Kuppersbusch KE 650-2-2T User manual

GB
Fridge-Freezer Combination
Side-by-Side
KE 650-2-2T

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

Service Manual KE 650-2-2T 3
For internal use only
Contents
1. Introduction ....................................................................................................................4
2. Components ...................................................................................................................6
2.1 Auto Damper Control Models ...............................................................................6
2.2 Defrost Timer ........................................................................................................9
2.3 No-Frost-System ................................................................................................12
2.4 Defrost Heater Replacement ..............................................................................13
2.5 Defrost Thermostat Replacement ......................................................................13
2.6 Condenser Fan Motor ........................................................................................14
2.7 Freezer Fan Motor ..............................................................................................15
3. Cabinet and Related Components ............................................................................. 17
3.1 Adjustable Cantilever Shelves ............................................................................17
3.2 Cantilever Shelf Trim ..........................................................................................17
3.3 Cabinet Doors and Associated Parts .................................................................18
3.4 Front Wheel Assembly .......................................................................................18
3.5 Cabinet Levelling ................................................................................................19
3.6 Door Seal ...........................................................................................................19
3.7 Toe-in & Toe-out Adjustments ............................................................................19
3.8 Hinge Adjustments .............................................................................................20
3.9 Door Alignment ...................................................................................................20
3.10 Door Switch ........................................................................................................20
3.11 Water/Ice Dispenser Freezer Door Removal .....................................................21
3.12 Fountain Assemblies – Manual Slide Control .....................................................23
3.13 Ice Crusher Bin Shelf Assembly .........................................................................26
3.14 Ice/Crusher Bin Shelf Enclosure Assembly ........................................................28
4. Ice-maker ...................................................................................................................... 30
4.1 Servicing ............................................................................................................. 30
4.2 Test Procedures .................................................................................................31
4.3 Service Procedures ............................................................................................31
4.4 Accessing the Control Box .................................................................................32
4.5 Module Components ..........................................................................................33
4.6 Water Fill Adjustments .......................................................................................34
4.7 Water Problems ..................................................................................................35
4.8 Temperature Problems .......................................................................................35
4.9 Thermostat .........................................................................................................35
5. Installation .................................................................................................................... 37
5.1 Harness ..............................................................................................................37
5.2 Leveling Icemaker ..............................................................................................38
5.3 Removing & Replacing Fill Cup ..........................................................................38
5.4 Other Information ...............................................................................................39
6. Troubleshooting ..........................................................................................................40
7. Specifications ...............................................................................................................46
8. Wiring diagrams ..........................................................................................................47

4 Service Manual KE 650-2-2T
For internal use only
1. Introduction
This refrigeration service manual provides the information necessary to service Side-by-Side model
refrigerators.
Note: The KE 650-2-2T 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 models are covered in this service manual:
KE 650-2-2T
Side-by-Side Model
W x H x D 915 x 1.815 x 733 mm
incl. handle
Total capacity. 603 l
Fridge area 402 l
Freezer area 201 l
Noise level 47 dB
Power consumption 1,9 kWh / 24 h
Energy efficiency class B
No-Frost-System Yes
No-Clean-Condenser Yes
Water inlet with Aquastop Yes
Free-standing unit on rollers Yes
Climazone technology Yes

Service Manual KE 650-2-2T 5
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General
The American style Fridge-Freezer Combination “Side-by-Side“ 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
♦Free-standing unit on rollers
♦Climazone technology
♦Automatic icemaker with dispenser and
separate light switch
Freezer area
Refrigerator area
Keeps food fresh for twice as long
“Keep fresh” chiller zone (around 0°C)
(ideal for meat and fish)
“Keep fresh” zones
(for fruit, vegetables and cheese)

6 Service Manual KE 650-2-2T
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2. Components
2.1 Auto Damper Control Models
The Auto Damper model refrigerator has two controls and both have capillary sensing. The Auto Damper
controls the fresh food temperature and the Freezer Temperature Control guides the freezer
temperature.
The fresh food compartment temperature is maintained by a damper assembly located at the back of the
temperature control housing. Changes in air temperature cause the damper door to open and close.
A control rod and gear connect the fresh food control knob to the damper control.
Turning the fresh food control knob to the
warmest position decreases the flow of chilled air into the fresh
food section. The freezer compartment temperature control warms at a slower rate and cools at a faster
rate, decreasing the compressor run time necessary to maintain a satisfied freezer temperature control.
Turning the fresh food control knob to a
warmer setting decreases the flow of chilled air into the fresh
food section. The freezer compartment temperature controls warms at a slower rate and cools at a faster
rate, decreasing the compressor run time necessary to maintain a satisfactory freezer temperature
control.
2.1.1 Checking the Auto Damper
1. Disconnect the unit from the mains supply.
2. Open the fresh food door and remove any items on the top shelf.
3. Set the fresh food control to the coldest position.
4. Remove the light shield cover by pulling down on the back corners of the cover and sliding the
cover forward.
5. Remove the fascia/radiant shield mounting screws. Remove the control housing mounting
screw at the back, bottom centre of the control housing. Slide the control housing to the right.
Lower the control housing.
6. Disconnect the temperature control housing electrical quick disconnect.
7. Remove the temperature control housing from the refrigerator and place on a flat work surface.
8. Remove the auto damper control rod retainer, control rod and the slide control gear from the
auto damper control.
9. Turn the control housing over.
10. Remove the two auto damper mounting screws, then remove the auto damper from the control
housing.
11. Mark the auto damper rod approximately 6 mm away from the housing.
12. Uncoil the auto damper capillary tube approximately 100 mm.
13. Submerge into a glass of ice (no water). Watch for door to move to the closed position.
14. Remove from ice and warm capillary tube (use your hand). Watch door for opposite reaction.
15. If no movement is detected, replace the control.

Service Manual KE 650-2-2T 7
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2.1.2 Exchanging the temperature regulator
1. Disconnect the appliance from the mains supply.
2. Open the fresh food door and remove any items on the top shelf.
3. Remove the light cover. To do this, pull the rear corners down and slide the cover forwards.
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.
Rear
Heatsink
Regulator housing
Front

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2.1.3 Auto Damper Control Replacement
1. Complete steps 1 through 10, checking auto damper.
2. Reinstall new auto damper.
3. Reinstall control housing in reverse order of removal.
2.1.4 Auto Damper Control - Exploded View

Service Manual KE 650-2-2T 9
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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, and stop immediately when the first click is heard. The
schematic illustrates the timer circuits in sequence.

10 Service Manual KE 650-2-2T
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1st Click – The timer turns off the compressor and freezer fan circuit for approximately 23 minutes, and
it energises 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.

Service Manual KE 650-2-2T 11
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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.
* See Maytag Monthly Bulletin, June 1993 volume: 03 Issue 40 Page 1 Low watt Timers (this test works on all low watt
timers).
2.2.2 Timer Replacement
1. Disconnect the unit from the mains supply.
2. Open the fresh food door and remove any items on the top shelf.
3. Remove the light shield cover by pulling down on the back corners of the cover and sliding the
cover forward.
4. Remove the fascia/radiant shield mounting screws. Remove the control housing mounting
screw at the back of the control housing. Slide the control housing to the right and lower it from
the control housing supports.
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. Remove the two timer mounting screws.
8. Disconnect the electrical connector from the timer.
9. 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

12 Service Manual KE 650-2-2T
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2.3 No-Frost-System
These models use a metal sheath heater to remove accumulated frost from the freezer evaporator and
drain through during a defrost cycle. The defrost timer (models) energises the defrost heater every 8
hours of accumulated compressor run time. When the temperature in the thermostat area reaches
approximately +6.1°C, the thermostat contacts open the circuit to the defrost heater.
An ohmmeter check will determine if all phases of the defrost cycle are functioning properly. The defrost
thermostat contacts open at approximately +6.1°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 permits checking the defrost heater 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 supply.
2. Open the fresh food door and remove any items on the top shelf. Remove the light shield and
the fascia/radiant shield mounting screws in the temperature control housing, remove the rear
mounting screws. Lower the control housing.
3. Disconnect the timer wire harness connector from the defrost timer.
4. Set the ohmmeter to R x 1K scale and connect the probes to the No. 2 and No. 3 terminals of
the disconnect plug.
5. The meter should read between 20 to 40 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. Disconnect the unit from the mains supply and plug into a wattmeter.
2. Plug the wattmeter into power source and manually advance the defrost timer to the defrost
cycle. See the defrost timer section for information on manually advancing the timer.
3. The wattmeter should read between 345 to 475 watts depending on the model (total wattage of
the timer motor and defrost heater). If the reading is 0 to 4.5 watts, 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.

Service Manual KE 650-2-2T 13
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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 R x 1K scale. If the reading is approximately 20 to 40 ohms, the
defrost heater and thermostat are operative.
2.4 Defrost Heater Replacement
1. Disconnect the unit from the mains supply.
2. Remove the icemaker, if fitted.
3. Remove the evaporator cover by loosening the top two 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. Install the replacement heater in the reverse order of removal.
2.5 Defrost Thermostat Replacement
The defrost termination thermostat is located on the top
right side of the evaporator.
1. Follow the first five steps in replacing the defrost
heater.
2. Disconnect the leads from the thermostat.
3. Remove the defrost thermostat and mounting clip
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 per the drawing below.

14 Service Manual KE 650-2-2T
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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 mains supply.
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 230 V test cable to condenser motor and plug into 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 mains supply.
2. Remove the insulated cover from the rear of the cabinet.
3. Disconnect the condenser fan motor lead connector on the motor terminals.
4. Remove the screws that mount the fan motor to the brackets.
5. Transfer the fan blade to the replacement motor, making sure it is installed in the same manner
as the original.
6. Install the fan motor leads and earth wire.
7. Install those parts previously removed. Test run the unit.

Service Manual KE 650-2-2T 15
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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 out towards the back of the evaporator fan cover. 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 mains supply.
2. Remove the freezer shelving.
3. Loosen the two top screws and remove the two bottom evaporator cover mounting screws.
4. Grasp the bottom of the cover. Carefully pull the cover forward and down to clear the upper
flange.
5. 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.
6. Remove the evaporator fan motor assembly and place it on a work surface.
7. Connect the motor terminals to a service cable and plug the cable into the mains supply.
8. If the motor fails to operate, it is defective and must be replaced.

16 Service Manual KE 650-2-2T
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2.7.2 Freezer Fan Motor Replacement
1. Follow steps 1 through 5 “Freezer Fan Motor Diagnosis”.
2. Remove the screws that secure the motor bracket assembly to the fan shroud.
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 to the rear mounting bracket. Mount the rear bracket to the front mounting
bracket.
6. Install the slinger disc and fan blade on the replacement in the same position as on the original
motor shaft.
NOTE: Make sure the slinger disc does not drag on the fan bushing.
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. It is properly installed when the blade is
positioned so the stop rests against the end of the shaft.

Service Manual KE 650-2-2T 17
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3. Cabinet and Related Components
3.1 Adjustable Cantilever Shelves
Type 1 – Two support hook frame design
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.
Check that the shelf is securely locked into position before loading it with food.
Type 2 – Three support hook frame design
To remove the shelf, grasp the shelf at the front with one hand and push up under the shelf back with
the other hand and pull out. To lock the shelf into another position, keep the shelf horizontal, guiding the
support hooks into the slots in the shelf support at the rear of the cabinet. Lower the shelf until the hooks
lock into position. Check that the shelf is securely locked into position before loading with food.
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 toward 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 in
place. Next, install the front trim on the glass and the front metal shelf cross brace.

18 Service Manual KE 650-2-2T
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3.3 Cabinet Doors and Associated Parts
3.3.1 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
alignment 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.
3.3.2 Outer Door Panel Replacement
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.
3.4 Front Wheel Assembly
The front wheel assembly is securely fastened by two screws to the faceplate of the cabinet.
Depending on the model, you will encounter adjustable or non-adjustable front wheel assemblies. To
lock the cabinet in place, lower the front levelling legs.

Service Manual KE 650-2-2T 19
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3.5 Cabinet Levelling
To enhance its appearance and maintain efficient performance, the refrigerator should be level. The
front wheels were adjusted at the factory so the doors were properly aligned and the cabinet level.
However, jarring in transit, or standing the refrigerator on uneven floors may cause the doors to shift out
of alignment. If front alignment is necessary, use a spanner to adjust the wheel. Clockwise raises the
cabinet, counter-clockwise lowers the cabinet. If front wheels are not adjustable, use levelling legs to
level.
3.6 Door Seal
The drawing shows a view of the magnetic door seal used on all models mentioned in this manual. The
magnetic strips are attracted to the metal cabinet front, providing an excellent seal around the entire
door. A visual inspection of the door seal while opening and closing will reveal any areas of poor seal.
You will notice a slight expansion and compression of the seal bellows as the door is opened and closed.
3.7 Toe-in & Toe-out Adjustments
To seal evenly around the entire door, the seal must make contact at the top and bottom at the same
time. For this reason, the door, when ajar, should not
toe-in or toe-out . To correct a toe-in or toe-ou t
condition, first check that the hinge-side of the door is parallel with the cabinet then proceed as follows:
1. Check the cabinet levellers and adjustable wheels. Raising the handle side may correct a toe-
out; lowering may correct toe-in.
2. Loosen all inner panel mounting screws along the top, bottom and handle side of the door. Do
not loosen the screws along the hinge side.
3. Hold the corner that toes-in stationary, and push in on the toe-out corner until the door is lined
parallel with the cabinet.
4. Open and close the door several times to ensure a proper fit.
If necessary, repeat steps 2 and 3.
5. Tighten all loosened screws.

20 Service Manual KE 650-2-2T
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3.8 Hinge Adjustments
Hinge adjustments are necessary when:
1. The seal is not sealed sufficiently along the hinge side of the door.
2. The seal is compressed more than 1.6 mm on the hinge side (causing a poor seal elsewhere
around the top.)
3. The distance between the door and cabinet is greater at the top than it is at the bottom, or vice
versa.
4. The hinge side of the door is not 1.6 mm out past the side of the cabinet when (measured from
the side of the cabinet), or when the door panel top is not 2.8 mm above the cabinet top.
5. If one or more of these conditions exist, adjust one or both hinges to correct the trouble. Raising
the hinge side may correct a door sag.
3.9 Door Alignment
The cabinet door on all models is in correct alignment when:
1. The hinge side of the door is an equal distance from the cabinet flange at the top and bottom.
2. The gasket seals smoothly and is compressed no more than 1.6 mm along the hinge side with
the door closed.
3. The door lines up with the side of the cabinet (viewed from the front). The door panel is parallel
with the cabinet top.
In many cases, levelling the refrigerator will eliminate the need for cabinet door adjustments. Ensure that
the refrigerator is plumb by checking all edges as well as both sides of the cabinet with a carpenter’s
level.
3.10 Door Switch
Disconnect the unit from the mains supply.
The door switches can be easily removed by using a flat blade screw driver or putty knife. Pry from the
liner and disconnect wires.