Service
This manual is to be used by qualified appliance technicians only. Maytag does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person. This Base Manual covers general information Refer to individual Technical Sheet for information on specific models This manual includes, but is not limited to the following: Side-by Side Refrigerators Maytag MSB1542ARW/A MSB2354ARW/A MSB2554ARW/A MSD2142ARW/A MSD2143ARW/A MSD2346AEW/A/B MSD2354ARW/A MSD2356AEW/A/B MSD2543ARW/A MSD2554ARW/A MSD2556AEW/A/B MSD2754ARW/A MSD2756AEA/W/B MSD2757AEA/W/B MSD2758DRW/B/Q MSD2759DRW/B/Q MSD2959DRW/B/Q Magic Chef CSB2121ARW CSB2122ARW/A CSB2323ARW/A CSD2122ARW/A CSD2123ARW/A CSD2324ARW/A CSD2325ARW/A CSD2524ARW/A CSD2525ARW/A CSD2725ARW/A Jenn-Air JCB2388ARW/A/B JCB2388ATW/A/B JCD2289AEW/A/BF/G/K/R/S/U JCD2289ATW/B JSD2388AEW/A/B JSD2574ARW/B JSD2588AEW/A/B JSD2774ARW/B JSD2789AEW/A/B/S JSD2789ATW/B JSD2989AEW/A/B Admiral ASD2514ARW/A 16010154 November 2003 SAFETY PRECAUTIONS
THIS MANUAL IS TO BE USED ONLY BY A MAYTAG AUTHORIZED SERVICE TECHNICIAN FAMILIAR WITH AND KNOWLEDGEABLE OF PROPER SAFETY AND SERVICING PROCEDURES AND POSSESSING HIGH QUALITY TESTING EQUIPMENT ASSOCIATED WITH MICROWAVE, GAS, AND ELECTRICAL APPLIANCE REPAIR. ALL INDIVIDUALS WHO ATTEMPT REPAIRS BY IMPROPER MEANS OR ADJUSTMENTS, SUBJECT THEMSELVES AND OTHERS TO THE RISK OF SERIOUS OR FATAL INJURY. USE ONLY GENUINE MAYTAG APPROVED FACTORY REPLACEMENT COMPONENTS. 16010154 ©2003 Maytag Corporation CONTENTS i INTRODUCTION
This refrigeration service manual provides the information necessary to service Side-bySide model refrigerators. NOTE: ALL MODELS COVERED IN THIS SERVICE MANUAL USE R134A REFRIGERANT. The manual is printed in loose leaf format. Each part of this manual is divided into sections relating to a general group of components and each section is subdivided into various parts describing a particular component or service procedure. The subdividing of the subject matter, plus the loose leaf form, will facilitate the updating of the manual as new models, and new or revised components of service procedures are introduced. Each page of this manual will be identified in the lower right hand corner. As new or revised pages are published, it will be easy to keep the manual up to date. This serivce manual is a valuable service tool and care should be taken to keep it up to date by prompt and proper filing of subsequent pages as they are issued. ALL "E" MODELS ARE ENERGY MODELS, AND HAVE A PREMIUM SOUND PACKAGE. 16010154 ©2003 Maytag Corporation CONTENTS ii 16010154 ©2003 Maytag Corporation CONTENTS iii CONTENTS
GENERAL SAFETY PRECAUTIONS ............................................................... i INTRODUCTION ..................................................................................... ii CONTENTS .......................................................................................... iv SECTION 1. GENERAL INFORMATION ....................................................... 1-1
ELECTRICAL REQUIREMENTS ........................................................................ 1-1 SAFETY PRECAUTIONS ................................................................................ 1-1 Grounding Instructions ............................................................................. 1-1 FORCED AIR SYSTEMS ................................................................................ 1-2 AIR FLOW - FORCED AIR SYSTEMS ................................................................. 1-2 CHECKING OPERATION ................................................................................ 1-3 TOOLS NEEDED FOR R134A SEALED SYSTEM REPAIR ........................................ 1-4 ADDITIONAL SYSTEM INFORMATION .............................................................. 1-5 R134A SEALED SYSTEM SERVICE PROCEDURE ................................................. 1-7 REFRIGERATION SYSTEM ............................................................................. 1-8 REFRIGERATION CYCLE ................................................................................ 1-9 D I A G N O S I S .............................................................................................. 1-10 SEALED SYSTEM DIAGNOSIS ....................................................................... 1-10 LEAK TESTING ........................................................................................... 1-12 C O M P O N E N T S .......................................................................................... 1-13 Drier .................................................................................................... 1-13 Condenser ............................................................................................ 1-13 Yoder Loop............................................................................................ 1-14 Evaporator ............................................................................................ 1-15 Heat Exchanger ...................................................................................... 1-15 Compressor .......................................................................................... 1-15 SYSTEM FLUSH ......................................................................................... 1-15 SEALED SYSTEM REPAIR SUMMARY ............................................................. 1-16 SYSTEM FLUSH PROCEDURE........................................................................ 1-16 SWEEP AND FINAL CHARGE ........................................................................ 1-19 SECTION 2. COMPONENTS .................................................................... 2-1
COMPRESSOR REPLACEMENT ...................................................................... REPLACING THE COMPRESSOR ..................................................................... CONDENSER REPLACEMENT ......................................................................... ELECTRICAL SYSTEM................................................................................... Testing the Compressor Direct .................................................................... Overload Protector................................................................................... Testing the Overload Protector .................................................................... PTC STARTING DEVICE AND RUN CAPACITOR ................................................... PTC Device Replacement ........................................................................... RUN CAPACITOR ......................................................................................... Testing the Capacitor ................................................................................ Alternate Method Using Ohmmeter .............................................................. TEMPERATURE CONTROL ............................................................................. Checking Operating Temperatures ............................................................... Temperature Control Replacement ............................................................... 2-1 2-1 2-2 2-4 2-4 2-5 2-5 2-6 2-7 2-7 2-7 2-7 2-8 2-8 2-9 16010154 ©2003 Maytag Corporation CONTENTS iv AUTO DAMPER CONTROL MODELS ................................................................. 2-10 Checking the Auto Damper ........................................................................ 2-11 Auto Damper Control Replacement .............................................................. 2-11 AUTO DAMPER CONTROL - Exploded View ........................................................ 2-12 DEFROST TIMER ......................................................................................... 2-13 Checking the Defrost Timer ........................................................................ 2-14 Timer Replacement .................................................................................. 2-14 ADAPTIVE DEFROST CONTROL ...................................................................... 2-14 Checking the Adaptive Defrost Control .......................................................... 2-15 AIR FLOW - FORCED AIR SYSTEMS .................................................................. 2-15 DEFROST HEATER REPLACEMENT .................................................................. 2-17 DEFROST THERMOSTAT REPLACEMENT ........................................................... 2-17 CONDENSER FAN MOTOR ............................................................................. 2-18 To Check Condenser Motor Direct ................................................................ 2-18 Condenser Fan Motor Replacement .............................................................. 2-19 FREEZER FAN MOTOR .................................................................................. 2-19 Freezer Fan Motor Diagnosis ...................................................................... 2-19 Freezer Fan Motor Replacement .................................................................. 2-20 SECTION 3. CABINET & RELATED COMPONENTS ........................................ 3-1
ADJUSTABLE CANTILEVER SHELVES............................................................... 3-1 ADJUSTABLE CANTILEVER SHELF TRIMS ......................................................... 3-1 CABINET DOORS AND ASSOCIATED PARTS ..................................................... 3-1 Inner Door Liner Replacement .................................................................... 3-1 Outer Door Panel Replacement ................................................................... 3-2 FRONT WHEEL ASSEMBLY ............................................................................ 3-2 CABINET LEVELING ..................................................................................... 3-2 DOOR SEAL ............................................................................................... 3-3 TOE-IN & TOE-OUT ADJUSTMENTS ................................................................. 3-3 HINGE ADJUSTMENTS ................................................................................. 3-3 DOOR ALIGNMENT ...................................................................................... 3-4 DOOR SWITCH ........................................................................................... 3-4 WATER/ICE DISPENSER FREEZER DOOR REMOVAL ............................................ 3-4 FOUNTAIN ASSEMBLY - Manual Slide Control .................................................... 3-6 Ice and Water Fountain Bracket Assembly Removal .......................................... 3-6 Checking and Replacing the Crusher and Water/Cube Switch ............................. 3-6 Checking and Replacing the Actuaring Switch ................................................ 3-7 Fountain Heater ....................................................................................... 3-7 PC BOARD CHECKS ..................................................................................... 3-8 Fountain Door Delay ................................................................................. 3-7 Excessive Door Delay ................................................................................ 3-7 Short Door Delay ..................................................................................... 3-7 FOUNTAIN ASSEMBLY - Electronic Control ....................................................... 3-8 Ice and Water Fountain Bracket Removal ....................................................... 3-8 Fountain Bracket Assembly ........................................................................ 3-9 Checking and Replacing the Actuator Switch .................................................. 3-9 Electronic Control Board Troubleshooting ...................................................... 3-9 ICE CRUSHER BIN AND SHELF ASSEMBLY ....................................................... 3-10 ICE/CRUSHER BIN SHELF ENCLOSURE ASSEMBLY ............................................ 3-11 16010154 ©2003 Maytag Corporation CONTENTS v SECTION 4. ICEMAKER .......................................................................... 4-1
SERVICING ................................................................................................ TEST PROCEDURES ..................................................................................... SERVICE PROCEDURES ................................................................................ ACCESSING THE CONTROL BOX .................................................................... MODULE COMPONENTS .............................................................................. WATER FILL ADJUSTMENT ............................................................................ WATER PROBLEMS ..................................................................................... TEMPERATURE PROBLEMS ........................................................................... T H E R M O S TAT ............................................................................................ INSTALLATION ........................................................................................... H A R N E S S .................................................................................................. LEVELING ICEMAKER ................................................................................... REMOVING & REPLACING FILL CUP ................................................................. OTHER INFORMATION .................................................................................. 4-1 4-1 4-2 4-2 4-3 4-4 4-5 4-5 4-5 4-6 4-6 4-7 4-7 4-8 SECTION 5. TROUBLESHOOTING ............................................................. 5-1 SECTION 6. SPECIFICATIONS ................................................................. 6-1
I N D E X....................................................................................................... 21' DISPENSER/NON DISPENSER .................................................................... 23'/25' DISPENSER/NON DISPENSER ................................................................ 21' NON DISPENSER (MAYTAG) ...................................................................... 23'/25' DISPENSER/NON DISPENSER (MAYTAG) .................................................. 23'/25' DISPENSER/NON DISPENSER (MAYTAG PREMIUM) .................................... 6-1 6-2 6-3 6-4 6-5 6-6 SECTION 7. SCHEMATICS ...................................................................... 7-1
INDEX ........................................................................................................ 7-1 Appendix A Climate Zone Technology.........................................................................A-1 16010154 ©2003 Maytag Corporation CONTENTS vi 16010154 ©2003 Maytag Corporation CONTENTS vii SECTION 1. GENERAL INFORMATION
INSTRUCTIONS - ELECTRICAL REQUIREMENTS
It is the personal responsibility and obligation of the appliance owner to provide adequate electrical service for this appliance. Observe all electrical and local codes and ordinaces. A 120 volt 60 Hz, 15 ampere fused electrical supply is required. An individual branch (or separate circuit serving only this appliance) is recommended. Warning - Electrical ground is required on this appliance! Grounding Instructions
This appliance is equipped with a power supply cord having a 3-prong grounding plug. For your safety, this cord must be plugged into a mating 3-prong type wall receptacle which is properly wired, grounded and polarized. If a mating wall receptacle is not available contact a qualified electrician to have the wall receptacle replaced. Do not use an AC adapter plug. If there is any question, local building officials or electrical utility should be consulted. Do not use an extension cord. Before plugging in power cord, operating or testing, follow grounding instructions in Grounding Section.
Electrical Service Grounding: 120 VOLTS, 60Hz Only IMPORTANT SAFETY PRECAUTIONS
WARNING: Personal Injury Hazard To prevent unnecessary risk of fire, electrical shock or personal injury, all wiring and grounding must be done in accordance with National Electrical Code and local codes and ordinances. Warning - Do not under any circumstances remove the grounding prong from the power supply cord. 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-1 FORCED AIR SYSTEMS
On all forced air models, an air circulating fan draws air from across the evaporator and directs it to the fresh food and freezer compartments. A carefully measured amount of chilled air is directed into the fresh food compartment through a baffle to maintain the desired fresh food compartment temperature. The greater part of chilled air is directed into the freezer compartment to maintain freezer temperature. Forced air models use a fan cooled condenser. Depending on the model, the evaporator is automatically defrosted every eight hours of compressor run time. Defrosting is accomplished by a defrost heater activated by a timer. The accumulated moisture is drained into a defrost pan located in the compressor area of the cabinet. FRONT VIEW FREEZER SIDE VIEW AIR FLOW - FORCED AIR SYSTEMS
The airflow balance between the fresh food and freezer compartments is an important factor in maintaining proper compartment temperatures in a forced air refrigeration system. A baffle is used to regulate the amount of chilled air directed into the fresh food compartment. If a colder freezer compartment temperature is desired, the baffle is adjusted so that less air is directed into the fresh food compartment. This causes the compressor to run longer since the thermostat sensing element is located in the fresh food compartment. Cold air is drawn across the evaporator and into the fan. A portion of the air is deflected into the fresh food compartment where it absorbs heat and returns to the fin and tube evaporator
16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-2 through the return opening in the divider. However, most of the air moving across the evaporator is blown through the freezer air tunnel and circulated throughout the freezer compartment. It then circulates back across the fin and tube evaporator where it begins another cycle. overload. Because some models can hold the entire charge in the condenser, the compressor may run continuously and a definite vacuum will be noticed in the low side. When moisture freeze-up causes a restriction, it usually occurs at the outlet end of the capillary tube. Normally, frost buildup can be detected in this area. NOTE: When using a heat gun or hair dryer, use low heat. Never use a torch. At the discharge end of the capillary, apply heat. If there is enough head pressure, and if the restriction is caused by moisture freeze-up, you will be able to hear a gurgling noise as the heat releases the refrigerant through the tubing. It is possible that this moisture will be absorbed by the drier and remedy the trouble. However, if the freeze-up reoccurs, you must replace the drier. A kink in the capillary tube will reveal the same symptom as a moisture freeze-up, except for the accumulation of frost. Where possible, check the capillary tube and straighten any kinks to relieve the restrictions. Check the unit operation. If the condition persists, replace the defective part. If the freeze-up condition does not exist and there is not a kink, you can assume that a foreign particle is causing the restrictions. The only remedy in this case is to replace the restricted part. CHECKING OPERATION
The following general information explains several methods for checking operation of the refrigeration system. This information applies to all systems covered in this manual. The correct operation of a refrigeration system is dependent upon the proper function of each of the parts comprising the system. If the system does not operate properly (long run periods, warmer than normal temperatures), the trouble may be caused by one of the following conditions: (1) - Restricted Capillary Tube
The opening of a capillary tube is about the same diameter as the period at the end of this sentence. Because of this, it is easy to restrict the tube. Extra precautions should be taken when any service procedure involves moving or touching the capillary tube. The slightest kink can cause a complete tube restriction. Restrictions of the capillary tube may be caused by: (1) moisture freeze-up, (2) foreign particles lodged in the tube, or (3) a bend or kink. If the capillary tube is restricted, there will be a noticeable lack of frost on all cooling surfaces; the compressor may operate for a short period of time and cycle on the (2) - Partial Restriction In Low Side Tubing
Bent tubing, foreign matter, or moisture in the system may cause a partial restriction in the low side tubing. This is usually indicated by frost-free tubing between the reSECTION 1. GENERAL INFORMATION 16010154 © 2003 Maytag Corporation 1-3 striction and the capillary tube and by frostcovered tubing between the restriction and the suction line. The restriction acts like a second capillary tube, increasing the pressure ahead of it (warming) and decreasing the pressure beyond it (cooling). To confirm the existence of a restriction in the low side tubing, perform operational pressure checks. TOOLS NEEDED FOR R134A SEALED SYSTEM REPAIR
The following list may help identify basic refrigeration tools needed:
· ALL HOSES AND EQUIPMENT MUST MEET STANDARDS FOR HANDLING R134A REFRIGERANTS APPROVED AND CERTIFIED RECOVERY EQUIPMENT AND RECOVERY CYLINDER (see local supplier for variety of equipment) MANIFOLD GAUGE SET / HOSES MUST HAVE LOW LOSS FITTINGS (Robinair 41365) HEATED CHARGING CYLINDER WITH R134A SCALE (Robinair 43134B) TEMPORARY ACCESS VALVES (2) (Robinair 40288) 1/4" FLARE TEE - MFL X MFL X FFL (Robinair 40399) 1/4" QUICK COUPLER VALVE (Robinair 40380) PROCESS TUBE ADAPTER SET (Robinair 12458) (3) - Slow Leak In System
On forced air models, long run time will be noticed during the early stages of a leak. As the refrigerant continues to escape, both compartments will gradually warm up and the compressor will run continuously. The freezer will probably warm up first. · · · · · · · 4) - Incorrect Refrigerant Charge
The sealed unit may have too much refrigerant (overcharged system) or too little refrigerant (undercharged system). The paragraphs below will inform you on how to recognize a system with these defects. An overcharged system may have a frost back condition appearing on the suction line. When the compressor stops, the frost melts and drips on the floor. A heat exchanger separation will also cause this symptom. An undercharged system, depending on the degree of undercharge, will operate with temperatures above normal and the compressor run time will be increased. The greater the undercharge, the higher the temperature will be and the longer the run time. An undercharged system must be purged, evacuated, and recharged with the proper amount of refrigerant. Before recharging, test for refrigerant leaks.
16010154 Other tools required, but not necessarily dedicated to R134A Service:
· · · TUBING CUTTER (Robinair 14987A) BRAZING TORCH (Robinair 12587) SWAGGING TOOLS (Robinair 14313) VOLT-WATT METER (MAYTAG CUSTOMER SERVICE 20000019) LEAK DETECTION EQUIPMENT FOR CFC/HCFC AND HFC OR EQUIVALENT PINCH-OFF TOOLS (Robinair 12294 or 12396)
SECTION 1. GENERAL INFORMATION · · · © 2003 Maytag Corporation 1-4 NOTE: Robinair equipment is listed as a reference only, equivalent substitutes may be used. Additional tools may be required for special situations. ADDITIONAL SYSTEM INFORMATION
CAUTION Always wear eye protection and protective clothing when handling any refrigerants. LEAK DETECTOR - Leak detectors compatible with R134A should be used. Due to the possibility of contaminating the sealed system with moisture, using soap bubbles can cause problems, especially if drawn into a low side leak. To minimize the possibility of moisture entering the system, the use of wet rags or towels to cool a brazed joint should be avoided. DRIERS/FILTERS - Any time a sealed system repair is made, the drier must be replaced. The drier on R134A systems is different, using a new desiccant which provides system compatibility and proper moisture absorption. Use of the old type drier on new R134A systems would result in a repeat sealed system failure. Part number 13900-1 is the drier which must be used on R134A systems. This drier may also be used on R12 systems and will supersede the 13900 drier, but be sure that the older 13900 is NOT used on the R134A system. Additionally, "unsoldering" a joint, rather than the score and break method, is not acceptable due to the possibility of chemical and moisture contamination. Always cut the drier out of the system-never apply heat. LIMIT TIME OF EXPOSURE TO THE ATMOSPHERE - Whenever a sealed system is repaired, do not expose an open line to the atmosphere for more than 15 minutes. Replacement components will come sealed by either brazing (drier) or plugs (compressor). Do not open the new drier to the atmosphere until you are ready to braze it into place. Before installing a new compressor, pull a plug to be sure the unit is still pressurized. If no pressure exists, do not use the compressor. If pressure exists, reinstall the plug to ensure non-contamination during the service procedure. LOW SIDE LEAKS - In the event of a low side leak, moisture has probably been drawn into the system. The compressor must be replaced in addition to the normal repair. Also, a system flush must be made before proceeding with the sweep charge and final charge. PLUGGED CAPILLARY TUBE - Moisture or other contaminants in the R134A system can cause the formation of gel-like or salt-type deposits within the system. This causes capillary tube restrictions which may not be removed by the flush procedure detailed later. If the restriction cannot be removed from the capillary tube, the heat exchanger, evaporator and compressor must be replaced.
1-5 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION SYSTEM FLUSH - Flushing of the system is required whenever there has been a low side leak, plugged capillary tube or compressor replacement. This is a procedure in which R134A refrigerant is flushed through the system and into the recovery system to remove moisture and noncondensables which may have entered the open system. The compressor must be isolated during the flush procedure, in order to prevent contaminants from being absorbed into the ester oil, resulting in a contaminated system.
The system flush procedure will be done in two parts. First, the condenser, including the yoder loop, will be isolated by means of process tube adapters and flushed with 4 ounces of R134A. After the drier has been replaced, the entire sealed system, minus the compressor, will also be flushed with 4 ounces of the refrigerant. This second step can take about 15 minutes in order to circulate the refrigerant through the condenser, the drier, the capillary tube, the evaporator and out the suction line into the recovery equipment. During this 15 minutes, the old compressor can be removed and the replacement set into place, mounted and prepared electrically. The compressor is totally installed except for the final brazing of the suction and discharge lines. 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-6 R134A SEALED SYSTEM SERVICE PROCEDURE
Any sealed system failure in the upper area indicated below requires the replacement of the evaporator, heat exchanger, drier and compressor. Perform system flush, sweep and add final charge according to procedure shown. Evaporator Suction Line Heat Exchanger Capillary Process Stub Suction Line Connection at the compressor 1 2 Leaks at joints 1 or 2 will require the replacement of the compressor and drier. Perform system flush, sweep and final charge. Condenser
Drier Yoder Heater Loop Leaks or repairs to joints or components in the lower area require repair or replacement of the component and drier. Perform system sweep and add final charge according to normal procedure. 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-7 REFRIGERATION SYSTEM
All refrigerators cool by removing heat from the cabinet rather than pumping in cool air. In a conventional refrigerator, liquid refrigerant enters the evaporator and vaporizes (boils) due to the low pressure, creating a very cold surface which removes heat from inside the cabinet. This causes the refrigerant to boil (evaporate) into a vapor state and be drawn into the compressor. The compressor pressurizes the vapor and pumps it into the condenser. The hot vapor in the condenser gives off the heat into the room. As the vapor cools, it condenses back into a liquid and returns to the evaporator to start the process over again. The system continually soaks up the heat inside the refrigerator and deposits the heat back into the room. · The compressor of the refrigeration system serves two purposes: it ensures movement of the refrigerant throughout the system and it increases the pressure and temperature of the vapor received from the suction line and pumps the refrigerant into the discharge line. The condenser receives this high temperature, high pressure refrigerant and allows the heat to be released into the cooler surroundings. This heat removal "condenses" the refrigerant vapor into a liquid. The yoder loop is the last pass of the condenser routed around the cabinet of the freezer to help prevent moisture formation. The drier is installed at the end of the condenser or yoder loop to capture moisture which may be present in the system. · The capillary tube meters the flow of refrigerant and creates a pressure drop. Size and length of the capillary is critical to the efficiency of the system. As the refrigerant leaves the capillary tube and enters the larger tubing of the evaporator, evaporator the sudden increase in tubing diameter, and the pumping action of the compressor, form a low pressure area. The temperature of the refrigerant drops rapidly as it changes to a mixture of liquid and vapor. In the process of passing through the evaporator, the refrigerant absorbs heat from the storage area and is gradually changed from a liquid and vapor mixture (saturated refrigerant) into a vapor. The suction line returns this low pressure vapor from the evaporator back to the compressor, and the cycle starts again. Part of the capillary tube is soldered to the suction line which forms a heat exchanger. Heat from the capillary tube is thus transferred to the suction line to superheat the refrigerant there and at the same time this further cools the liquid in the capillary tube. This cools the refrigerant before it enters the evaporator and also heats the refrigerant before it enters the compressor to ensure a vapor state. · · · · · 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-8 REFRIGERATION SYSTEM 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-9 DIAGNOSIS
Sealed system diagnosis of R134A refrigerant systems is to be performed identically to that of R12 systems. In fact, as shown in the following flow chart, the service procedures are virtually the same, except for low side leaks, plugged capillary tube or compressor failure which results in a system flush.
REFRIGERATOR DIAGNOSIS LISTEN: · What is the customer complaint? · Are the fans operating? · Is the compressor operating? LOOK: · Are ice cubes present? · Is the light on/off when the switch is operated? · Are the controls set properly? · Do door gaskets seal properly? · Is there an ice buildup on the evaporator cover? · Are the return air ducts free of ice? TOUCH: · Is the evaporator cover warm? · Is air felt exhausting from the kick plate? · Is air circulating in the freezer and fresh food compartments? · Is the quarter inch discharge line from the compressor hot? · Is the condenser warm? SEALED SYSTEM IDENTIFY REFRIGERANT R12 RECOVER REPAIR SWEEP FINAL CHARGE R134a RECOVER REPAIR LOW SIDE LEAK, PLUGGED CAPILLARY TUBE, COMPRESSOR REPLACEMENT? NO YES FLUSH* SWEEP FINAL CHARGE SEALED SYSTEM DIAGNOSIS
Once it has been determined that the other refrigerator systems are working properly, a probable sealed system problem can be confirmed through the use of a wattmeter and checks of low and high side pressures. Access valves are not to be left on a sealed system after service. To measure low side pressure, a temporary access valve can be installed on the compressor process tube. To remove the valve after repair, a pinch off tool may be used to seal the tube while the valve is removed and the hole brazed shut. To check high side pressure, a temporary access valve should be installed on the discharge line. When the high side valve is inSECTION 1. GENERAL INFORMATION * FLUSH INCLUDES COMPRESSOR REPLACEMENT Remember, before entering the sealed system, all other systems must be tested and properly repaired. These include the electrical system, defrost system, control operation, and air flow systems: evaporator and condenser motors. Before "turning a screwdriver", many checks can be made simply by using your senses: 16010154 © 2003 Maytag Corporation 1-10 stalled, the technician is committed to replacement of the drier and a sealed system repair. Once again, this valve must be removed upon completion of repair. Make sure the gauges which are used to check the operating pressures are accurately calibrated. When not connected to a system, the gauge pointer should indicate zero pressure. If necessary, turn the calibrating screw until the pointer is at "0." NOTE: The following situations are typical, however other factors such as gauge placement, line voltage and ambient temperature must also be considered. The following symptoms use high and low side pressures plus wattage measurements to diagnose sealed system problems. Normal low side pressure will range from below zero to about six pounds of pressure, depending on several factors such as refrigerator model, ambient temperature, load and customer usage. Normal high side pressure is also dependent on external factors but will range in the 100 to 125 p.s.i.g. range. Wattage and pressure figures will vary based on the model and age of the refrigerator. Refer to the performance data table(s) at the end of the manual. Symptoms: Symptoms :
High Side Low Side Wattage Near normal pressure Slightly lower pressure Lower than normal Symptoms: Symptoms :
High Side Low Side Wattage Lower than normal Slightly lower than normal Lower than normal Diagnosis - High side leak. Both high and low side pressures will drop as more refrigerant escapes.
Symptoms: Symptoms :
High Side Low Side Wattage Higher than normal Slightly lower than normal Higher than normal Diagnosis - Low side leak. High side pressure will continually increase since air is being drawn into the system through the leak and becomes trapped in the high side tubing. The low side may show a slight increase in pressure because of the air being drawn in through the leak.
Symptoms: Symptoms :
High Side Low Side Wattage Lower than normal In a vacuum Lower than normal Diagnosis - Capillary tube restriction. High side pressure will take much longer (or not at all) to equalize with the low side pressure when the compressor is stopped.
Symptoms: Symptoms :
High Side Low Side Wattage Higher than normal Higher than normal Higher than normal Diagnosis - Low side restriction. The evaporator, suction line or other low side tubing is probably restricted (kinked or blocked with a foreign article such as moisture or contaminant). This condition is usually accompanied with a frost build up on the low side of the restriction. High side pressure will take longer to balance with the low side pressure when the compressor is stopped.
16010154 Diagnosis - Overcharged system. The extent of the pressure increase depends on the amount of overcharge and ambient temperature. An overcharge may also cause the suction line to be frosted during the run cycle, resulting in water on the floor after cycling off. © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-11 Symptoms: Symptoms :
High Side Low Side Wattage Lower than normal Higher than normal Lower than normal LEAK TESTING
Once it has been determined through proper diagnosis that a leak is present in the sealed system, attempt to find the leak before opening the system if possible. To check the high side for leaks, be sure that the compressor is running. During run time the high side pressure is greater. To increase the pressure slightly, stop the condenser fan blade or block the air flow through the condenser. To check the low side for leaks, stop the compressor. During off times, the low side pressure will increase to equalize with the high side. By warming the evaporator, this pressure will increase. If too much refrigerant has leaked out to create enough pressure to locate the leak, add 4 ounces of the proper refrigerant to the system and proceed with the test procedure. The presence of oil around a tubing joint usually indicates a leak. Care must still be taken to pinpoint the exact location. Remember that a leak detector compatible with R134A refrigerant must be used. A sealed system component, such as the evaporator or yoder loop, should not be condemned unless a non-repairable leak is confirmed. This should be determined by either locating the actual leak or by isolating the component from the rest of the system and determining if it holds pressurization or a vacuum - whichever method is chosen. Diagnosis - Inefficient compressor. Cooling surfaces may be covered with a thin film of frost, but the temperature will not descend to cut off temperature of the control, even with continuous running. Also, the condenser will be noticeably cooler to the touch than normal. Once the confirmation that an inefficient compressor is made, the compressor should be replaced.
Symptoms: Symptoms :
High Side Low Side Normal Normal to slightly higher than normal suction line possibly sweats Normal Wattage - Diagnosis - Separated capillary tube. The capillary tube must be connected to the suction line to provide proper heat transfer. Without this transfer, liquid refrigerant in the capillary tube enters the evaporator at a slightly higher temperature thereby lessening the ability to remove heat from inside the refrigerator. The customer complaint would be long run time, slow ice production, warmer fresh food temperature, in general, poor overall performance. Another symptom of a separated capillary tube could be moisture on the floor behind the refrigerator. The heat from the capillary tube is utilized by the suction line to ensure that vapor rather than liquid refrigerant is returned to the compressor. If liquid is present in the suction line, frost or moisture forms on the outside of the line and eventually drips to the floor. 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-12 COMPONENTS Drier
Whenever the sealed system is entered, the drier must be replaced. For R134A refrigerant systems, use a 13900-1 drier. This drier has the proper desiccant suitable for the refrigerant. The drier is stamped with an arrow which indicates the direction of refrigerant flow. The drier inlet has two lines one connects to the yoder loop and the other will be used as a process tube through which the system sweep and final charge will be made. The drier outlet will be connected to the capillary tube. Care should be taken to ensure that the capillary is not inserted too far into the drier to make contact with its internal screen, yet in far enough to prevent restricting the small diameter capillary tube opening with the solder alloy. SUCTION LINE EVAPORATOR YODER CONDENSER LOOP HEAT EXCHANGER COMPRESSOR Condenser
DRIER The condenser is a long folded tube which receives the hot, high pressure vapor from the compressor. While the most common problem is keeping the condenser clean from lint and dirt buildup which prevents proper airflow and the required transfer of the heat to the surroundings, it is possible that due to an unrepairable leak or a nonremovable restriction, the condenser could require replacement. As with any R134A sealed system repair, the key to success is the limiting of the time of atmospheric exposure. Do not remove the plugs on the condenser inlet and outlet tubes until the new condenser is mounted in place and made ready for brazing. The inlet side will connect to the compressor discharge line and the outlet to the yoder loop.
16010154 DISCHARGE TUBE CAPILLARY TUBE CONDENSER © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-13 Yoder Loop
The yoder loop is a non-replaceable component of the sealed system routed within the walls of the cabinet. To diagnose the yoder loop, the tubing must be isolated from the sealed system. This procedure is shown below. If the loop fails to hold the vacuum, a heater repair assembly is to be installed and the loop bypassed by connecting the condenser outlet tube directly to the inlet of the drier. Yoder Condenser Loop YODER LOOP DIAGNOSTIC TEST
1. Isolate yoder loop from remainder of sealed system. 2. Cap or seal one end of the loop (braze or use process adaptor and cap). 3. Attach process adaptor to open end of loop. 4. Attach compound gauge and vacuum pump to the loop. 5. Pull a vacuum and close valve to test for leak in the loop. 6. If unit holds a vacuum, no leak is indicated. Reconnect the yoder loop to the system, replace
the drier and recharge the system to specifications. A VACUUM WILL BE MAINTAINED IF THE SYSTEM IS GOOD.
16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-14 Evaporator
The evaporator is a long aluminum tube folded or coiled within the freezer compartment. If a leak is present in the evaporator, it is not repairable and must be replaced. On R134A systems, whenever the evaporator is replaced, the heat exchanger must also be replaced as well as the compressor. The replacement evaporator will come with the heat exchanger attached. Leave the caps in place on the opposite end of the heat exchanger. Again, whenever the evaporator and heat exchanger are replaced on R134A units, the compressor must also be replaced and the sealed system flushed. Do not connect the suction line to the replacement compressor until the system has been flushed (see System Flush Procedure) . After mounting the evaporator in place, connect the capillary tube of the heat exchanger to the replacement drier. Compressor
The compressor is the "heart" of the refrigerator, consisting of an electrical motor and a "pump" sealed inside a steel case. The compressor used on R134A refrigerant systems is virtually the same in external appearance as the compressor used with R12 refrigerants. However, due to changes in lubricants and other internal differences, the compressors are not to be interchanged, otherwise system failure will result. Diagnostic procedures will be the same as with the R12 refrigerant systems, except that the high side pressure will be slightly higher and the low side pressure will be slightly lower. If a new compressor is to be installed, pull one of the plugs to ensure that it is properly pressurized. If no pressure is observed, do not use the compressor. If unit is pressurized, reinstall the plug and keep the compressor sealed until it is installed and ready for solder connections. Whenever the compressor is replaced on a R134A refrigerator, the sealed system must be flushed (see System Flush Procedure). Heat Exchanger
The heat exchanger is composed of the capillary tube and suction line soldered together. The heat exchanger should be replaced if there is a non-repairable leak, plugged capillary, more than 3 inches have been removed from the capillary or the capillary tube separates from the suction line. If the heat exchanger is replaced, the evaporator must also be replaced as well as the compressor. SYSTEM FLUSH
Before accessing the sealed system, it is necessary to determine that the problem is actually a sealed system problem by utilizing a wattmeter, thermometer, visual and touch indicators. Once it has been determined that the problem is in the sealed system, and diagnosis indicates a low side leak, plugged capillary tube, or a defective compressor, in addition to the normal repair, the system must be flushed and the compressor must be replaced. 16010154 © 2003 Maytag Corporation SECTION 1. GENERAL INFORMATION 1-15 SEALED SYSTEM REPAIR SUMMARY
A. Recover the refrigerant in the system, if any. Repair the low side leak or replace the evaporator and heat exchanger, whichever applies. If the complete low side is replaced, do not braze the suction line to the replacement compressor until the completion of Step 3 of System Flush Procedure. Proceed with the following flush procedure which includes the compressor replacement. After flushing procedure is completed, continue with the normal sweep and final charging procedure. B. C. D. Next, score and break the tube at the yoder loop to the input side of the drier. Attach a process tube adapter to the condenser side of this break. Connect a quick coupler hand valve to this process adapter. Connect the hose from the recovery equipment to this valve (figure 1). Use the heater on the charging cylinder to ensure the cylinder pressure to be approximately 30 pounds above room ambient temperature. For example, if room temperature is 70 degrees, cylinder pressure should be 100 p.s.i.g. Start the recovery system and open the valve at the process adapter attached to yoder loop. Open the valve from the charging cylinder and allow 4 ounces of R134A to flow through the condenser and into the recovery system. This process should take about two minutes. Keep the process adapters and hoses attached at this time. SYSTEM FLUSH PROCEDURE
1. Isolate and flush the Condenser Score and break the discharge line at a convenient location to which the replacement compressor tubing can be connected later. Attach a process tube adapter to the condenser side of this break. Connect a quick coupler hand valve to the process adapter. Connect the hose from the charging cylinder to this valve (refer to figure 1). This connection will remain in place throughout the flush procedure in Step 3. NOTE: Due to the extra flushing and sweep charge procedures, about 12 ounces of R134A refrigerant should be added to the original charge specified on the model/serial plate and loaded into the charging cylinder initially.
16010154 SECTION 1. GENERAL INFORMATION © 2003 Maytag Corporation 1-16 FIGURE 1 FIGURE 2 Flush into discharge line, through hi-side and out the yoder loop at drier inlet.
2. Replace the Drier Score and break either one of the two inlet lines on the new drier (the other line will remain sealed until the sweep charge, at which time it will be the process tube). Prepare the drier outlet side for connection to the capillary tube. The capillary tube should be inserted about 3/4 inch into the drier to prevent solder alloy from plugging the capillary tube or the capillary tube extending too far into the drier and contacting the screen. To facilitate the installation, place a slight bend in the capillary tube about 3/4 inch from the end and insert into the drier. Remove the process tube adapter from the yoder outlet and prepare the tube for connection to the drier inlet. The drier inlet joint will be the only copper-to-steel connection which will require the silver solder and flux. To help prevent flux from entering the system, first insert the line from the yoder loop into the drier inlet, then apply the flux. Braze both the inlet and the outlet joints of the replacement drier. Flush the entire system (less compressor) out the suction line.
3. Isolate and flush the remainder of the system Score and break the suction line close enough to the old compressor to be able to reconnect it to the replacement compressor later. Attach a process tube adapter to the evaporator side of the suction line. Connect the hand valve and hose from the recovery equipment to this adapter (figure 2). Be certain that the pressure in the charging cylinder is about 30 p.s.i.g. above ambient temperature. Start the recovery unit and open the hand valve to the suction line. Release four (4) ounces of R134a from the charging cylinder into the system. It will take about 15 minutes for the refrigerant to pass through the condenser, yoder loop, drier, capillary tube, evaporator, suction line and into the recovery system. This 15 minutes time can be utilized to remove the old compressor (figure 3) and prepare the new compressor by mounting into plac