OFF” position.
2. Remove door handle and trim.
3. Use a soft lead pencil to trace around the upper hinge. (This will aid in replacing the hinge).
4. Remove the upper hinge and place it on top of the unit with newspaper or cloth underneath to
prevent scratching. Do not misplace the spacers. Place the door on a padded work surface.
5. Transfer the handle, trim, plug button, bushings, gaskets and liner to replacement panel.
6. Install the top hinge using the tracing to align the hinge.

20 Service Manual KE 470-2-2T
For internal use only
Lower Door
NOTE: Remove all food from the fresh food door.
1. Remove upper door.
2. Remove the interior centre hinge screw and carefully open the door pulling it over far enough so
the centre hinge clears the outside shoulder screw. Lift the door up and off the lower hinge pin.
3. Place the door on a padded work surface.
4. Transfer the handle, trim, plug button, bushings, door seal, (metal retaining strips if used) and
liner to the replacement panel. Do not tighten the liner mounting screws.
5. Position door onto bottom hinge and mount the door on the centre hinge. Close the door.
6. Install the upper door and hinge.
7. Open and close the doors and tighten the liner mounting screws.