Monogram ZIS42 User manual

Monogratn
Refrigerator
Service Manual
Models -ZIS36, 42, 48
THIS MANUAL IS INTENDED
FOR USE BY A QUALIFIED
SERVICER ONLY
WE STRONGLY RECOMMEND THAT
ANY S.ERVICE BE PERFORMED
BY A QUALIFIED SERVICE PERSON.
Pub. No. 31-5238

IMPORTANT SAFETY NOTICE
Major appliances are complex electromechanical devices. This Service Manual is
intended for use by individuals possessing adequate backgrounds of electrical,
electronic and mechanical experience. Any attempt to repair a major appliance
may result in personal injury and property damage. GE Appliances cannot be
responsible for the interpretation of its service publications, nor can it
assume any liability in connection with their use.
SAFE SERVICING PRACTICES
To preclude the possibility of resultant personal injury* and/or property
damage,** it is important that safe servicing practices be observed. The
following are examples, but without limitation, of such safe practices.
1. Before servicing, always disconnect the product from its electrical power
source by removing the product's electrical plug from the wall receptacle,
or by removing the fuse (or tripping the circuit breaker to OFF) in the
branch circuit serving the product.
NOTE: If a specific diagnostic check requires electrical power be applied
(e.g., a voltage or amperage measurement, etc.) reconnect electrical power only
for the time required for such a check, and disconnect it immediately
thereafter. During any such check, ensure no other conductive parts (panels,
etc.) - or yourself - come in contact with any exposed current-carrying metal
parts.
2. Never interfere with or bypass the proper operation of any feature, part or
device engineered into the product.
3.
If a replacement part is required, use the specified GE Appliances part, or
an equivalent which will provide comparable performance.
4.
Prior to reconnecting the electrical power source to the refrigerator or
freezer, be sure that:
a. all electrical connections within the product are correctly and securely
connected,
b. all electrical harness leads are properly dressed and secured away from
sharp edges, high-temperature component~ (e.g., resistors, heaters, etc.)
and moving parts,
c. any uninsulated current-carrying metal parts are secure and adequately
spaced
from all non-current-carrying metal parts,
d. all electrical grounds -both internal and external to the product -are
correctly and securely connected,
e.
all water connections are properly tightened on refrigerators with
automatic icemakers or dispensers,
f. all panels and covers are properly and securely reassembled.
5.
Read the SAFETY PRACTICES section beginning on Page G-1 in the GE Appliance
Service Handbook - Refrigerator and Freezer, Pub.No. 31-4564-6 for
additional SAFE SERVICING PRACTICES.

6. Don't attempt a product repair if you have any doubts as to your ability to
complete
it in a safe and satisfactory manner.
*PERSONAL INJURY, in the form of electrical shock, burns, cuts or abrasions,
etc., can occur spontaneously to the individual while attempting to repair or
service the product; or
may occur at a later time to any individual in the
household
who may come in contact with the product -unless safe servicing
practices are observed.
**PROPERTY DAMAGE, resulting from fire, flood, etc., can occur immediately or
at a later time as a result of attempting to repair or service the product -
unless safe servicing practices are observed.

PREFACE
This MANUAL contains information and service procedures to assist the service
technician in correcting conditions that are not always obvious. Service
procedures considered obvious are
intentionally omitted.
Using
the information in this MANUAL in conjunction with the Mini-Manual
included with
the product, will provide comprehensive information on this
model.
All electrical data, schematics and pictorial wiring diagrams are in the
Mini-Manual with the product.
~ GENERAL ELECTRIC COMPANY 1992
ALL RIGHTS RESERVED

INSTALLATION
Electrical Connection
Water Connection
Leveling
Decorative Panels
Top Panel
Door Panels
Base Panel
OPERATION AND PERFORMANCE
Temperature Control Settings
Freezer Control
Fresh
Food Control
Energy Saver Switch
Icemaker
Condenser Cleaning
REFRIGERATION SYSTEM
Refrigerant Flow
Slide-Out Chassis
Chassis
Extended
CONTENTS
Hood Removal (Optional) -Prior to Installation
Compressor
Overload
Relay
Run Capacitor
Condenser
Condenser
Loop
Case Flange/Mullion &Auxiliary Heater
Dryer
Heat Exchanger
Evaporator
AIR FLOW SYSTEM
Unit Compartment
Condenser Fan
Freezer Compartment
Fresh Food Compartment
Evaporator Fan
Evaporator Fan Delay
Fan Delay Thermostat
Freezer Temperature Control
Fresh
Food Temperature Control
To Test the Fresh Food Damper Control
WIRING DIAGRAM (Dispenser Model)
DEFROST SYSTEM
Defrost Control
Drain Trough and Heater
Defrost Heater
Defrost Thermostat
Drain Tube
Drain Pan
(CONTINUED ON NEXT PAGE)
PAGE
1
1
2
2
2
3
3
4
4
4
4
4
4
5
5
6
6
6
7
7
7
7
7
7
7
8
8
8
9
9
9
9
10
10
11
11
12
12
13
13
13
14
14
14
15
15

INTERIOR LIGHTS
Fresh Food Lights
Storage
Bin Lights
Freezer Light
Light Switches
Light Thermostats
CABINET HEATERS
CONTENTS
Case Flange/Mullion Heater + (Auxiliary Heater)
How to connect Auxiliary Heater
ICEMAKER and WATER SUPPLY
Icemaker
Water Fill Adjustment
Ice Storage
Bin Location
Dispenser Service
Recess
Removal
Fill Tube Heater
Water Valve
Plastic Fill Tubing
CABINET SERVICE
Outer Door
Inner Door
Door
Assembly
Door Handles and Trim
Door Shelves/Modules
Door Gaskets
Door Hinges
Door Closure Mechanisms
Door Adjustment
Door Removal
INTERIOR
Breaker Strips
Fresh Food Shelves
Freezer Shelves
Storage
Bins
DIAGNOSIS
Electrical System
Refrigeration System
PAGE
16
16
16
16
17
17
17
18
18
18
19
19/20
21
21
22
22
22
22
23
23
23
24
24
24
25
26
26
26
26
27
27

MONOGRAM REFRIGERATORS
INSTALLATION
Complete detailed Installation Instructions
are supplied with each
refrigerator. Refer
to these instructions before installing
refrigerator.
Electrical Connection
A 115 volt electrical receptacle should be
provided in the wall behind the unit
compartment, near the center.
CAUTION: Care should be taken when
disconnecting the power cord to avoid
contacting
refrigeration system tubing
which may be extremely warm.
ZIS MODELS
WARM
Before connecting the power cord to the receptacle, turn the freezer temperature
control to the "off"
position. Then, after connecting the power cord, set the
control
to position "5".
Water Connection
Copper tubing (1/4-inch 0.0.) must be
connected to the tubing connector provided
on the inlet of the water valve. The valve
is located behind the base panel. The
water valve should be connected to a
frequently
used cold water line with
pressure
between 15 and 120 PSIG. A
shut-off valve, having a minimum 5/32-inch
inside diameter, should
be provided at the
connection to the water supply
line.
NOTE: If the refrigerator is to be
operated before the water supply has been
connected, the icemaker should be set to
the
"OFF OR STOP" position.
- 1 -

MONOGRAM REFRIGERATORS
leveling
The refrigerator must be level (zero tilt)
from front-to-back and side-to-side.
Rollers at the base of the cabinet, near
all four corners, aid the installer in
positioning the
refrigerator in its final
location. The rear rollers are adjustable
but the front
rollers are non-adjustable.
To raise the rear of the cabinet, turn the
7/l6-inch hex-head bolt located
in the base
channel near each front corner of the
cabinet.
Four full turns clockwise will
raise the rear roller approximately
3/l6-inch.
To level the front of the
cabinet, adjust the leveling legs at
each
front corner of the base channel.
Decorative Panels
Decorative panels, selected
by the consumer
as desired, are installed at the top, on
the door fronts and on exposed sides of the
refrigerator. The panels are custom made
and trim kits are available for a variety
of
panel thicknesses. The consumer will
need to order the trim kits from Trim
Options Book.
CAUTION: When servicing the refrigerator
use extreme care to avoid damage to the
custom panels because they are not
available
as replacement parts.
Top Panel
The top panel (not included with the
product)
is mounted into a trim frame.
locator pins, near the top of the frame,
engage notched brackets at each side to
mount the panel and frame to the cabinet.
Slotted holes in the brackets permit
adjusting the height of the
panel as much
as 1.S-inches. This provides added
flexibility in being able to adjust the top
panel to match upon installation.
- 2 -
ZIS MODELS
BASECHANNEL~
ROLLER
LEVELING LEG ___ _
TOP PANEL / F~~:E
SLOTS
MOUNTING
BRACKETS

MONOGRAM REFRIGERATORS
Door Panels
Custom panels installed on the doors can be
removed after removing the door handle end
caps and door handles. Adhesive backed
foam pads placed behind the panels may have
been used to ensure a tight fit on 1/4-inch
thick panels. Retainer screws are used to
hold 3/4-inch
thick door panels in place
and are driven through the outer door edge
trim and must be removed prior to removing
the custom panels. To remove the panel,
open the door and remove the screws. Custom
handles can also be an option chosen by the
consumer.
All options and variations are
not
listed in this manual.
Base Panel
A plastic base panel, supplied with the
refrigerator, is attached to the cabinet
base with
two screws. If a custom base
panel
is installed, it should also be
attached with screws to provide access to
the water valve and other components
located below the cabinet.
- 3 -
ZIS MODELS
r==~
II ~ -='-~
-=?5i!r S
-~
~.-.- -- L-FREEZER DOOR
~ __ __L.. PANEL 11I1M
~
END CAP
-- --~
~D~ ,-_ ~
END CAP ________ ~
l !
I BASE PANEL

MONOGRAM REFRIGERATORS
OPERATION AND PERFORMANCE
Temperature Control Settings
The temperature controls for both
compartments are located in the upper rear
of the fresh
food compartment. The control
knobs located in a console just in front of
the controls,
have extensions which provide
the
means to set the controls. Both
controls, having settings "1" through "9",
should
initially be set at "5". At these
settings, under average use conditions, the
freezer temperature should
be near 00 F and
the fresh food temperature approximately 38
0
F. The control positions are illuminated
by the upper fresh food lights. The light
shield should be in-place for proper
lighting.
ZIS MODELS
NOTE: When changing a control setting, allow 24 hours for the temperatures to
stabilize before making another change.
Freezer Control
The freezer control is an electrical temperature control that senses air supply
temperature
in the freezer compartment to regulate the compressor run time.
NOTE: The freezer temperature control has an "off" setting which stops the cooling
for
both compartments, but power is still on to the unit.
Fresh Food Control
The fresh food control is an automatic air damper control that senses air
temperature in the fresh food compartment to regulate the amount of cold air
supplied to the fresh food compartment.
Energy Saver Switch
The energy saving switch is located on the control console and between the freezer
and fresh food control knobs. If moisture appears on the case flange or area
between the doors, position the switch to eliminate the moisture.
Icemaker
Automatic cycles of the icemaker can be stopped by raising the feeler arm up to .
engage "OFF OR STOP" position. Under average use conditions, the icemaker will
produce approximately
120 crescent shaped ice cubes in 24 hours' until the feeler
arm senses the ice bin is full.
Condenser Cleaning
Anytime the refrigerator is being serviced,
for
any reason, the top panel should be
removed and the condenser cleaned if
needed.
- 4 -

MONOGRAM REFRIGERATORS
REFRIGERATION SYSTEM
The refrigeration system, not removable as
a separate unit, consists of:
• a reciprocating type compressor,
• a fin-and-tube type condenser,
• a condenser loop,
• a dryer,
• a fin-and-tube type evaporator
and
• a heat exchanger
Refrigerant
Flow
The compressor discharges hot high pressure
refrigerant gas into the condenser. The
condenser is cooled by a fan and the cooled gas
is converted to a high pressure liquid. The high
pressure
liquid flows through the dryer where
any moisture is removed. The warm dry liquid
enters the condenser loop, passing first down
the mullion side of the freezer compartment,
across the bottom, then
up the left side and
back to the unit compartment and enters the
capillary. The capillary meters the flow of
liquid refrigerant entering the evaporator. The
liquid refrigerant boils and vaporizes inside
the evaporator, picking
up heat from inside the
cabinet. Refrigerant vapor
is then returned to
the compressor through the suction tube.
The
heat exchanger provides for warming of the
suction tube
by the capillary and cooling of the
capillary by the suction tube.
- 5 -
ZIS MODELS
SUCTION
LINE
~
DISCHARGE
TUBE
/
.. ~~'II
..
~==~
CONDENSER~
CAPILLARY t
~CONDENSER
/' LOOP
DRYER/

MONOGRAM REFRIGERATORS
Slide-Out Chassis
The compressor and condenser are mounted on a
slide-out chassis that can be pulled out of
the unit
compartment to facilitate servicing
the
refrigeration system. To slide the
chassis out of the unit compartment, dismount
the top panel,
grille, and upper right hinge
cover.
Remove the 7/16-inch hex-head bolt in
the
right front corner of the chassis.
Remove the screw from the air deflection
baffle on right side of the right chassis
track
and the ground screw on the right.
Dismount the sound baffles at the front and
left side of the chassis. Two screws at the
rear of the left sound baffle holds the
baffle in place. Two slots in the baffle
allows it to be removed without removing the
screws.
Remove the two drain tube clamps and
rotate the tube out of the drain pan. Remove
the right light switch from the upper trim
piece.
Remove the retaining strap screw at
top of the condenser loop tubing.
Chassis
Extended
Pull the chassis forward (approximately
14-inches) until
it reaches the stops
provided in
tracks. Work the refrigeration
tubing as you pull the chassis out.
CAUTION: Avoid kinking the refrigeration
tubing while sliding the chassis out and back
in.
NOTE: When sliding the chassis back into
position -
make sure the heat exchanger tubing
has not dropped down below the rear shipping
bracket.
If it does, the chassis will not go
back into position correctly.
Hood Removal (Optional)
If the refrigerator has not been installed, the
hood, partially enclosing the right side of the
unit compartment,
can be removed for additional
access to the
refrigeration system.
- 6 -
ZIS MODELS
CHASSIS EXTENDS 14"

MONOGRAM REFRIGERATORS
ZIS MODELS
CAUTION: To prevent an electrical shock hazard, disconnect the power cord before
servicing
electrical components or disconnecting the wiring harness.
Compressor
The compressor, mounted on 4 rubber grommets,
is positioned in the defrost water pan at the
right front corner of the unit compartment.
The compressor terminals, arranged in the
traditional (pyramid) configuration, are
positioned
toward the front for easy access.
The terminal cover, mounted to the compressor
case with a spring steel
clamp, also provides
an enclosure for the overload and relay.
Overload
The overload protector is mounted directly
on the compressor common terminal.
Relay
The solid state (PTe) relay is mounted
directly on the compressor start and run
terminals.
Run Capacitor
A
run capacitor is mounted at the right
front corner of the compressor. The 36 &
42" models use a 12 Mf capacitor and the
48" uses a 15 Mf capacitor.
Condenser
The condenser, made of 5/16-inch copper
tubing,
is mounted at the right rear of the
unit compartment.
Condenser loop
The condenser loop, made of 1/4-inch copper
tubing,
is positioned around all sides of the
freezer
compartment front. Foamed in place,
the condenser
loop is not replaceable.
Case Flange/Mullion &Auxiliary Heater
To assist the condenser loop in keeping the
flange
and mullion area above dew point, a
heater
is foamed-in-placed. An auxiliary
heater, also foamed-in-place, but not
connected,
is provided in case the primary
mullion heater
fails. The connectors for the
heater are located behind the fresh
food
control console. The mullion heater is in
series with the energy saver switch.
- 7 -
COMPRESSOR
+
~RE~Y
RUN CAPACITOR

MONOGRAM REFRIGERATORS
Dryer
The dryer is located in the unit
compartment and connected between the
condenser
and the condenser loop. It is
positioned behind the compressor and
connected at the inlet to the capillary
Heat Exchanger
The heat exchanger consists of the
capillary and suction tube. An insulation
tube is positioned over the heat exchanger
to prevent sweating
and to protect it from
rattling.
Evaporator
The evaporator is mounted above the
evaporator fan
diffuser panel and light
shield in the freezer compartment on
non-dispenser models. On dispenser models
it is located above the ice service shelf
and evaporator fan diffuser panel.
For access to the evaporator, remove the
light shield if a non-dispenser model, the
icemaker, (ice service
shelf if dispenser),
plenum, diffuser panel, foam housing and
drain trough. To remove the plenum, remove
the screws, cut through the RTV sealer and
rotate the plenum out from the left side.
To replace the evaporator, see instructions
furnished with the replacement evaporator.
All components of the refrigeration system
(except the condenser loop) are replaceable
separately.
Most leaks that may arise in
the
refrigeration system can be repaired
without replacing a
component since all of
the tubing
is copper.
- 8 -
ZIS MODELS
EVAPORATOR~ i<::::>"'~~
.,...-- ". -~-')'
: ... ..,.....:
'... I I
..... I I
...... I I
........ I oJ
EVAPORATOR../1" ...... J •.•••••
FAN DIFFUSER
PANEL

MONOGRAM REFRIGERATORS
AIR FLOW SYSTEM
Unit Compartment
While the compressor is running, the
condenser
fan circulates air through the
unit compartment. Air intake
and discharge
passages for the unit
compartment are
located along the top
and bottom of the top
panel
and through the grille. Room air
enters the unit compartment at the center
of the top panel
and grille. The condenser
fan
draws the room air through the
condenser
and expels the warm air, from the
condenser
and compressor, at the right side
of the top panel
and grille.
Condenser Fan
The condenser fan is mounted to a shroud at the right
side of the condenser. The fan shroud is mounted to the
condenser with a
screw in each corner. For access to
the
fan motor the slide-out chassis must be pulled
forward
from the unit compartment (see Slide-Out
Chassis,
page 6).
To remove the fan motor, disconnect the wiring harness
and remove the 3 motor mounting screws. Rotate the fan
assembly and remove the nut from the blade. Remove the
blade, then the motor,
from the fan shroud. Reverse the
procedure to reassemble.
Freezer
Compartment
The evaporator fan, located at the top rear of
the freezer compartment,
circulates cold air
from the evaporator while the compressor is
running. Cold air from the evaporator, forced
downward into the plenum by the fan, is
discharged into the freezer compartment at the
rear. Freezer return air is directed back to
the evaporator through openings
in the light
shield (on non-dispenser models) and the
evaporator
fan diffuser at the upper front of
the freezer compartment.
Fresh
Food Compartment
Some cold air from the evaporator fan, is
diverted to the fresh food compartment through
a duct
in the compartment divider. The air
passes through the fresh food air damper
control and enters the fresh food compartment
behind the control panel. Warm air entering
louvers
at the lower left side of the liner,
passes through a duct in the compartment
divider and is returned to the evaporator.
ZIS MODELS
AIR FLOW THROUGH
CONDENSER
- 9 -
_COLDAIR
~MIXEDAIR
c:::::J WARMER AIR

MONOGRAM REFRIGERATORS
Evaporator Fan
The evaporator fan assembly is mounted
horizontally to a diffuser panel, above the
light shield on non-dispenser models and
above the ice service shelf on dispenser
models,
in the top of the freezer
compartment.
For access to the fan motor; the icemaker,
ice service
shelf, light shield and plenum
must be removed (see page 8 - Illustration
#2). To replace the fan motor, remove the
brackets
and pull the fan blade from the
motor shaft.
NOTE: For proper air circulation, the fan
blade must be positioned on the motor shaft
13/64-inches from the end of the shaft.
Evaporator Fan Delay
ZIS MODELS
13
,1 ".-~
i'64 __ -~
Operation of the evaporator fan is delayed for approximately 10 minutes after the
compressor
resumes operation: 1) upon initial installation, 2) after long periods
of non-use (house vacant),
and 3) following each defrost cycle. A fan delay
thermostat, connected
in series with the evaporator fan motor and mounted to the
rear of the evaporator,
opens when the evaporator temperature reaches 450 F. The
thermostat will remain open until the evaporator temperature is lowered to 250 F.
This prevents warm air from being circulated into the fresh food and freezer
compartments until the evaporator is cold.
- 10 -

MONOGRAM REFRIGERATORS
Fan Delay Thermostat
The evaporator fan delay thermostat is
mounted to the right rear of the evaporator
below the defrost thermostat.
For access to the fan delay thermostat; the
ice service
shelf, the icemaker, plenum,
and fan diffuser panel must be removed on
dispenser models - on non-dispenser models
the light shield must be removed first ...
Then, to remove the thermostat; reaching up
behind the right side of the evaporator,
dismount the lower thermostat
clamp by
compressing it at the bottom. Pull the
clamp out of the bottom mounting slot and
remove the thermostat. When reinstalling
the thermostat, use a flashlight and mirror
to locate the
clamp and mounting slot.
Position the thermostat in the clamp and
push the bottom of the clamp back into
position.
Freezer Temperature Control
The temperature control for the freezer
compartment is mounted to a panel, behind
the control console,
at the top rear of the
fresh
food compartment. The control
capillary, covered with a vinyl sleeve, is
routed through the wall in the compartment
divider and extends into the freezer
compartment.
The exposed end of the
capillary is coiled and clamped to secure
its position in the cold air stream behind
the
plenum.
For access to the freezer control; remove
the light shield, control console, knobs
and extensions, and fresh food control.
Then, remove the screws that secure the
control panel to the
liner.
To replace the control, disconnect wiring
leads,
and remove the two mounting screws.
Then remove the ice bucket and plastic
plug button in the plenum. This plug
ZIS MODELS
DEPRESS
CLIP
ROTATE
TO REAR
...-T--------;:::"!
// I ./ I
// I ./././ I
~-----t_--__( I
I I I I
REMOVE
THERMOSTAT
I ./{--~-I---- I
I ./ .-1-'1--- -- __ 7"----- __ _
I ./././ ./-1-t-+---J-_-x;pi,,-------- /1
1
~
I./ ./ \1; ~~'7., ...... lJII // I I
_ ./ \' I 1 /'.\~t: ... I I
----- -,----,.,.£_ I. / I
I r---·-={~:- "i!t-_S-
I !
--=-~7( I I
I I !t -, I----~ I I 7' I : I
I I FREEZER _ll I I I I I I I
I I CONTROL r I----I FREEZER I I I
I I CAPILLARY I! \ CONTROL I I I I
I I PLUG PLENUM I
BUTTON
KNOBS
button provides access to the clip holding ,
the
end of the capillary. rn~I'I- -;1 !
Remove the screw ho1 di ng the control capi 11 ary ,_J ~ l.._--,
clip and let the capillary drop down below the l u ~-, !
plenum -uncoil the capillary -save clip. Pull the "______.. f~
control capi 11 ary out of the sl eeve and through to the.b, ------------______.. j iI,
fresh food compartment and replace the control. Use the -
sleeve to guide the
capillary back into position. Coil the
capillary 1 1/2-times at the end and place clip at top of
coils. Push the capillary into position from rear of plenum
and secure the clip. Make sure capillary is not touching the
rear liner.
- 11 -

MONOGRAM REFRIGERATORS
Fresh Food Temperature Control
Fresh food temperature is regulated by an
adjustable air damper control mounted
behind the control console, at the left
side of the control panel. The damper DAMP'FR---
opens and closes automatically, by means of
a
mechanical linkage with a capillary and
bellows assembly in reaction to changes in
the fresh food air temperature. Upon
temperature rise in the fresh food
compartment, the damper gradually opens.
If the temperature continues to rise, the
damper will continue to open, providing a
supply of cold
air upon demand -- as sensed
by the capillary. The capillary is coiled
and positioned in front of the control
body.
NOTE: To prevent abnormally warm fresh
food temperatures, the capillary must not
touch
any metal surfaces.
For access to the control and mechanical
linkage: remove the screws and bracket
attached to the
damper housing.
To replace the control and damper housing
as an assembly, remove the light shield,
control console,
knobs and extensions.
Then, remove the screws that secure the
control
panel to the liner. Remove the foam
strip and cut through the RTV sealer around
the damper housing and then, remove the
screws holding the damper housing to the
compartment divider.
To Test the Fresh Food Damper Control:
Uncoil the capillary and hold an ice cube
in contact with the capillary. The damper
should slowly close in response to the cold
temperature of the ice cube.
Then, while
grasping the
end of the capillary by hand,
the damper should open.
- 12 -
ZIS MODELS
AIR DAMPER CONTROL