R-102 CONSUMER CARE TECHNICAL EDUCATION GROUP PRESENTS 2003 69˝ HIGH COUNTER-DEPTH SIDE-BY-SIDE REFRIGERATOR Model GC1SHAXM JOB AID Part No.
FORWARD This Whirlpool Job Aid, “2003 69˝ High Counter-Depth Side-By-Side Refrigerator” (Part No. 8178551), provides the technician with information on the installation, operation, and service of the 2003 69˝ High Counter-Depth Side-By-Side Refrigerator. For specific information on the model being serviced, refer to the “Use and Care Guide,” or “Tech Sheet” provided with the refrigerator. The Wiring Diagram and Strip Circuits used in this Job Aid are typical and should be used for training purposes only.
TABLE OF CONTENTS Page GENERAL .............................................................................................................................. 1-1 Refrigerator Safety ............................................................................................................. 1-1 Model & Serial Number Designations ................................................................................ 1-2 Model & Serial Number Label And Tech Sheet Locations............................................
COMPONENT TESTING ........................................................................................................ 5-1 Component Testing Chart .................................................................................................. 5-1 DIAGNOSTICS & TROUBLESHOOTING ............................................................................. 6-1 User Interface Failure Feedback ........................................................................................
GENERAL REFRIGERATOR SAFETY Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.
MODEL & SERIAL NUMBER DESIGNATIONS MODEL NUMBER MODEL NUMBER G C 1 S H A X PRODUCT GROUP G = Whirlpool Gold PRODUCT IDENTIFICATION C = Counter Depth (24˝ Deep) CAPACITY / CUBIC FOOT SIZE 1 = 11 or 21 MODEL SERIES / SHELVES S = Shelf Variation MODEL FEATURES / PANS H = Crisper Variation MODEL FEATURE CODE A = IDI W/Grille Filter DOOR SWING X = SXS YEAR OF INTRODUCTION M = 2003 COLOR CODE Q = White B = Black S = Stainless ENERGY/POWER DESIGNATOR (NUMERIC) 0 = Original, 1 = 1st Change, 2 = 2nd Change, e
MODEL & SERIAL NUMBER LABEL AND TECH SHEET LOCATIONS The Model/Serial Number label and Tech Sheet locations are shown below.
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INSTALLATION INFORMATION CUTOUT DIMENSIONS 36" (91.5 cm) 131/4" (34 cm) 161/2" (42 cm) 69" (175.0 cm) 2" (5.1 cm) 121/2" (32 cm) 201/4" (51.5 cm) 21/2" (6.4 cm) 91/4" (23.5 cm) 2-1 2" (5.
DOOR REMOVAL TOOLS REQUIRED 3. 1/2ʺ & 5/16ʺ Hex-Head Socket Wrenches Flat-Blade Screwdriver #1 & #2 Phillips Screwdrivers 4. BEFORE YOU BEGIN Turn the refrigerator control OFF. Unplug the refrigerator or disconnect power. Remove the food and any adjustable door or utility bins from the doors. HANDLE REMOVAL (OPTIONAL) 1. 2. Using a Phillips screwdriver, remove the screws located on the inside of each door handle. Pull the door handle straight out from the door (see Illustration 1).
4 Top Left Hinge 3 Water Dispenser Tubing Connection 5 Door Removal 1 Handle Removal (Optional) 6 Top Right Hinge 7 Bottom Hinge 1 1. Do Not Remove Screws 2 1 Base Grille 1. Red Outer Ring 1. Screws 1 Door Closing and Alignment 8 Level 9 10 Door Alignment Rear Leveling 11 Front Leveling 1 1 1. Rear roller leveling screw 1.
DOOR AND HINGE REPLACEMENT DOOR CLOSING AND ALIGNMENT Door Closing 1. If removed, replace both bottom hinges and tighten the screws. 2. Carefully feed the dispenser tubing through the bottom left hinge before replacing the freezer door on the hinge. NOTE: Provide additional support for the doors while the top hinges are being replaced. Do not depend on the door magnets to hold the doors in place while you are working. 3.
4 Top Left Hinge 3 Water Dispenser Tubing Connection 5 Door Removal 1 Handle Removal (Optional) 6 Top Right Hinge 7 Bottom Hinge 1 1. Do Not Remove Screws 2 1 Base Grille 1. Red Outer Ring 1. Screws 1 Door Closing and Alignment 8 Level 9 10 Door Alignment Rear Leveling 11 Front Leveling 1 1 1. Rear roller leveling screw 1.
WATER HOOKUP READ ALL DIRECTIONS COMPLETELY BEFORE YOU BEGIN. IMPORTANT: In order to prevent possible leakage resulting in property damage, be sure: 1. If you are operating the refrigerator before installing the water connection, turn the ice maker to the OFF position to prevent operation without water. 2. Use copper tubing. 3. Install tubing only in areas where temperatures will remain above freezing. 4. All installations must be in accordance with local plumbing code requirements. 5.
THEORY OF OPERATION OVERVIEW The control system consists of an electronic user interface, located on the ice and water dispenser, an electronic control board, located at the left rear of the unit compartment, and thermistors, located in the refrigerator and freezer compartments. These controls communicate with each other, and manage virtually all of the functions of this refrigerator, with the exception of the in-door ice making feature.
USER INTERFACE The user interface allows the customer to adjust the temperatures, choose what kind of ice to be dispensed, and monitor the remaining water filter capacity. There are also lockout modes for the temperature controls and the ice and water dispenser. The temperatures are only displayed in Fahrenheit. NOTE: At the first power-up, the control will start in the following DEFAULT operating mode: • Unit is in the “On” state. • Freezer temperature is set at 0ºF; Refrigerator temperature set at 37ºF.
ICE MODE—This keypad toggles between cubed and crushed ice. In the cubed mode, the CUBED ICE indicator will illuminate. In the crushed mode, the CRUSHED ICE indicator will illuminate. GROCERY SAVOR—Pressing this keypad places the refrigerator section into continuous cool-down mode for 6 hours. The temperature is regulated down to 33°F. After the 6 hour period, the control returns to the last refrigerator set temperature. Pressing the keypad a second time will terminate the GROCERY SAVOR mode.
ELECTRONIC CONTROL BOARD sources, such as water valves, thermistors, defrost bimetal, refrigerator and freezer light switches, and the air damper. The electronic control board directly controls, or supplies power to, virtually all functions of the refrigerator. The main electronic control board is located at the right rear of the unit compartment (facing from the rear). The main electronic board communicates with the user interface.
DEFROST OPERATION Defrost is controlled by the main control board, and incorporates the use of the “pulsed” defrost. However, this defrost system is uniquely different than other Whirlpool electronic refrigerators. • Defrost is initiated by a different set of criteria (listed below). • The bimetal/thermofuse combination switches off the defrost heater, and provides additional defrost circuit protection.
FAN OPERATION AND DELAY Both the condenser and evaporator fan motors operate on DC voltage. The control board supplies 115 volts AC to each motor, where it is converted to DC. DEFAULT SETTINGS If communication between the user interface and the control board is lost for more than 3 minutes, the user interface assumes the board is working correctly. The control board stores the current temperature settings, but will go into a “default mode,” and maintain preset temperatures.
IN-DOOR ICE IMPORTANT: The In-Door Ice (IDI) feature and function on this product is the same as on all other IDI refrigerators. Although physically interchangeable with other IDI electronic controls, these control boards are unique to this product and will not function in other IDI product, nor will other IDI controls function in this product. If replacement controls are needed, order by model number. The IDI control board and the ice maker are powered directly from the control board.
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COMPONENT ACCESS This section instructs you on how to service components inside the 2003 69˝ High Counter-Depth Side-By-Side Refrigerator. The components and their locations are shown below. NOTE: Some of the components called out below are not serviced in this section. COMPONENT LOCATIONS WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
REMOVING A REFRIGERATOR OR FREEZER LIGHT BULB 1. 2. Unplug refrigerator or disconnect power. To remove the freezer light bulb: a) Unhook the four tabs from the light cover (located behind the in-door ice maker) and remove the cover. 3. To remove the refrigerator light bulb: a) Remove the screw from the lens. b) Lower the back of the lens and unhook the three tabs from the liner slots. Freezer Light Cover Refrigerator Light Lens Light Bulb b) Pull the light bulb out of the socket.
REMOVING THE DEFROST BIMETAL 7. WARNING Lift the top evaporator cover and unhook the two tabs from the slots in the cover, then pull the cover up around the drawer slides, and out of the unit. Top Evaporator Cover 2 Tabs In Slots Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. 3. Screw (1 of 4) 2 Shelf Supports Unplug refrigerator or disconnect power.
REMOVING THE REFRIGERATOR THERMISTOR HOUSING 4. WARNING 5. Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. 3. Unclip the refrigerator thermistor and wire from the housing. Place the thermistor in ice water (refer to page 6-9 for the correct readings). Unclip Refrigerator Thermistor Unplug refrigerator or disconnect power.
REMOVING THE WATER & ICE DISPENSER BOARD INTERFACE WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Pull Out Unplug refrigerator or disconnect power. Lift the overflow tray from the water and ice dispenser. 4. Disconnect the two edge connectors from the board interface and remove the housing assembly. Board Interface Edge Connectors Overflow Tray 3.
5. Remove the three screws from the interface board cover and remove the cover. IMPORTANT: Due to static electricity, always handle circuit boards by the edges to avoid damage to the circuitry. 6. Remove the two screws from the interface board and remove the board from the housing.
REMOVING THE EVAPORATOR TRAY 3. WARNING Remove the two 9/32ʺ (7 mm) hex-head screws from the filter bracket, and push the bracket assembly to the right as far as it will go. Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. NOTE: The evaporator tray is not customer removable. 1. Unplug refrigerator or disconnect power. 2. Remove the two screws from the bottom grille and remove the grille.
REMOVING THE CONTROL BOARD 4. WARNING Using a small screwdriver, start at the top of the cover, and pry the tabs on the housing from the loops on the cover. When all the loops are free, remove the cover. Top Of Housing Cover Open Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Unplug refrigerator or disconnect power.
REMOVING THE WATER VALVES 3. WARNING 4. 5. Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. 6. Unplug refrigerator or disconnect power. Remove the six screws from the unit compartment cover and remove the cover. Disconnect the two water outlet lines from the water valves. Disconnect the four electrical connectors from the valve terminals.
REMOVING THE CONDENSER FAN MOTOR 4. WARNING Remove the three Torx (#15) screws from the condenser fan motor and remove the motor from the bracket. Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Unplug refrigerator or disconnect power. Remove the six screws from the unit compartment cover and remove the cover. Fan Motor Torx Screws (2 of 3) 5.
REMOVING THE COMPRESSOR TERMINAL BOX, THE RELAY & OVERLOAD AND RUN CAPACITOR 4. WARNING Pry Top Of Terminal Box Away From Compressor Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. To remove the compressor terminal box: a) Use a screwdriver and pry the top of the terminal box away from the compressor. Unplug refrigerator or disconnect power.
5. To remove the relay and overload: a) Remove the terminal box from the compressor (see step 4 for the procedure). b) Pry the relay off the top two pins of the compressor. c) Pry the overload off the bottom pin of the compressor. 6. To remove the run capacitor: a) Remove the terminal box from the compressor (see step 4 for the procedure). b) Use a 1/2˝ socket and remove the run capacitor nut from the bracket.
COMPONENT TESTING WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. The chart below lists all major electrical components and the procedure for checking them. All continuity/resistance checks should be done with harness connectors unplugged.
COMPONENT VOLTAGE AT COMPONENT RESISTANCE / WATTS TEST LOCATIONS Electronic Control Board 120 VAC N/A Will have 120V at Control Board terminals 3 & 2. User Interface Board 120 VAC N/A Will have 120V at User Interface pins 5/3 & 5/1. Defrost Bimetal 120 VAC Opens @ 45ºF±5º (7ºC±3º) Closes @ 19ºF±5º (–7ºC±3º) Thermofuse 120 VAC Opens @ 162ºF (72ºC) Defrost Heater 120 VAC 550 to 650 Watts 27 to 21 Ω Check resistance at Control Board terminals 16/1 & 12/1 or at heater.
DIAGNOSTICS & TROUBLESHOOTING WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Diagnostics on this product are different than on other Whirlpool SxS refrigerators. Several error codes are available, however there is no “diagnostic mode” that can be “entered” on the electronic control to allow operation of each function separately.
SUGGESTIONS ON DIAGNOSIS Display Is Normal • Disconnect power for 10 seconds and reconnect power. If error code is displayed after 3 minutes, refer to the “User Interface Failure Feedback” and “Component Testing” charts, and check out the appropriate component(s). • If no error codes display and a malfunction is occurring, check or troubleshoot the following appropriate areas. Also refer to the “Component Testing” and “Troubleshooting” charts.
USER INTERFACE FAILURE FEEDBACK The User Interface can display several failure codes. The display will only show the code(s) for 10 minutes, then revert back to the set temperature(s). To access these codes again, disconnect power to the refrigerator for 10 seconds and then power it up again. It may take 3 minutes for the error code(s) to display. The following table summarizes these codes. WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating.
FAILURE POSSIBLE CAUSE TEST PROCEDURE—ACTION Code “CF” blinking on the freezer display. Communication failure between main board and user interface. Verify the proper connections & circuits for RX and TX. Replace the user interface and if the problem persists, replace the main board. 18ºF (–8ºC) or higher temperature reading is blinking on the freezer display. Over-temperature condition due to power failure. Verify proper main plug connection. Press the freezer temperature keypad to reset.
TROUBLESHOOTING CHART The following table shows the various types of appliance faults: WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. PROBLEM POSSIBLE CAUSE TEST PROCEDURE—ACTION No indicators or functions on user interface. No power supply. Verify circuits RX and TX. Verify proper wire connections from main board pins 12/11 & 12/12, to user interface pins 3/1 & 3/2.
PROBLEM POSSIBLE CAUSE TEST PROCEDURE—ACTION Ice maker not producing any ice. Loose connections. Ice maker failure. IR receiver relay failure. IR receiver and emitter optics failure. Verify proper wire connections. Refer to the wiring diagram. Refer to the ice maker “Diagnostic & Troubleshooting” section in In-Door Ice Job Aid #4322658A. Replace the IDI electronic boards. NOTE: In-Door Ice infrared electronic boards used in this product are unique to this product.
PROBLEM POSSIBLE CAUSE TEST PROCEDURE—ACTION Will not defrost. Defrost heater. Defrost bimetal / thermofuse. Control board. Defrost can be initiated by disconnecting and reconnecting power. Main control board will attempt to initiate defrost upon restart: • If bimetal is closed, defrost cycle will start. Relay on main control board will click one time. • If bimetal or defrost circuit is open, defrost cycle will not start, and the cooling cycle will begin.
ELECTRONIC CONTROL BOARD PIN LOCATIONS 3 PIN CONNECTOR (Control Board) Pin 1 Pin 2 Pin 3 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16 Line Compressor Command (Line) Neutral 6 PIN CONNECTOR (Control Board) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 12 PIN CONNECTOR (Control Board) Ice Maker Ice Valve Return (Line) Water Valve Feedback (Line) Condenser Fan Line (Line) Ice Maker Ice Valve Neutral (Neutral) Water Valve Neutral (Neutral) Condenser Fan Load (Neutral) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin
USER INTERFACE BOARD PIN LOCATIONS 5 PIN CONNECTOR (User Interface) 3 PIN CONNECTOR (User Interface) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 1 Pin 2 Pin 3 Neutral Dispenser Lamp Load (Neutral) Line DC Ice Motor DC Ice Motor Door TX (Signal) Door RX (Signal DC Ice Motor Power Supply (Line) 5 4 3 2 1 1 2 3 THERMISTOR RESISTANCE / TEMPERATURE CHART Temperature °F 77.0 50.0 45.0 40.0 35.0 * 32.0 30.2 25.0 20.0 15.0 10.0 5.0 0 –5.0 –10.0 –15.0 –20.0 –25.0 –30.
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WIRING DIAGRAM & STRIP CIRCUITS WIRING DIAGRAM User Interface L L N N BK 4/3 WH 1 16 / 11 16 / 8 Ice Maker IDI Emitter 2 Plug 8 6 3 7-1 BK 2 Ice Chute Door Heater Dispenser Heater 2 BL 4 BK WH BL BR 6 / 1 6/4 BK 16 / 15 BL BL 12 / 3 6/5 BL Disp. Valve I/M Valve FZR Thermistor 4/4 L 3 4 3 * Early Production Input Communication S BL 1 IDI Receiver Door Heater Switch* Door Heater YL Water Disp. Sw. WH 6 / 2 V BL 16 / 9 6/6 Cond.
STRIP CIRCUITS COMPRESSOR L1 N Control Board BR 1 Compressor Overload 2 RUN C BK START S PTC Relay Run Capacitor BL M CONDENSER FAN MOTOR L1 N Condenser Fan Motor Control Board BR 1 6/3 BR Control Board 6/6 BL BL 3 (Fan Delay) DEFROST L1 N Control Board BR 1 Defrost Thermofuse 16 / 1 BR Defrost Heater Bimetal Control Board WH 16 / 14 OR S BL 3 BL OR 12 / 1 Bimetal Feedback To Control Board EVAPORATOR FAN / DELAY L1 N Evaporator Fan Motor Control Board BR 1 16 / 1 Contr
DAMPER (AIR DOOR MOTOR) Air Door Motor (Door Open) L1 Control Board Control Board 3 BR 16 / 4 1 N 1 V 12 / 7 OR 12 / 5 2 BR 3 BL Air Door Feedback To Control Board REFRIGERATOR LIGHT L1 BR Refrigerator Light Sw. Control Board PK 16 / 5 BR 1 N Refrigerator Light Control Board BL BL 3 16 / 13 16 / 7 PK Feedback To Control Board FREEZER LIGHT L1 Freezer Light Control Board BR Freezer Light Sw.
WATER DISPENSER L1 Control Board BR 1 Water Dispenser Sw. 6/3 V 3 6/5 BL BL User Interface L1 N Control Board Control Board 16 / 2 BR BR Dispenser Valve WH ICE DISPENSER 1 Control Board 6/2 16 / 9 BR N Control Board Ice Dispenser Sw. DC Power Supply S BL 3/3 5 5/1 BL BL 4 Y NOTE: The ice dispenser motor rotates CW to dispense crushed ice, and reverses rotation CCW to dispense cubes. Reversing the DC voltage to the motor changes its rotation.
IDI ICE MAKER BR Freezer Light Sw.
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TECH TIPS REMOVING THE ORIGINAL GASKET 3. Clean the remaining soft gasket burr from all sides of the door. NOTE: Replacing the gasket requires trimming away only the soft part of the original foamedin-place (FIP) gasket. Once the soft part of the FIP gasket is removed, a channel is exposed to install the service gasket. To remove the original door gasket: 1. Cut the soft corner section of the FIP gasket. Soft Burr Channel 4.
INSTALLING THE SERVICE GASKET 2. Seat the service gasket securely into the rigid foamed gasket channel with a mallet. 1. Insert the service gasket into the rigid foamed gasket channel.
PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-253-2870 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR LITERATURE ORDERS: PHONE: 1-800-851-4605 FOR TECHNICAL INFORMATION AND SERVICE POI