UD-35 SERVICE UPDATE FIRST HALF—2009 - Whirlpool

SERVICE UPDATE
FIRST HALF—2009
Home Appliances
Prepared by: WHIRLPOOL CONSUMER CARE
UD-35
PART NO. 8178773

FORWARD
The following service update information is provided to make you more knowledgeable
about Whirlpool, Roper, KitchenAid, Maytag, Jenn-Air and Amana major appliances.
Service update information is designed for the experienced service specialist. It keeps
you advised of the most recent improvements and product changes, and allows you to
service these products more efficiently.
WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on
our products by anyone other than authorized In-Home Service Professionals.
Copyright © 2009, Whirlpool Corporation, Benton Harbor, MI 49022
- ii -

TABLE OF CONTENTS
COOKING .................................................................................................................. Page 1
Product Updates ...................................................................................................... Page 1
KitchenAid Freestanding Electric Range ................................................................. Page 1
KitchenAid and Whirlpool Built-In Single and Double Ovens Blower Assembly. ..... Page 2
KitchenAid Freestanding Ranges Storage Drawer .................................................. Page 3
All Gas Ranges Eliminating LP Conversion Kit ....................................................... Page 4
Warming Drawer Feature ........................................................................................ Page 5
LAUNDRY .................................................................................................................. Page 7
Laundry Product Updates ........................................................................................ Page 7
Steam Washer Changes .......................................................................................... Page 7
Extra Thermister ...................................................................................................... Page 7
Different Flow Rate .................................................................................................. Page 8
CCU ......................................................................................................................... Page 9
Drained and Refilled.. ............................................................................................ Page 10
Front Load Washers ................................................................................................Page 11
Failure Codes on Set-up ........................................................................................Page 11
Shaking and Noises ............................................................................................... Page 12
Clinch Lock ............................................................................................................ Page 12
"Sport" Bellow ........................................................................................................ Page 13
Squeaking Noise During Spin ................................................................................ Page 14
Squeaking Noise During Spin ................................................................................ Page 15
Squeaking Noise During Spin ................................................................................ Page 16
Air Trap .................................................................................................................. Page 17
Washer Design Changes ......................................................................................... Page 18
Proper Loading ...................................................................................................... Page 19
HE Top Load Washers ............................................................................................. Page 20
Motor ..................................................................................................................... Page 20
Tier III ........................................................................................................................ Page 21
Classic Top Load Washers ..................................................................................... Page 22
Inlet Valve / Vacuum Break Assembly ................................................................... Page 22
Pressure Switch vs. Pressure Sensors ................................................................. Page 23
Load Sense ........................................................................................................... Page 24
Dryers ....................................................................................................................... Page 25
FL Failure Codes Changing ................................................................................... Page 25
Broken Belt Switch ................................................................................................ Page 25
Dryer tech Sheet Location ..................................................................................... Page 26
In-Door Lint Screen ............................................................................................... Page 26
RAST Connector .................................................................................................... Page 27
DISHWASHER (Clean-up) ...................................................................................... Page 29
Hot Water Dispensers ............................................................................................ Page 29
Replacment Components ...................................................................................... Page 29
Pre-Washing Dishes .............................................................................................. Page 29
2 Piece SS Tank Transition ................................................................................... Page 30
Silverware Zone ..................................................................................................... Page 30
Silverware Zone ..................................................................................................... Page 31
Silverware Zone ..................................................................................................... Page 32
Dish Drawer Door Alignment ................................................................................. Page 33
Horizontal Pump No/Slow Drain ............................................................................ Page 33
Maytag Plastic Tall Tub Dishwashers .................................................................... Page 34
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TABLE OF CONTENTS
REFRIGERATION UPDATE ......................................................................................... Page 36
KABIR Update ........................................................................................................... Page 37
BIR Model Refresh ................................................................................................ Page 37
BIR Model Refresh ................................................................................................ Page 38
Ice and Water Update ............................................................................................ Page 39
Ice Cubes Sticking Together .................................................................................. Page 39
Ice Cubes Sticking Together .................................................................................. Page 40
Dispenser Door With Stepper Motor Not Closing .................................................. Page 40
New Front Water Connection Installation Instructions .......................................... Page 41
New Front Water Connection Installation Instructions ........................................... Page 42
In-Door Ice Diagnostics ......................................................................................... Page 43
In-Door Ice Diagnostics ......................................................................................... Page 44
In-Door Ice Diagnostics ......................................................................................... Page 45
Ice Maker Wiring Issues (bottom mount) ............................................................... Page 46
Water Valve Wiring Issues ..................................................................................... Page 46
Returned Unit - Deemed Not Repairable ............................................................... Page 47
Emitter & Receiver Issues ..................................................................................... Page 47
Returned Unit - Deemed Not Repairable ............................................................... Page 47
Frost Build-Up - Dispenser Door Not Closing ........................................................ Page 48
Cabinet Door Issues .............................................................................................. Page 49
Doors Out of Alignent - SxS FDBM ....................................................................... Page 49
Doors Out of Plane - SxS ...................................................................................... Page 50
To Install Shim Behind RC Bottom Hinge .............................................................. Page 51
To Install Shim Behind RC Bottom Hinge .............................................................. Page 52
BIR Bottom Mount Freezer Drawer Misalignment ................................................. Page 52
BIR Bottom Mount Freezer Drawer Misalignment ................................................. Page 53
Door Not Closing ................................................................................................... Page 54
Door Noise (Light Switch Assy.) ............................................................................. Page 54
Light Switch Pad .................................................................................................... Page 55
Removing the Door Skin ........................................................................................ Page 56
Gap Between UI and FC Door ............................................................................... Page 57
Electrical ................................................................................................................... Page 58
Unit compartment .................................................................................................. Page 58
Main Control .......................................................................................................... Page 59
Main Block Diagram .............................................................................................. Page 60
Dispenser Control .................................................................................................. Page 61
Niagara Block Diagram .......................................................................................... Page 62
Average Crisper Temperatures KABI SxS ............................................................. Page 63
Warm RC, Normal FC Temperatures ..................................................................... Page 64
Intermittent Over temperature ............................................................................... Page 65
Audible Alarm ........................................................................................................ Page 65
Connectors ............................................................................................................ Page 66
Performance Issue ................................................................................................ Page 67
Performance Issue ................................................................................................ Page 68
Performance Update ............................................................................................. Page 68
Performance Update ............................................................................................. Page 69
Sealed System ......................................................................................................... Page 70
Sealed System Update .......................................................................................... Page 70
SxS Sealed System Joint Locations ...................................................................... Page 70
Bottom Mount Sealed System Joint Locations ...................................................... Page 71
Alarms and What They Mean .................................................................................. Page 72
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TABLE OF CONTENTS
Main User Interface ............................................................................................... Page 73
Diagnostics Mode .................................................................................................. Page 74
Running Diagnostics .............................................................................................. Page 74
Diagnostics ............................................................................................................ Page 74
Diagnostics ............................................................................................................ Page 75
Showroom Floor Mode .......................................................................................... Page 76
Holiday Mode ......................................................................................................... Page 76
Component Testing ................................................................................................ Page 77
Compressor Converter .......................................................................................... Page 77
KABIR Diagnostic Inverter ..................................................................................... Page 78
Air Door ................................................................................................................. Page 78
Air Door ................................................................................................................. Page 79
Checking thermistors ............................................................................................. Page 79
Service Pointers BIR ............................................................................................. Page 80
Literature Revisions ............................................................................................... Page 80
SERVICE POINTER INDEX ......................................................................................... Page 81
- v -

- NOTES -
- vi -

COOKING UPDATES
KITCHENAID FREESTANDING ELECTRIC RANGE
ACCU-SIMMER SWITCH
We have seen a condition in the field with the accu-simmer rocker switch used to reduce
the temperature of the right front burner to simmer temperatures. This switch is
used on S-line KitchenAid Freestanding ranges (KERS205SBL0 and KERK901SSS0).
The problem is the switch will not hold up to the high voltage going through it and will
arch or short if the customer sets the switch after the burner is on. The strip circuits
show how the switch is used in a 240 volt circuit and a 120 volt circuit. Engineering
is putting together a field fix kit that will include a new rocker switch, 2 current limit
thermistors one for the L1 side of the circuit and one for the Neutral side of the circuit.
The kit will be available within the next couple of weeks.
1

COOKING UPDATES
KITCHENAID AND WHIRLPOOL BUILT-IN SINGLE
AND DOUBLE OVENS NEW BLOWER ASSEMBLY
Condition
• Oven does not operate after a Self-Clean cycle.
• Oven completely stops during the Self-Clean cycle.
Cause: The oven TOD located at the back of the range has blown because of higher
than expected temperatures.
A new Blower assembly, part number W10176670 (replaces 4457289) has been
made available to reduce temperature build up at the back of the oven. This blower
has been tested and verified to reduce the average temperature at the back of the
oven by 20˚. When replacing the blower also replace the original TOD, from the parts
list.
notes:
• This blower motor assembly is rated at 1200 RPMs versus the 950 RPM blower
assembly that was used in manufacturing and may be slightly louder (3dBA) because
of the increased RPMs.
• For double ovens: only the upper blower should be replaced with the higher speed
blower.
2

COOKING UPDATES
KITCHENAID FREESTANDING RANGES
STORAGE DRAWER
Tulsa Built KitchenAid electric freestanding ranges - If Consumer complains under
the first year warranty about the quality of the storage drawer install Part number
W10238961 drawer kit, which has roller bearing tracks and a new drawer.
3

COOKING UPDATES
ALL GAS RANGES
ELIMINATING LP CONVERSION KIT
Start Date unknown at this time, but will happen in the near future. (June 2009)
4

COOKING UPDATES
WARMING DRAWER FEATURE
Complaint - Control Indicates Warming Drawer Feature Is Not Available (scrolls
across the screen “FEATURE NOT AVAILABLE”)
For Whirlpool Ranges built since August of 2008 (WFE and WFG models) there are a
few items that may cause the control to indicate that the warming drawer function is
not available (listed in order of most probable first).
1. The unit is in the self clean mode with the door locked. If the oven door is locked
then the ERC control will not allow the warming drawer to be used.
2. If there are fault codes related to the warming drawer then the warming drawer will
not function. The fault codes can be checked in diagnostic mode.
3. The warming drawer sensor is disconnected, either at the control (P10 connector
pins 3 and 4) or at the in-line connector near the sensor. The warming drawer
sensor can be tested in diagnostic mode to verify that it is reading correctly.
5

- NOTES -
6

LAUNDRY PRODUCT UPDATES
STEAM WASHER CHANGES
Coinciding with a digit change, the steam generator is being replaced with a steam
sump heater.
THE STEAM HEATER
The steam heater is integrated with the wash heater located in the sump. It mounts
the same as the single heater.
EXTRA THERMISTOR
There is an extra thermistor, located on the rear tub. On the 4.0 cu/ft tubs the NTC is
located on top of the rear tub. The 4.4 tubs have the NTC on the back of the rear tub.
7

STEAM WASHER CHANGES (continued)
VALVE HAS A DIFFERENT FLOW RATE
The triple valve has a different flow rate of water for the steam cycle. The water for
the steam portion of the wash enters the sump through the vent tube on the rear of
the machine.
(APS) HAS BEEN IMPROVED
The analogue pressure sensor (APS) has been improved to be more robust, reducing
the tolerance drift and may be used to replace existing sensors.
8

STEAM WASHER CHANGES (continued)
CCU
The CCU incorporates the expansion board and has an accelerometer. It is attached
to the side of the cabinet. The accelerometer consists of a motion sensor and a set
of algorithms. It is able to detect wash unit unbalance. Failures of the accelerometer
will not result in error codes, the machine will default to the traditional unbalance detection
algorithm. If you suspect problems with the accelerometer, make sure that the
unit is level and the CCU is secured tightly to the cabinet.
9

STEAM WASHER CHANGES (continued)
DRAINED AND REFILLED
The Sump Steamer requires that the sump be drained and refilled to the correct level
to generate steam, so the steam portion of the cycles is now at the end of the main
wash cycle.
Customer cannot tell if steam is being produced. The steam will not be visible.
3 new error codes have been added
F-64 for the steam valve
F-60 for the steam heater
F-67 for the steamer NTC
10

FRONT LOAD WASHERS
FAILURE CODES ON SET-UP
The complexity of the electronics in today’s products makes installation issues more
apparent than in the past. Installers are suppose to put newly delivered units into
delivery test cycles. They may get an error code. These codes are built-in to help
assure the installer that they have everything correct with the installation, not to show
that there is something wrong with the unit.
Many people still relate an error code with “a problem with the unit.” Error codes no
longer just mean that there is something wrong with the unit. They can tell you that
the environment is not right. For example, if all of the shipping bolts are not removed
you will have a shaking problem with an error code. Using “old thought“, the process
would go something like this; “There is something wrong with this unit, it must be
defective. After all, there’s an error code telling me that something is wrong with it”.
With “new thought”, it would go like this; “What is this error code telling me and, is it
related to this machine shaking”? This will lead to correcting an installation issue.
In the long run, these error codes are good. They help the installer to correct installation
errors, thus preventing the need for the customer to have a non-warranty service
call. This benefits everyone. Error codes thought patterns need to switch from
negative connotations to thoughts of aid and assistance.
Don’t forget that Steam units may not start right away, due to the Automatic Adjustment
Mode that is built into the electronics.
11

SHAKING AND NOISES
The following information is updates to correcting shaking and noise complaints.
CLINCH LOCK
For loose cabinets, place self-drilling screws in front of each clinch lock.
12

“SPORT” BELLOW
A “softer” bellow is available (W10130455) to help vibration issues on Monterrey
built units. It is the black bellow that is used on commercial units. A softer gray
bellow is scheduled to soon be released.
13
Continued next page

SQUEAKING NOISE DURING SPIN
Check for squeaking noise coming from the bottom of the unit during the spin. Press
the toe panel against the whole unit. If the noise disappears, remove the toe panel
and go to it’s back side.
We will be working on the right hand side, when viewed from the back.
14

SQUEAKING NOISE DURING SPIN
Make a mark 4¾ inches from the inner edge of the side flange. Make sure that you
measure from where the arrow is pointing.
We will be working only with this part of the top flange, a little more than two inches.
15
Continued next page

SQUEAKING NOISE DURING SPIN (continued)
Using a pair of pliers, bend the flange flat, from the edge to the mark you made.
Make sure that you smooth any sharp edges
and use touch-up paint to cover marks and
scratches.
16

AIR TRAP
The air trap may be rattling against the tub. Check the wire tie around the foam. If
the wire tie head is contacting the tub, remove and replace the wire tie, making sure
that the head is away from the tub.
17

WASHER - DESIGN CHANGES
You will be noticing some changes in the design of front load washers. The most obvious
changes being a die-cast pulley and the dispensers will start using Cross Flow
technology.
18

PROPER LOADING
Proper loading of washers (especially front loaders and HE top loaders) aids in reducing
tangling and twisting complaints. For best results, clothes should be loaded in
loose heaps. Allow the washer to rearrange the clothes for best cleaning motion and
balance.
19
Continued next page

HE TOP LOAD WASHERS
MOTOR
The motors on HE top loads will be changing to a new rotor technology - New rotors
will be black (instead of white). They will have stronger magnets that have a different
magnetic pattern. This will allow the use of an aluminum stator. Parts are NOT
backwards compatible. Make sure to order parts using the complete model number
with it’s revision.
20

TIER III
The new Tier III washers boast a 5.0 capacity. This is attained by changing the tub
ring. In order to make room for the extra space, the basket will be dropped by about
1/2”. This means you will need to be sure to order replacement parts by using the
correct and full model number. The suspension rods and drain hose will be longer
and the basket has been revised. The new basket is the only part that will work on
older products. All replacement baskets will be this new design (the bottom skirt has
a cut out). The feet will be factory installed and will not be removable.
21
Continued next page

CLASSIC TOP LOAD WASHERS
PRESSURE SWITCH/HOSE
Replacement parts will come as a kit. They will have the new style barbed pressure
switch, a new pressure hose and a spring clamp.
INLET VALVE/VACUUM BREAK ASSY.
The new Vacuum Break that was introduced in UD31 (1st Half 2007) is in production.
It has the water inlet valves and temperature sensor attached to it. This eliminates
the need for a hose and two hose clamps.
22

PRESSURE SWITCH VS PRESSURE SENSORS
Pressure Switches, even
adjustable ones, are only
switches. They do a very
good job but do not have the
sensitivity of Pressure Sensors.
A limiting factor for a
Pressure Switch, when
coupled with electronic
technology, is that if the
water level in the tub drops,
or there is a pressure leak in
the hose, the switch will not
react until there is a sizeable
differential.
The Pressure Sensor, an electronic device, does not switch – it measures and
reports its findings to a control. It has the ability to measure minute drops in water
level or air pressure. So, slight changes from a siphon effect, water leak or pressure
hose leak will get reported to the control. The control will then try to make
adjustments or give failure codes. Diagnosing units that have Pressure Sensors
requires careful inspection of the air dome, pressure hoses, wire connections and
drain systems.
23 Continued next page

LOAD SENSE
The classic top loader’s Load Sense Switch is an example of a pressure sensor.
For consistency’s sake, the parts department has called it a switch - because it takes
place of a water level switch in the control panel. In reality, it is really a pressure
sensor and an electronic control combined together. It monitors and controls several
functions:
1.) Critically senses the water level.
2.) Supplies power to the ATC Switch and the Timer’s #12 (Rinse) contact .
3.) Monitors the volume of water that has entered through the Flow Meter.
4.) Monitors the Fabric Select Switch’s position.
5.) Calculates how much water has been absorbed by the clothes.
6.) Switches power from the fill section to the motor section.
24

DRYERS
FL FAILURE CODES CHANGING
In order to make error coding more consistent across platforms, dryers will
be changing to the use of F and E error codes. This change is due in August.
The tech-sheet will reflect all of the needed information.
BROKEN BELT SWITCH
The broken belt switch design will be changing, coinciding with digit changes. Eventually,
this will be the only design across all dryer platforms. It replaces a 6 piece
assembly into one snap in switch. The motor mounting bracket will be changed to
accept it.
25
Continued next page

DRYER TECH SHEET LOCATION
Look for a change in the dryer’s tech-sheet location, clipped in near the main control.
IN-DOOR LINT SCREEN
A center support rib will be added to the lint screen. The change will happen platform
by platform and replacement parts will change as stock of old parts are depleted.
Both parts are interchangeable and there is no reduction in air flow by adding the rib.
26

RAST CONNECTOR
Care needs to be taken to insert the RAST connectors straight into the receptacle. If
it is inserted at an angle, there is a good chance that the internal wire terminal could
bend. Bending of the terminals contact can keep the connector from properly mating
to the control board contacts, even though it is fully seated into the receptacle.
27

- NOTES -
28

CLEAN UP UPDATES
HOT WATER DISPENSERS
Whirlpool Brand is exiting ALL MODELS of the hot water dispenser business effective
12/31/08.
REPLACEMENT COMPONENTS
As stock runs out, original dishwasher replacement parts will sub to a kit that has the
newer RAST connector style component, one of these jumpers and an instruction
sheet. They will be included with the Water Inlet Valve, Turbo Zone Wax Motor, Optical
Water Indicator, Vent Wax Motor and the Drain Motor.
PRE-WASHING DISHES
Customers who pre-wash their dishes and use the Normal Cycle could be getting
poor results. If the customer pre-rinses her dishes, selects the NORMAL CYCLE and
chooses to use no OPTIONS, then the OWI will sense a low soil situation and choose
to use the PRE-WASH water for WASH. If that first fill is at 119°F or higher, it will not
add heat. A 119°F first fill is not sufficient to activate dishwashing detergent. Have
the customer select the HI-TEMP option to improve results.
29
Continued next page

2 PIECE SS TANK TRANSITION
2 PIECE SS TANK
The current two piece tank design will be
changing to a 3 piece design.
SILVERWARE ZONE
30
3 PIECE SS TANK
Replacement parts will sub over to the
3 piece tub as stock is depleted.
A new feature called the Silverware Zone will be offered on some Maytag models in
June 2009.

SILVERWARE ZONE (continued)
It will consist of three new parts, held together with 4 screws….
It will use the current Power Scour system, including the control with no software
change.
Continued next page
31

SILVERWARE ZONE (continued)
With no power to the actuator wax motor, the water will be directed to the middle
spray arm. When the actuator magnet is drawn to the tub, the SS balls will divert the
water to the silverware spray zone.
DOOR HANDLE
MISSING HANDLES ON THE NEW WHIRLPOOL GOLD
FULLY INTEGRATED DISHWASHER MODELS
The Handle for the new Whirlpool Gold Fully Integrated dishwasher models
GU2275XTV and GU2475XTV comes packaged along with the dishwasher in the
lower rack (just as with the KitchenAid Fully Integrated models). Please ensure that
your customers are aware of this and do not accidentally discard.
32

DISH DRAWER DOOR ALIGNMENT
Units drawers not lined up and off by
about 1/8”.
HORIZONTAL PUMP NO/SLOW DRAIN
33
Correct alignment may be obtained by
assuring the level and driving the side
mounts according to where you want to
move the drawers.
For no drain or slow drain complaints
on the horizontal pump dishwashers,
the tub’s drain screen height may
be out of spec. Call the techline at
(800) 832-7174 to request a Stainless
Steel Washer to be sent. To install
it, remove the Collector and it’s contents
from the Tub. Insert the washer
between the Funnel and the Gasket.
Reassemble the Collector, test run the
unit for leaks and proper drain function.

MAYTAG PLASTIC TALL TUB
DISHWASHERS
There have been two recent Service Pointers for the Maytag Plastic Tall Tub Dishwashers.
K8178708 (August 2008) “REPLACEMENT TUBS AVAILABLE” is for replacement of
the tub when the tub is damaged or cracked, failing to contain water. Do not order tub
for a complaint of tub-to-door popping or rubbing noises.
K8178759 (December 2008) “DOOR MAKES NOISES” is for replacement of the inner
door panel when the tub lip may be bowed and causes the door panel to rub against
it. The customer complaint is usually a popping or rubbing noise when opening or
closing the door. It is normal for the tub to bow after settling into a new environment.
Tub replacement for this problem may cause the symptoms to return after the
replacement tub settles – resulting in a repeat call. Replacement door panels are
designed to work with tub lip bow and solve the customer complaint of the door popping
or rubbing.
34

- NOTES -

KABIR UPDATE - 2009
36

KSSC42QMS03, starting December 2006
•
•
Double lock connectors
Added additional connectors, wire to wire connectors changed to a more
robust connector that should help eliminate back-outs and disconnects.
IDI coupling redesign - Same as freestanding
Bottom layout redesign, fixed drain pan
KSSCQTS00 or KBFO42FTX00, starting March 2007
• SxS features
• Niagara\Advanced dispenser water system (smartvalve, stepper
- motor, etc).
- Fixed drain pan
- Push button water filter
- Redesigned bottom layout carried over from KSSC42QMS03 (ex.) models
•
BMT features
- Temp. controlled pans
- IDI icemaker controls
BIR MODEL REFRESH
BIR MODEL REFRESH
KSSC42QTS02, starting December 2007
37

January 2008, started production of Jenn-Air BIR models in Ft Smith, AR. with the
KitchenAid model line.
BIR MODEL REFRESH
Ft. Smith, AR produced models, starting July ‘08
Model Number Serial Number
38

Original Large Reservoir
Dispenser drip
KABIR UPDATE -2009
ICE AND WATER UPDATE
2327509
Verify the 2327509 tank is installed. This is the smaller baffle tank. See figure 1.
Verify the inlet and outlet is installed correctly from the reservoir tank. The correct
inlet and outlet connections are Critical to ensure dispenser dripping is minimized.
The 2314271 with 5/16” check valve has been helpful at both the door union (Tline
models) and tapped into the line right after the reservoir outlet connection.
Removing the ARD on the M line will help. Use regular ¼ tubing. You will need
a bracket at the top in the dispenser to hold the tube. The water reservoir tank,
2327509, has dramatically reduced our dispenser drip calls. Make sure the
technicians are using this smaller baffle tank as a service part, not the larger
baffle tank. The larger baffle tank does not improve dispenser drip as well as the
2327509 tank does.
39
Inlet
Figure 1
ICE CUBES STICKING TOGETHER
Infrequent Use
Outlet
Ice cubes will stick together over time. Customers that dispense ice infrequently
(more than a week or so between dispensing) will notice this because it is normal.
This is probably the most common cause of cube clumping complaints. Look for
cubes which otherwise appear fairly normal (although over long periods of time some
frost may build). Sublimation and melting occur at the molecular level even at temperatures
which remain well below freezing. The water molecules condense and
refreeze back on the cubes and this will cause cubes to freeze together at points of
contact.
The main points to take away from this are:
Neither warm temperatures nor airflow are necessary for ice cubes to stick together.
Over time, this will occur even at extremely cold temperatures. The cause is that
molecules of water (ice) on adjacent cubes of ice join into the same ice crystal at the
point of contact. The size and strength of the bonds grow with time. It begins happening
immediately, but is at first too weak to notice. Use of the dispenser drives an
auger motor which breaks up bonds, at least until they have grown too strong.

Moisture
ICE CUBES STICKING TOGETHER
Unusual moisture levels in the freezer will accelerate the formation of bonds between
ice cubes. In this case the water forming the bonds do not come from the ice cubes
themselves but from the air. Look for cubes which appear to have frost built up upon
them. The moisture deposits onto the cubes. The moist air may leak in through
damaged or incomplete seals on the dispenser ice door or gaps in the freezer door
gasket. To a lesser extent, unwrapped fresh food items may release moisture which
can get into the freezer through the air return. Moisture causes become more likely in
tropical environments.
Occasional Warm Temperatures
If the temperature goes above freezing, there will be visible melting which will then
refreeze when temperatures return to normal. This is probably the least common
cause of cube clumping complaints. Look for cubes which are misshapen because
they appear to have melted and for over temperature, door open or call service faults.
The most likely causes are power failures, the freezer having been left open for an
extended period, or the ice dispenser door failing to close completely.
DISPENSER DOOR WITH STEPPER
MOTOR NOT CLOSING
P5
Ice Door Stepper Motor
Verify the P5 connections are made and are fully inserted into the connector.
Verify the gasket on the ice door is sealing to the chute
Verify the stepper motor is closing the ice door through operation.
The p5 connection (as shown on the Niagara control board in the upper unit compartment)
is an area to review if there are issues with the dispenser door (with the stepper
motor) not closing. We have seen in some cases a wire backed out of the Molex
connector or wires switched within the connector. This is an area for the technician to
review through diagnosing the root cause for a dispenser door not closing.
40

ICE AND WATER UPDATE –cont.
Shortened Water Supply Tube; Production started June 16th.
Improvements:
Installers provide the tubing from the product to the supply valve.
Kinked\damaged supply tubes drastically reduced with short tube
This short water supply tube project has the greatest affect on Installers, not technicians,
but if a technician has to replace the supply tube, use this information for their
reference. Note pictures and the instructions provided on the next slides of this presentation.
This change was made as a running change in production. All T-line digit
03 models will have this change in production as sent out from Ft. Smith.
41

ICE AND WATER UPDATE –cont.
Connection point now located
at the front of the product
A shut off valve can be installed at the connection
point
42
Strain relief location for
the 1/4turn filter
Strain relief location for
the push button filter

IN DOOR ICE DIAGNOSTICS
The next three pages steps through the IDI diagnostics sheet, included with the service
and wiring diagram information with the unit. This sheet is located on the side of
the unit cover, folded in a sleeve.
If there is no ice production and you suspect the emitter or receiver, shut the refrigerator
power switch off for one minute and repeat diagnostics. This will eliminate the 40
minute waiting period.
Note: Unscrew light bulbs when making check.
Do not replace boards unless they fail diagnostic test
43

IN DOOR ICE DIAGNOSTICS (continued)
Note, step 7 shows to wait 1 minute prior to opening the door for the icemaker to
cycle.
44
Continued next page

IN DOOR ICE DIAGNOSTICS (continued)
The typical cycle time of an entire revolution of the icemaker averages to be 3 minutes.
We have had a request from an FSR to provide a new diagnostic tool for the icemaker.
This tool jumps the two connection on the receiver to bypass the optics when
diagnosing the root cause for no ice. If you are interested in receiving these tools for
tech usage, please let Tom Kros know, and he will communicate to engineering your
request.
ICE MAKER WIRING ISSUES
(BOTTOM MOUNT)
45
No power to Ice Maker due to a misconnected
wire.
This is more likely than a broken wire
inside the cabinet.
Unit was returned for a broken wire in
the cabinet.

WATER VALVE WIRING ISSUES
(BOTTOM MOUNT)
RETURNED UNIT – DEEMED NOT REPAIRABLE
White wire to Water
Valve backed out
PEX Unit – Deemed Not repairable. The unit could have been easily repaired.
White wire to Water
Valve backed out
PEX Unit – Deemed Not repairable. The unit could have been easily repaired.
46

EMITTER & RECEIVER ISSUES
(BOTTOM MOUNT)
RETURNED UNITS – DEEMED NOT REPAIRABLE
Emitter & Receiver issues - wires backed out. The unit could have been easily repaired.
RETURNED UNIT – DEEMED NOT REPAIRABLE
Bent terminal on Stepper Motor
connector at control board
resulted in return of product.
PEX Unit – Deemed Not repairable.
The unit could have been easily repaired.
47

FROST BUILD UP - DISPENSER DOOR NOT CLOSING
This unit was exchanged as being non repairable. If you are experiencing a “ice
door not sealing condition, Examine this area to insure the dispenser wires are not in
the way of the ice flapper door. A new part has been added at production to prevent
this this issue from from occurring.
PEX PEX Unit – Deemed Not repairable. repairable. The unit could have been easily easily repaired.
No Seal
Good Seal
No Seal
Good Seal
To verify the ice door seal, press the ice flapper door against the ice chute to make an
impression into the seal. Remove the flapper door. If you see an impression across
all four sides of the ice chute, you have a good seal.
48

CABINET & DOOR ISSUES
DOORS OUT OF ALIGNMENT –SXS & FDBM
Condition: Doors are not aligned at top, RC or FC door is higher. RC is pre-set to
be 1.5mm higher than FC at factory, under assumption food load will level them out.
•
Service Fix:
-Check door gaps between RC and FC at top and bottom.
If door out of align and gaps are uneven, loosen hinge screws for door that
is lower, pull top of door toward hinge and hold as you re-tighten the hinge
screws. See figure 1
-If gaps are even or parallel, take clip off of bottom hinge bushing and use
wrench to raise and lower door height. A combination of raising one door
and lowering another should be enough to fix most door alignment issue. Be
sure to check door seal after adjustment. See figure 2
Figure 1
CAB/DOOR ADJUSTMENT RANGE
49
Clip
Figure 2
Right to left – Each door has 10mm, (.4 inches) of total movement right to left. However,
this varies the height by 3mm. There should be a gap of approx. 6mm, (.2
inches) between doors. The top hinge has enough right movement to move too far
to the right causing light switch arm to hit side trim, so always check for interference
when done adjusting. No left right movement in bottom hinge.
Up and down – The bushing on the bottom hinge allows for 10mm, (.4 inches) of
adjustment.
In and out – Top hinge tap plate allows for 5.5mm, (.2 inches) of in and out movement.
No bottom hinge movement.

DOORS OUT OF PLANE –SxS
Condition: Doors are sealing but one door sticks out away from the cab more than
the other by more than 1/4” (1/4” or less is normal but can be adjusted out.) In most
cases there is an apparent difference in the compression of the gaskets on the hinge
and handle side.
•
•
Service Fix: SxS
- Applying permagum under corner of compressed gasket will work in most
cases.
-Heat gasket w/ heat gun or hair dryer, stretching gasket while applying heat,
then apply ice cube to gasket so that it takes new stretched set.
-If loss of door seal, move top hinges in and out by loosening tap plate screws,
not hinge screws. See figure 1
Gasket may be too compressed on hinge side, moving top hinge in has re
verse affect on handle side and pulling hinge out may move handle side in.
50

TO INSTALL SHIM BEHIND RC BOTTOM HINGE
First Remove RC Door:
Start by removing door closer spring. See figure 1. Then remove hinge post top
screw. Next. Remove front two hinge leaf screws, and back out rearmost two almost
all the way out.
Lift hinge up out of the way, and pull door off product.
Note: For 36 BM only, the screw in bottom hinge bushing must be removed.
See figure 2.
Door Spring
Hinge Post Screw
Figure 1 Figure 2
51
Hinge Screw

TO INSTALL SHIM BEHIND RC BOTTOM HINGE (cont.)
With the door removed, peel off the Hinge cover, remove the 4 hinge screws. Be very
careful not to round out the screw head if using a power screwdriver.
Replace hinge after adding 1.5mm (p/n 2207470) shim behind it. Replace hinge
cover, may need 2 sided tape if adhesive is no longer sticky. Check to make sure top
hinge does not need to now be adjusted out (Loosen Tap Plate). Check door seal.
Hinge Cover
BIR BOTTOM MOUNT FREEZER DRAWER
MISALIGNMENT
Condition : Drawer is not level (i.e. one side is higher than other)
52
Hinge Screws

MISALIGNED FREEZER DRAWER (continued)
Always check product levelness, do not reference FC drawer off RC door in case RC
door is sagging or the issue. RC door is easier to adjust.
If product is Overlay, check door alignment with panel off, make sure panel is not the
issue.
Tighten all screws; bolts connecting drawer to basket, see figure 1, screws connecting
basket to slides, see figure 2 and bolts connecting slide brackets to the product, see
figure 3.
Condition: Top/Bottom of drawer is tilted out or drawer is not sealing across the top
or bottom. Loosen top drawer to basket bolts and remove the bottom bolts on each
side. See figure 4.
There are 2 adjustment holes to use to reposition the lower bolts. See figure 5.
Tilt the door in the direction it needs to go, and re-insert the bottom bolts in the corresponding
holes to change the drawer angle.
Figure 4
Drawer to
Basket Bolts
Figure 1
Basket to
Slide Screws
Figure 2
53
Slide Bracket to
Liner Screws
Figure 3
Adjustment Holes
Figure 5

•
•
•
•
•
•
Drawer out of plane side to side
• First make sure it is not the RC door
w/ the issue. Easiest way to check
is to open RC door and look down at
the gasket gap across the top of the
FC Drawer. If the gasket looks more
compressed on one side than the
other it is an FC issue. If Door to product
gap looks even for FC, proceed w/
earlier shim insertion for RC bottom
hinge.
•
It is ok to horizontally slot the Drawer
bracket holes, but by no more than a
¼” on each side. Maker sure when
re-inserting bolts adequate torque is
applied to keep this bolts tight and further
movement of drawer alignment.
DRAWER NOT CLOSING
Make sure Door to basket nuts are on the inside and bolt heads are on the outside.
Check for frost or obstructions along Evaporator cover in back of drawer.
Remove Ice and Crisper Pans to make sure it is not obstructing closing.
Adjust tilt of door if top or bottom of drawer is hitting breaker first.
Make sure drawer is not hitting side trim.
All else fails replace basket and or slides.
DOOR NOISE – PRIMARILY LIGHT SWITCH EXT. ARM
ASSEMBLY
Condition: Popping noise or squeak when cycling door.
Service Fix: Remove screw and add Loc-tite 222MS from approved List, to screw
thread and re-insert.
Add grease to nylon bushing to fix squeak or moan.
Adjustment Holes
New Screws w/ serrated head
54
Nylon Bushing

LIGHT SWITCH PAD
(36BM and 42FDBM Only)
Condition – Door Open Alarm is on. Light switch checks ok and continuity to board
is good. The back of drawer might not be contacting the switch actuating arm. The
switch is located in right rear of FC compartment when closed to turn off FC lights.
See figure 1.
Service Fix – Add SPACER-FC Basket, part number W10221048 (available through
Exparts) to the back of the basket on the right side. Apply 50x50mm Foam Pad w/
Mylar Coat 1” down from back flange and along the fold edge of the side of the basket.
See figure 2.
Info: BIR Bottom Mount products with a serial # of SW33000 or greater will already
have this pad. This pad is approved to be used on any model # for this issue.
Light Switch
(Freezer drawer viewed from the rear)
Figure 1 Figure 2
55
Fold Edge
1” Down
Foam Pad

•
•
•
•
Removing Door Skin Replacing
Handle
Remove hinge side screws,
top screws, and bottom screws.
See figure 1
Figure 1
Pull the spacers from all sides but
handle side (it is 2-sided taped in)
then pull skin off door. See figures 2
and 3.
Remove screws from backer plate to
remove door handle. See figure 4.
For FC skin, there are 2 screws holding
skin to top of Dispenser housing
and 2 screws holding skin to dispenser
housing underneath the drip tray. It
is recommended to remove the door
to remove the skin
REMOVING DOOR SKIN
56
Figure 2
Figure 3
Figure 4

SMALL GAP BETWEEN UI AND FC DOOR
Small Gap between door skin and
Dispenser User Interface. See figure 1
This is usually caused by the UI being
bowed in and not the door skin. Sometimes
bowing occurs over time from use.
Remove the skin, and shim the backside
of this Disp. UI out to close the gap. A
service part is in the works. See figures 2
and 3. Contact Tech line if part is needed.
A service Pointer will be issued.
Figure 2
57
Figure 1
Figure 3

Main Control Board
ELECTRICAL
UNIT COMPARTMENT
The unit compartment is at the top on Built-in’s. All built-ins of the M-line and T-line
(all recent model built-ins) have a Gemini ES—it is the main control board on the
left. T-line dispenser models have a Niagara board as well, it is used to control the
dispenser and smart valve. The unit compartment power switch in the front shuts off
power to everything.
58
Dispenser Control Board

MAIN CONTROL
The Gemini ES is the main control board and is mounted vertically with P1 in the topleft
corner. Neither P1 nor P2 need shunting connectors. If the left two pins of P1
are tied together on an M-line, the unit will go into manufacturing diagnostics mode
each time it is powered up. The NTC (negative temperature coefficient) Thermistors
are connected to connector P3. Line voltage AC inputs go into P4, and the switched
neutral comes out of P4. P8 is in the bottom left corner and gets the AC power
directly from the power switch. On the bottom right, AC outputs are driven out of
P5. On the top right, DC outputs come out of P7. On the top left, the P6 connector
provides 3-wire WISP communications with the user interface in the top of the refrigerator
compartment (RC) from the top row of silo’s; the lower row of 3 silo’s are for
older QUISP style communications.
59

MAIN CONTROL BLOCK DIAGRAM
This is the block diagram for the same control board. The freezer compartment (FC)
thermistor for example is connected through pin 2 of the P3 connector (P3-2) and pin
7 of the same connector (P3-7). This diagram is more conceptual than precise; for
example, the power switch is not show between the service connector and the rest of
the system and the inverter is not shown between the Gemini and the compressor.
60

DISPENSER CONTROL
The Niagara board is present in T-line dispenser models. It is mounted to the right
of the Gemini board with the P1 connector in the upper left (rotated 90º counterclockwise
from the orientation shown in this diagram). P6 and P7 are WIDE serial
communications ports with the dispenser user interface and the smart valve, respectively.
The board is powered through P1 and detects when the FC (freezer
compartment) door switch is closed—the unit will not dispense when the door is open.
61

NIAGARA BLOCK DIAGRAM
This is a block diagram of the same Niagara board. The dispenser housing heater
(connected to P3-1 and P3-2) is line voltage; all other outputs are DC. Use of the
Ice door heater has was discontinued; it is not present in T-line models or later M-line
models.
62

AVERAGE CRISPER TEMPERATURES KABI SXS’S
These are recommended temperature settings. The temps will vary by shelf location
and based on loading and usage and air flow.
•
TEMPERATURE CONTROL PROBLEMS
Cold Freezer with Warm Fresh Food
-This is typically caused by insufficient airflow between the freezer compart
ment and the refrigerator compartment. The low airflow causes the RC
to warm up. The controller sees the warm temperatures which drives the
compressor & evap fan, which in turn makes the FC colder.
-Check the air damper & air return for proper operation or blockage. Check
foam blocks.
63

WARM RC, NORMAL FC TEMPERATURES
Serial numbers less then QT28
Service pointer, 8178478
Top right hand side may be loose, out of
position, damaged or missing.
See figure 1.
Replace the original foam air baffle and
block using kit number 8201798. This kit
contains a redesigned air baffle and three
foam blocks, one each for 36”, 42” and
48”models. See figures 2 and 3. Follow
the instructions completely.
Figure 2.
64

•
•
•
INTERMITTENT OVER TEMPERATURE
Recurring over-temperature alarms can be caused by a bad bimetal. A bimetal
that opens too soon can lead to frost build up that restricts airflow between the FC
& the RC.
Restricted airflow between the FC & the RC can lead to an RC that is too warm
and an FC that is too cold.
A sticking baffle can cause this same situation.
• Associated with a hot or yellowed mullion, a condenser fan could be failing and
causing intermittent over temperature.
The condenser fan motors sometimes develop “a bad spot” such that—if the blades
stop in that position—the motor has trouble starting. A push start (or even vibration
perhaps) could get the fan going. The condenser fans that have this issue have
metal blades. If a unit may have this problem and has a condenser fan with metal
blades, replace the condenser fan with service kit W10181323.
AUDIBLE ALARM (LOCATED ON THE USER INTERFACE)
•
•
•
•
•
BIR SxS models have audible and visual alert signals to indicate:
-Door Open
-Over Temperature
-Call Service
The reset turns off the audible alarm.
The piezo will be disabled for that alarm condition until power or cooling is turned
off and then on again.
The piezo is always disabled for bottom mounts.
CONNECTORS
No Connectors Depicted
Schematics typically do not currently show connectors between harnesses
-All schematics created from this point forward for new models will show these
connectors.
65

•
•
•
Loose Connection
CONNECTORS
Figure 1
Connectors can be accessible yet obscured.
A loose connection from the inverter to the compressor resulted in a no cool complaint
and a returned unit. See figure 1.
Re-plugging this connection fixed the no cool condition.
66

Old Cover
Drain pan Overflows
Models produced before November
2006, (example) KSSCQMS02
and prior
Tape over all but the 3 left rows,
see figures 1 and 2, or order grille
part #2307682 with 5 slots
(if customer will not accept tape)
PERFORMANCE ISSUE
67
Service Fix
Tape over all but the
3 left rows
New evaporation kit being tested
Service Kit W10197978
• Aids evaporation using a small fan
• Designed for M-line starting with the 01 digit advance and greater, which
is susceptible to this problem in certain environments. KBRC36FMS01,
KBLC36FMS02,KBRC36FMX03, KBRC36FTX00, KBRC36FTX02 and
KBRC36FTX03
• Kits available through the Techline. The released kit will be available in
the future directly through Plainfield.

PERFORMANCE ISSUE (continued)
Production Fix. New drain pan,
starting November 2006. Example:
KSSCQMS03
•
•
•
PERFORMANCE UPDATE
Noise\Normal Sounds
T-line BM units have a different
“normal sound” with the evaporator located
vertically. Different noise found
to be related to the air flow through
the compartment (air flow noise noted
in U&C detail).
Lower speed evap. fan motor in
process for BM customers desiring a
quieter product.
68
Front of the Product
Back of the Product

•
•
•
•
•
PERFORMANCE UPDATE
(continued)
•
PERFORMANCE UPDATE
The ambient humidity effects the temperature values. These values are based
on 70% humidity.
Internal temperatures, 0º FC, 37º RC
Crispers: Average, 2.5º-3.7º above RC temp.
Temp. controlled pan:
- At coldest setting, a window of approximately 4º below RC average temp.
but greater then 26º.
- Other than coldest setting: Temp setting of 32º or higher. The difference
between the meat pan temp at coldest and warmest settings is
designed to be be at least 4º.
Ice mode: FC automatically goes to -5º F for auto max ice. This temp. may show
on the display until the unit is out of auto max ice mode for a time.
Warm Crisper Complaint SXS; Service
kit being tested for models: M00,
01, 02, 03, and T00.Only available
through the Techline at this time.
- Currently being trialed through
engineering before
the formal service kit is released.
- Purpose of the kit is to improve
the temperature performance in
both the temp. controlled pan as
well as the non-temp. controlled
crisper pans.
69
Parts provided with pre-notched slots on
air baffle assembly.
Add new gasket on temp. control baffle.
Verify the evaporator tube is installed and
installed correctly.

•
•
SEALED SYSTEM
SEALED SYSTEM UPDATE
Mullion repair service kit. (yellow mullions) Service kit part number W10204863.
UV-Dye drier in production (W10175593). The UV dye drier started in BIR production
with the Ft. Smith transition. T-line 03 digit models include the dye drier.
Service pointer number 4317741.
SXS SEALED SYSTEM JOINT LOCATIONS
SXS Sealed System joints – diagram included in diagnostics packet with the
products. Reference this diagram when diagnosing sealed system leaks.
This diagram is included with the built-in refrigerator, service diagrams (on the side of
the unit compartment, at the top of the product), for reference to the sealed system
joints. If the unit is experiencing a leak in the sealed system, reference these diagrams
to check the sealed system, noting the potential leak points.
70

BOTTOM MOUNT SEALED SYSTEM JOINT LOCATION
This diagram is included with the built-in refrigerator, service diagrams (on the side of
the unit compartment, at the top of the product), for reference to the sealed system
joints. If the unit is experiencing a leak in the sealed system, reference these diagrams
to check the sealed system, noting the potential leak points.
•
•
•
•
SEALED SYSTEM
Serviceable heat exchanger, BIR SxS K and M models
(model number examples)
KSSC42QKS00 KSSC42QMS00
T-line SxS models, with the initial production of T-line, a wiring harness was routed
in the path for the drilled evap tubing hole.
- No - ~QT11 – QW19
- Yes - QW20 – present
Kit number 8201818.
BM heat exchanger, not feasible on current models, being investigated for future
models.
71

•
•
•
•
•
ALARMS AND WHAT THEY MEAN
Door Open Indicator
- Door switch shows door or drawer has been open continuously for
10 minutes.
Over Temperature Indicator
- Temperature is above 15º in freezer or above 48º in the fresh food for
90 minutes without decreasing.
- Indicator will remain on until temperature recovers and reset is pushed.
- Check Refrigerant levels and check frost patterns—check for leaks and
restrictions. Check for excessive frosting, if present replace the bimetal. Run
through diagnostics.
Call Service Indicator
- Check thermistors and thermistor connections. The compressor, fans and air
- door can operate as if on a timer until this is corrected.
Flashing Temperature Display
- Will identify affected compartment for either Over Temperature or Service
Indicators.
Piezo audible tone
- Indicates key press.
- Used in conjunction with alarms in some cases
- The tone beeps a few times every two minutes until the condition is
- fixed or until the tone is silenced.
- Press “Reset” to silence the tone
- If the tone is silenced or the condition is fixed then the tone will not
- recur for the same alarm unless cooling is turned off for ten seconds.
72

•
•
•
MAIN USER INTERFACE
Not all models have all the indicators & buttons shown above
Showroom floor mode: Max Cool & Cooling On/Off
Diagnostics mode: RC (+) & Cooling On/Off
The main user interface (UI) is located at the top of the refrigerator compartment
(RC). Not all models have all of the indicators and buttons shown in the representation
above.
There have been reports of new units out of the box arriving in Showroom floor mode.
There is no cooling in showroom floor mode but the lights, pushbuttons and indicators
work. In a no cool situation, please verify that the unit is not in showroom floor mode.
The unit will not go into diagnostics mode if it is showroom floor mode. You can take
the unit out of showroom floor mode by holding the “Max Cool” and “Cooling On/
Off” buttons simultaneously for 2 seconds (until the unit beeps). If the unit turns off,
you are pressing the “Cooling On/Off” button first; try pressing the “Max Cool” button
first then adding the “Cooling On/Off” button. The unit is placed into showroom floor
mode by this same key sequence. The setting is saved into memory when the door
switch is cycled. On power up, the unit will return to whichever state it was in the last
time the door was open & closed.
To get into diagnostics mode, press and hold the RC temperature up (+) button and
the “Cooling On/Off” button simultaneously for 2 seconds (until the unit beeps). See
the next slide (or the service sheet) for more information regarding diagnostics mode.
Hit the “RC (+)” key again to advance through the diagnostic steps.
Should a service bulletin or technical advisor require firmware version information for
the Gemini-ES, the User Interface, or the Phoenix Zone Control, then this can be displayed
from the UI by holding down the “FC(+)” and the “FC(-)” keys simultaneously
for 2 seconds. The FC display will show “Pb” (Power board) for the Gemini while the
RC displays the firmware version in the Gemini. Next, the FC display will show “UI”
(User Interface) while the RC displays the UI’s software version. The FC will display
“Ph” (Phoenix) while the RC displays the Phoenix board’s software version.
The “door open” alarm indicator will light up if the door is left open for 10 minutes;
the interior illumination will shut off. If this happens when the door has actually been
closed, check the door switches for both the FC and the RC. Touch the “Reset” button
to clear the alarm and turn of the piezo audible alarm.
The “Over Temperature” alarm will come on if the FC temperature is 15ºF or more
for 1.5 hours and is not decreasing, or if the RC temperature is 48ºF or more for 1.5
hours and is not decreasing. The piezo will sound. The piezo will turn off when the
over temperature condition is correct, but the indicator will remain lit until the “Reset”
button is touched.
The “Call Service” indicator will flash when the FC thermistor or RC thermistor has
failed; the system will operate in an error routine since it can not control based on
temperature.
73

•
•
DIAGNOSTICS MODE
RUNNING DIAGNOSTICS
Description The main user interface at the top of the fresh food section allows you
to test one component at a time so that you can see what is working and what is
not.
How to Access Press the RC+ button and the Cooling On/Off button at the same
time (if the unit turns off, then you touched the Cooling On/Off button first). Press
the RC+ button to advance through the steps.
All
BIR
French
Door
Component
Description
FC Thermistor
RC Thermistor
DIAGNOSTICS
FC
Sequence
01
02
RC
Code RC Code Description
01 Freezer Thermistor within "Operating Region"
02 Freezer Thermistor within "Open Region"
03 Freezer Thermistor within "Short Region"
01 Refrigerator Thermistor within "Operating Region"
02 Refrigerator Thermistor within "Open Region"
03 Refrigerator Thermistor within "Short Region"
Evaporator Fan Motor 03 ** Evaporator Fan Motor "ON"
Condenser Fan Motor 04 ** Condenser Fan Motor "ON"
VC Compressor 05
01
02
VC Compressor "On at 4500 RPM"
VC Compressor "OFF waiting in min off delay"
Air Door 06 ** Air Door "opens to full position, closes and stops"
Defrost Heater /Bimetal
07
01
02
Defrost Heater energized "Bi-Metal Closed"
Defrost Heater energized "Bi-Metal Open"
Bin Accent Lighting 08 ** Turn on Bin Accent Lighting "This step only"
01 Left Bin Thermistor " Within Operating Region"
Left Bin Thermistor 09 02 Left Bin Thermistor " Within Open Region"
03 Left Bin Thermistor " Within Short Region"
Left Bin User Selection
LED test
10
01
02
Correct key press
Incorrect key press
Left Bin Air Door 11 ** Air Door "opens to full position, closes and stops"
01 Right Bin Thermistor " Within Operating Region"
Right Bin Thermistor 12 02 Right Bin Thermistor " Within Open Region"
03 Right Bin Thermistor " Within Short Region"
Right Bin User
Selection LED test
13
01
02
Correct key press
Incorrect key press
Right Bin Air Door 14 ** Air Door "opens to full position, closes and stops"
END ROUTINE RESUME NORMAL COOLING
See the previous page for how to enter and advance through diagnostics mode. The
first seven diagnostic steps are available in all BIR, the remainder are only in applicable
models. The sequence (or step number) is shown in the FC display of the
UI, while for some steps an informative code is shown in the RC displays. For steps
such as 03 there is no RC information; the technician will verify that the Evaporator
fan motor runs in this step but in no others.
74

Component
Description
FC Thermistor
RC Thermistor
DIAGNOSTICS MODE (continued)
FC
Sequence
01
02
RC
Code RC Code Description
01 Freezer Thermistor within "Operating Region"
02 Freezer Thermistor within "Open Region"
03 Freezer Thermistor within "Short Region"
01 Refrigerator Thermistor within "Operating Region"
02 Refrigerator Thermistor within "Open Region"
03 Refrigerator Thermistor within "Short Region"
Evaporator Fan Motor 03 ** Evaporator Fan Motor "ON"
Condenser Fan Motor 04 ** Condenser Fan Motor "ON"
VC Compressor 05
01
02
VC Compressor "On at 4500 RPM"
VC Compressor "OFF waiting in min off delay"
Air Door 06 ** Air Door "opens to full position, closes and stops"
Defrost Heater /Bimetal
07
01
02
Defrost Heater energized "Bi-Metal Closed"
Defrost Heater energized "Bi-Metal Open"
Bin Accent Lighting 08 ** Turn on Bin Accent Lighting "This step only"
01 Left Bin Thermistor " Within Operating Region"
Left Bin Thermistor 09 02 Left Bin Thermistor " Within Open Region"
03 Left Bin Thermistor " Within Short Region"
Left Bin User Selection
LED test
10
01
02
Correct key press
Incorrect key press
Left Bin Air Door 11 ** Air Door "opens to full position, closes and stops"
01 Right Bin Thermistor " Within Operating Region"
Right Bin Thermistor 12
02 Right Bin Thermistor " Within Open Region"
03 Right Bin Thermistor " Within Short Region"
Right Bin User
Selection LED test
13
01
02
Correct key press
Incorrect key press
Right Bin Air Door 14 ** Air Door "opens to full position, closes and stops"
END ROUTINE RESUME NORMAL COOLING
See the previous page for how to enter and advance through diagnostics mode. The
first seven diagnostic steps are available in all BIR, the remainder are only in applicable
models. The sequence (or step number) is shown in the FC display of the
UI, while for some steps an informative code is shown in the RC displays. For steps
such as 03 there is no RC information; the technician will verify that the Evaporator
fan motor runs in this step but in no others.
75

•
•
•
•
SHOWROOM FLOOR MODE
Recently some new units have been in showroom floor mode at the time of
installation.
Showroom floor mode has interior lights & user interface functionality, but no
cooling.
Service diagnostics will not function
To remove from diagnostics mode, press the “Max Cool” and “Cooling On/Off”
button
• Door switch needs to be cycled to save the settings.
Always check for showroom floor mode in no-cool situations where the cause is otherwise
unknown. The unit will not go into diagnostics mode if it is in showroom floor mode.
•
•
•
•
HOLIDAY MODE
Disables lights, indicators and ice production.
Instruct customer to allow ice door to close before placing unit in Holiday mode.
New BIR SxS models (e.g. KSSCQTS03) have improved Star-K compliance.
Improvement is backwards compatible and includes Main UI (software update) so
that service diagnostics mode works correctly with the new door switch harness
Touch the “Holiday Mode” button to put the unit in or take it out of holiday mode. Ice production is turned off in
holiday mode on the theory that customers will not need more ice while they are away on vacation. However, the
indicators and illumination are turned off for Star-K compliance (Sabbath observance). The holiday mode light
itself will be on, but the idea is that nothing should turn on or turn off due to customer activity (such as opening the
door) during the Sabbath.
There is a current Star-K issue whereby indicators on the ingredient care center (ICC) and the in-door icemaker
(IDI) can come on when both the FC and the RC door are opened at the same time on a side-by-side. One solution
is just simply not to open both doors during the Sabbath if you observe these prohibitions. However, there
will also be a kit coming out that corrects this situation. The kit consists of a door switch harness and a new UI
with update software. A UI with version 29 or greater (see slide 7 for how to get version information) will work
with the new door switch harness. The harness itself corrects the holiday mode issue, but if a UI with earlier version
software is used then the UI display will be off during diagnostics mode.
76

Compressor Inverter
COMPONENT TESTING
COMPRESSOR INVERTER
RED to RED/WHITE = 3-6 volts DC
BLACK to WHITE = 120 volts AC
Diagnosis Step 5 - Compressor running on high.
240 VAC across any 2 output wires to the compressor
Compressor windings are 9-10 ohms
Compressor Inverter
The compressor is required to run at high speed in diagnostic mode step 5. In step 5,
the Gemini board should be putting 6VDC on the RD to RD/WH control wires going to
the inverter. Assuming the inverter is getting 115 VAC on BK to WH, then the inverter
should output 230 VAC to the compressor.
Air Door
You should see 6-8 V from any of the four winding feeds to P6-6. The controller is actually
switching 0-12 VDC voltages very rapidly on the windings and so as it turns out
with a VOM you should see voltage in the same range with the meter on AC as you
would DC.
77

KABIR DIAGNOSTIC INVERTER
This change will greatly improve the diagnosis of compressor, control and inverter
failures.
Note: Diagnostics aren’t foolproof. Since there is no communication between
the inverter and the Gemini, the inverter displays the most likely failure. The
intent is to point the Tech in the right direction.
AIR DOOR
•
DIAGNOSTIC CODE
• LED Off: No failure detected
• 2 Flashes: No 3-6vdc signal from the
control
• 3 Flashes: Inverter failure
• 4 Flashes: Compressor failure or full
restriction
Air door is driven by a stepper motor.
- Each phase 370 Ω – 460 Ω
- WH to BU and YL to RD should each be 370-460Ω
- Operated by 12VDC pulses
- 200 pulses/second
- 1750 steps open to close
78
Note: Always check wires and connectors
first
During operation (diagnostic step 6), either AC or DC can be measured to ground (e.g. P6-6) VOM
should show 6 to 8 V.
Air Door
VOM voltage readings will show “average” readings of 12V pulses. Diagnostic Step 6 will operate the
door operate the door just once in each direction. On the French Door, diagnostic steps 11 and 14 operate
the same way for the left & right bins, respectively.

AIR DOOR
During operation (diagnostic step 6), either AC or DC can be measured to ground
(e.g. P6-6) VOM should show 6 to 8 V.
P6 is the Gemini board connector with the WISP connection; it is left side of the top
edge on the board. P6-6 is an empty silo in the lower right corner of the connector.
Since it is empty, it can be a convenient place for a VOM probe. P6-6, and P6-3 just
above it with the BK/WH wire, are DC grounded (which is isolated from AC ground).
•
•
•
CHECKING THERMISTORS
Thermistor resistance goes down as the temperature goes up.
The display will flash and show 70°F for shorted Thermistors and -10°F for open
thermistors. The “call service indicator will come on”.
To check the accuracy of a thermistor, disconnect it and check the resistance
with the head (not wires) of the thermistor submerged in ice water. The resistance
should be 8700 to 8800 ohms. If the resistance is off by more than 400
ohms, it is inaccurate by 2°F or more and should be replaced.
79

SERVICE POINTERS-BIR
R4317440 Gap between freezer drawer and refrigerator
R4317441 UV drier installed at the factory BIR
R4317433 Mullions discolored
4317426 - Condenser fan motor failure
4317421 – Heat exchanger kit
8178478A – Foam block kit at evaporator
8718568A – Dye Drier, BIR service drier 2317845
8178570 – Will not dispense ice, safety shield
8178548 – Dispenser tabs breaking, M-line models
4317390 – BM overproduction of ice
8178512 – Disp. drip, anti-run-on for M-line models
4317372 – IDI Icemaker fill tube frozen
4317371 – Warm top RC shelf
4317366 – Air return blocked with ice
4317365 – ice door sticks open
4317360 – Crisper support
LITERATURE REVISIONS
KAid SxS, Install-2316565C U&C–W10161714A
KAid BM, Install–2320680B U&C–2320682A
Jenn-Air SxS, Install–W10183782A, U&C–W10151251A
Jenn-Air BM, Install–W10183782A, U&C–W10183787A
80

SERVICE POINTER INDEX
COOKING
BRAND & ID# DESCRIPTION DATE ISSUED
KitchenAid
4317435 Outdoor Cooking Grills 9/08
KNU367TSS, KBSU487TSS, KBSU367TSS, KBNU487TSS
Grill burners will not light and Oven lights go dim.
KitchenAid
4317437 Kitchen Aid Combination Built-In Ovens and
Built-In Microwave Ovens
11/08
Condensation accumulating on the microwave inner door.
KitchenAid
4317438-A K/A Combination Built-In Ovens and 10/08
Built-In Microwave Ovens
KBHS109SSS01, KBHS179SSS01, KEHU309S, KEMD308S
KEMD378S, KEMS308S, KEMS378S
“F6E0” is displayed on the microwave.
KitchenAid / Whirlpool
4317445 Whirlpool and KitchenAid Built-In Single and Double Ovens 12/08
built prior to code date XW49 (December 2008)and All
KitchenAid 24” Built-In ovens
See pointer for Model list
• Oven does not operate after a Self-Clean cycle.
• Oven completely stops during the Self-Clean cycle.
Jenn-Air
8178682 Jenn-Air Wall Oven Electric 9/08
JJW7530DDB/S/W, JJW8527DDB/Q/S/W, JJW8530DDB/Q/S/W
JJW8627DDB/Q/S/W, JJW8630DDB/Q/S/W, JJW9527DDB/S/W
JJW9530DDB/P/S/W, JJW9627DDB/S/W, JJW9630DDB/S/W
JJW9827DDB/P/S/W, JJW9830DDB/P/S/W, JMW858527DAB/Q/S/W
JMW8530DAB/Q/S/W, JMW9527DAB/S/W, JMW9530DAB/S/W
Noise, vibration or rattling in the top of the unit.
Jenn-Air / Amana
8178739 Microwave Hood Combination
AMV5206BA*, JMV8208BA*, JMV8208BA*14, JMV8208BAW15,
JMV8208BC*, JMV8208BC*14, JMV8208BAW15, MMV4205BA*,
MMV5207BA*, MMV5207BC*
5/08
Microwave thermal overload trips/opens and unit stops working
after a few minutes
81

COOKING (continued)
BRAND & ID# DESCRIPTION DATE ISSUED
Maytag / Admiral
Magic Chef
8178740 Ovens
Starts A Bake Or Broil Function Before The
Desired Temperature Is Selected 5/08
AER4311AA*, AGR4412AD*, CER1125AA*, CER1125AC*
CER3725AG*, CER4351AG*, CE35400AA*, CE35400AC*,
CG31600AD*, CGR1425AD*, CP31600AD*, LLR4451AJ*
MER4351AA*, MER4351AG*, MGR4451AD*, MGR4451BD*,
MGR4452AD*, MGR4452BD*, MLR4451AJ*, PER1125AC*,
PER4311AC*, PGR4420LD*
All
8178744 All Gas Freestanding and Slide-In Ranges 9/08
Oven Does Not Heat
Roper
8178745 Gas Freestanding Ranges Surface Burners may not ignite
FGP305KW6, FGP305KW7, SF110AXSQ1, SF110AXSQ2,
SF111PXSQ1, SF111PXSQ2, SF114PSXB1, SF114PSXQ2,
SF114PXST2, SF114PXSW2, SF216LXSM1, SF216LXSQ1,
TGP305TT0, TGP305TQ0, TGP305TQ1,TGP314TT0
Code Date: VEU49 through VEW21
9/08
Jenn-Air
8178755 Dual Fuel Downdraft Slide-In 9/08
JDS9865BDP, JDS9860BDB, JDS9860BDS, JDS9860BDW
When a two burner cartridge is installed in place of the E-Burner grill,
burners seem to have High and Off settings only.
Whirlpool
8178756 Whirlpool, Estate and Ingles Gas and Electric
Freestanding Ranges
RF114, RF 212, WFE301, WFE361, TES325, TES 326,
TE P340, TGS 325, TGS326, IVE323, IVP338, IVE823,
IVP858, YRF115, YWFE301, YWFE361
9/08
Clock display shows “LOC” and only the “CLOCK”, “OVEN LIGHT”
and “TIMER” keypads work.
Jenn-Air
8178758 Jenn-Air Gas and Duel Fuel Ranges
PRG3010LP PRG3010NP PRG3610LP PRG3610NP
PRG4810LP PRG4810NP PRD3030NP PRD3630NP
Burner flame does not carry completely around the burner.
82
9/08

COOKING (continued)
BRAND & ID# DESCRIPTION DATE ISSUED
All
8178768 “for IKEA by Whirlpool” Cooktops and Built-In Ovens
See Pointer for model list 10/08
Model/Serial number is incomplete on tag
KitchenAid
4317439 2008 Dishwasher Drawers
KUDD03DTSS/BL/WH/PA, KUDD03STSS/BL/WH/PA 12/08
The Drawer Will Not Stay Open
Whirlpool
8178747 Whirlpool Dishwashers
DU1145XTP7, DU1148XTP7, DU1145XTP8, DU1148XTP8 7/08
Serial Numbers: FT01 and later.
Sensing light will not come on after control replacement service
Whirlpool
8178748 Whirlpool Dishwashers
DU1145XTP9, DU1148XTP9, DU1145XTPA, DU1148XTPA 7/08
Serial Numbers: FT01 and later.
Sensing light will not come on after control replacement service
Maytag
8178759 Maytag Plastic Tall Tub Dishwashers
See pointer for model list 12/08
Serial Numbers: All
Door makes noises
CLEAN-UP
83

LAUNDRY
BRAND & ID#
Whirlpool
DESCRIPTION DATE ISSUED
8178720-A Cabrio and Bravos Clothes Dryer
Noise From Idler Area
11/08
WED6200S*, WED6400S*, MED6300T*, MED6400T*,
WGD6200S*, WGD6400S*, MGD6300T*, MGD6400T*
SERIAL NUMBERS: Prior to MW27*
Whirlpool
8178742 Cabrio and Bravos Washers 6/08
Intermittent Water Leak
WTW6200S, MTW6300T, WTW6300S, MTW6400T
WTW6400S, MTW6500T, WTW6600S, MTW6600T
WTW6700T, MTW6600T, WTW6200T, MTW6700T
WTW6200V, WTW6500W
Serial Numbers: Prior to CW2270900
Whirlpool
8178746 Whirlpool Built Top Load Washers 6/08
See pointer for model list
Hot Water May Enter When Cold Water Is Selected
Whirlpool / Maytag
8178752 Top-Load Washers 8/08
MAT14CS
Serial Numbers Prior TO: CW2600000
Unit will run a complete cycle and will and shut off properly, but will
take money and not start another cycle.
Maytag
8178754 Maytag Neptune Drying Center 8/08
MCE8000AY* MCG8000AW*
Serial Numbers: All
Long Dry Times or Intermittent Steamer, when Both Dryers Are In Use
Whirlpool
8178764 24 Inch Whirlpool Washers 10/08
LHW0050PQ0-4
Serial Numbers: All
The START button sticks
.
Whirlpool
8178766 24” Thin Twin Washers (Technical Training Pointer) 10/08
A modification to the 24” Thin Twin Washer Suspension Springs was made on the 23rd week of
2007 (date code MU27). Correct installation of these springs is crucial for their proper operation. All
individual Suspension Spring part numbers sub to kit number W10207783. This kit contains three
shocks, three self tapping screws, blue Loctite® and an instruction sheet. Use all of the parts in the kit
and follow the instructions.
Whirlpool / Maytag
8178767 HE Top Load Washers 10/08
WTW6200S, WTW6300S, WTW6400S, WTW6600S,
WTW6700T, MTW6300T, MTW6400T, MTW6500T,
MTW6600T, MTW6700T
Serial Numbers: CT01 – CU52
F1 Error Code
84

BRAND & ID# DESCRIPTION DATE ISSUED
Kitchen Aid
4317436 KitchenAid French Door Counter Depth Refrigerator 9/08
KFCS22EVWH, KFCS22EVBL, KFCS22EVMS
Personality code missing digit
KitchenAid,
Jenn-Air
4317441 Service Initiative - Factory Installed UV Dye Drier
Jenn-Air and KitchenAid Built-In Refrigerators Only 10/08
(Technical Training Pointer)
KitchenAid Whirlpool
Jenn-Air, Maytag
Amana
4317444-A French Door Refrigerators with Ice and Water in the Door 12/08
Refrigerator Compartment Too Cold
ALL
8178760 SXS Refrigerators 10/08
2007 and 2008 SXS’s manufactured with “P trap” drain tubes
Doors hard to open
REFRIGERATION
ALL
8178761 SXS Freezer Doors With In Door Dispensers
All Brands All Models 9/08
(Technical Training Pointer)
Whirlpool, Roper,
Amana, Jenn- Air,
Maytag
8178765 SXS Refrigerators – Non IDI (In Door Ice)
See pointer for list of model numbers
Not Dispensing Ice. 10/08
85

TRAINING EVALUATION
Please use this page as a reminder to provide us with feedback on
today’s meeting.
Complete the online evaluation form, located on the Service Matters
website @:
www.servicematters.com
Instructor’s Name:
Today’s Training Date:
86

- NOTES -
87

- NOTES-
88