Troubleshooting and Repairing Major Appliances

Contents

Acknowledgments

Part I Fundamentals of Service

1 Selecting, Purchasing, and Installing Major Home Appliances and Air Conditioners

Electric and Gas Ranges, Cooktops, and Ovens

Freestanding Ranges

Slide-In Ranges and Drop-In Ranges

Built-In Cooktops

Microwave Ovens

Checklist for Cooking Products

Refrigerators and Freezers

Compact and Portable Refrigerators

Single-Door Refrigerators

Two-Door Refrigerators

Two-Door Refrigerators with Bottom Freezers

Side-by-Side Refrigerators

Checklist for Refrigerator and Freezer Products

Built-In Dishwashers

Convertible/Portable Dishwashers

Undersink Dishwashers

Dishwasher-Sink Combination

Checklist for Dishwashers

Laundry Equipment

Automatic Washers

Top-Loading Automatic Washers

Front-Loading Automatic Washers

Compact Automatic Washers

Automatic Dryers

Checklist for Washers and Dryers

Air Conditioners

Sizing Room Air Conditioners

How to Purchase the Best Air Conditioner or Appliance Value Using the EnergyGuide Label

Major Appliance Consumer Action Panel (MACAP)

Purchasing Decisions

Appliance Warranties

Full vs. Limited Warranties

Warranty Time Limitations

Appliance Installation Instructions

Appliance Use and Care Manual

Where to Get Help

Product Recalls and the Internet

National Appliance Service Technicians Certification (NASTeC)

2 Safety Precautions

Safety Procedures

Individual Safety Precautions

Electrical Safety Precautions

Gas Safety Precautions

Chemical Safety Precautions

Appliance and Air Conditioner Safety

Operating Safety

Installation Safety Precautions

Grounding of Appliances

Checking Appliance and Air Conditioner Voltage

What to Do If You Smell Gas

3 Tools Needed for Installation and Repair

Safety Precautions

Individual Safety Precautions

Safety Precautions When Handling Tools

Specialty Tools

Advantages of Digital Meters

4 Becoming a Professional Technician

What Is Customer Satisfaction?

Customer Satisfaction Is Important for Business

Why Is Customer Satisfaction Important to the Technician?

What Does the Customer Expect of the Service Technician?

How Can a Service Technician Increase Customer Satisfaction Skills?

Communication Skills

Verbal Communication

Nonverbal Communication

Paraverbal Communication

Customer Empathy

Listening to the Customer

Reflective Listening Skills (Feedback)

Asking Questions

Preparing for a Service Call

Prescreen the Service Call for Parts

Proper Grooming for a Service Technician

When You Arrive at the Service Call

Repairing the Appliance or Air Conditioner

Follow-Up Calls

Things to Avoid While on a Service Call

How to Turn Customer Dissatisfaction into Customer Satisfaction

Angry Customers

Don’t Lose Your Cool

Encourage the Customer to Vent Their Emotions

Find Out the Facts

Understand Your Customer’s Feelings

Suggest a Way to Fix the Problem

End on a Positive Note

Never Stop Learning

5 Basic Techniques

Product Failure

Diagnosis and Correction Procedure

Technicians Diagnostic Guide

Part II Electricity, Electronics, and Gas

6 Electricity

Electrical Wiring

What Is a Circuit?

Circuit Components

Three Kinds of Circuits

Parallel Circuits

Series-Parallel Circuits

Types of Shorts in a Circuit

Types of Electric Current

Theory of Current Flow

Ohm’s Law Equation Wheel

Wiring Diagram Symbols

Timer Sequence (Esterline) Charts

Wiring Diagrams

Sample Wiring Diagrams

How to Read the Volt-Ohm-Milliammeter Test Instrument

Measuring Voltage

Making the Measurement

Selecting the Scales

Reading the AC Voltage Scale

Measuring Line Voltage

Testing for Ground and Polarity

Measuring 240-Volt Receptacles

Testing a Three-Wire Receptacle for 240 Volts

Testing a Four-Wire Receptacle for 240 Volts

Measuring Resistance (OHMS)

Setting Up the Meter

Electrical Safety Precautions

Operating Appliances and Room Air Conditioners on a Generator

7 Electronics

Simplified Circuits

Electronic Controls

Low-Voltage Board

High-Voltage Relay Board

Touchpad (Customer Interface)

Three-Board Electronic Control System

Troubleshooting Circuits

Two-Board Electronic Control System

Motor Board Electronic Control System

Resistance Color Bands

Testing a Diode

Bridge Rectifier

Testing a Triac

Integrated Circuits and Circuit Boards

LED Multiple Segment Displays

Electrostatic Discharge

8 Gas

Liquefied Petroleum Gas

Carbon Monoxide

Testing for Carbon Monoxide

The “Flame”

Flame Appearance

Yellow Flame Tips

Appliance Burner Components

Burner Operation

Troubleshooting Ventilation Problems

Measuring Gas Pressure

Testing for Gas Leaks

Combustible Gas Detector

Gas Conversion Procedures

Gas Pressure Regulator

Converting Surface Burners

Converting the Oven Bake Burner

Converting the Oven Broil Burner

Converting the Bake/Broil Thermostat

Gas Appliance Maintenance

Part III Refrigeration and Air Conditioning

9 Principles of Air Conditioning and Refrigeration

Introduction to Air Conditioning and Refrigeration

Saving the Ozone Layer

Change of State

Law of Thermodynamics

It’s All About Heat

Methods of Heat Transfer

Room Air Conditioner vs. Refrigerator/Freezer

The Basic Refrigeration Cycle

Refrigeration Components

Compressor Safety

Trained Personnel Only

Terminal Venting and Electrocution

Compressor Motor Starting Relays

Current Type Relay

Compressor Thermal Protectors (Overloads)

Evaporator Coil

Metering Device

Other Components Used in the Sealed Refrigeration System

Diagnosing Sealed Systems

10 Electric Appliance and Air Conditioner Parts

Pressure Switch

Electromechanical Timer

The Cam Switches

Testing a Capacitor

Heating Elements

Mechanical Linkages

How to Strip, Splice, Solder, and Install Solderless and Terminal Connectors, and How to Use Wire Nuts on Wires

Circuit Protection Devices

11 Electronic Parts

Electronic Components in General

How Electronic Appliances and Air Conditioners Operate

Electrostatic Discharge

Testing Printed Circuit Boards

Touch Panel Membrane

Integrated Circuit Chip

Temperature Detectors

Resistance Temperature Detector

Bridge Rectifier

Piezoelectric Ignitor

12 Gas Appliance Parts

Pressure Regulator Controls

Water Heater Thermostat/Regulator Combination Control

Dryer Gas Valve

Sensing Devices

Resistance Temperature Detector

Glow-Bar Ignitor

Spark Electrode Ignitor

Part V Error/Fault or Function Codes

13 Error/Fault or Function Codes

Error/Fault or Function Codes

Admiral Oven and Range Error/Fault or Function Codes

ASKO Dishwasher Error/Fault or Function Codes

ASKO Washer Error/Fault or Function Codes

ASKO Dryer Error/Fault or Function Codes

Dacor Oven and Range Error/Fault or Function Codes

Estate Oven and Range Error/Fault or Function Codes

Friedrich Room Air Conditioner Error/Fault or Function Codes

Frigidaire/Electrolux Dishwasher Error/Fault or Function Codes

Frigidaire/Electrolux Washer Error/Fault or Function Codes

Frigidaire/Electrolux Dryer Error/Fault or Function Codes

Frigidaire/Electrolux Refrigerator Error/Fault or Function Codes

General Electric and Hotpoint Room Air Conditioner Error/Fault or Function Codes

General Electric and Hotpoint Dishwasher Error/Fault or Function Codes

General Electric and Hotpoint Microwave Error/Fault or Function Codes

General Electric and Hotpoint Range Error/Fault or Function Codes

JennAir Oven and Range Error/Fault or Function Codes

LG Dishwasher Error/Fault or Function Codes

LG Side X Side Refrigerator Error/Fault or Function Codes

LG French Door Refrigerator Error/Fault or Function Codes

LG Washer Error/Fault or Function Codes

LG Frontload Washer Error/Fault or Function Codes

Maytag Laundry Center Error/Fault or Function Codes

Maytag Washer Error/Fault or Function Codes

Maytag Dryer Error/Fault or Function Codes

Maytag/Jenn-Air Oven Error/Fault or Function Codes

KitchenAid/Roper/Whirlpool Gas and Electric Range Error/Fault or Function Codes

Samsung Freezer Error/Fault or Function Codes

Samsung Refrigerator Error/Fault or Function Codes

Samsung Refrigerator Single Evaporator Error/Fault or Function Codes

Samsung RB Series Refrigerator Error/Fault or Function Codes

Samsung Washer Error/Fault or Function Codes

Samsung Dryer Error/Fault or Function Codes

Samsung Range Error/Fault or Function Codes

Samsung Dishwasher Error/Fault or Function Codes

Sears Appliances

Thermador Oven and Range Error/Fault or Function Codes

Whirlpool Room Air Conditioner Error/Fault or Function Codes

Whirlpool and KitchenAid Microwave Error/Fault or Function Codes

Whirlpool Front-Load Washer Error/Fault or Function Codes

Whirlpool Front-Load Dryer Error/Fault or Function Codes

Who Makes What?

Where to Locate the Model and Serial Numbers on the Appliances

Part VI Appliance Service, Installation, and Preventive Maintenance Procedures

14 Automatic Dishwashers

Principles of Operation

Dishwashers in General

Location and Installation of a Dishwasher

Functions and Cycles

Water Temperature

Loading the Dishwasher

Types of Dishwasher Systems

Water Fill Cycle

Water Circulation Systems

Motor/Pump Assemblies

Dishwasher Filtering Systems

Dispensing Systems

Step-by-Step Troubleshooting by Symptom Diagnosis

Common Washability Problems

Poorly Cleaned Dishes

Lime Deposits on the Dishwasher Interior

Suds or Foam in Dishwasher

Darkened Aluminum

Discoloration of Copper

Cracking (Crazing) of China

Chipping of China and Crystal

Metal Marks on Dishes and Glassware

Staining of Melamine Dinnerware

Melting or Warping of Plastic Items

Discoloration of Silverplate

Tarnishing of Silverware (Sterling or Silverplate)

Bluish Discoloration of Stainless Steel

Corrosion or Rusting of Stainless Steel

Dishwasher Maintenance

Repair Procedure

Water Inlet Valve

Motor and Pump Assembly

Dishwasher Timer

The Dishwasher Door Is Hard to Close

Dishwasher Heating Element

Cycle Selector Switch

Dishwasher Door Switch

Float and Float Switch

Wetting Agent and Detergent Dispensers

Water Heater Operating Thermostat or Thermistor

High-Limit Heater Thermostat

Dishwasher Motor Start Relay

Electronic Control Board, Display Board, and Touch Pad Panel

Turbidity Sensor

Diagnostic Charts

15 Garbage Disposers

Continuous Feed Disposers

Batch Feed Disposers

Principles of Operation

Garbage Disposers in General

To Free Jams from Foreign Objects

Installation of Garbage Disposer

Garbage Disposer Maintenance

Step-by-Step Troubleshooting by Symptom Diagnosis

Repair Procedure

Garbage Disposer Assembly

Diagnostic Charts

16 Electric Water Heaters

Principles of Operation

Electric Water Heaters in General

Electric Water Heater Maintenance

Step-by-Step Troubleshooting by Symptom Diagnosis

Repair Procedures

Upper Thermostat

Lower Thermostat

Heating Element

Diagnostic Charts

Help on the Internet

17 Gas Water Heaters

Principles of Operation

Gas Water Heaters in General

Gas Water Heater Maintenance

Thermal Expansion

Negative Air Pressure

Step-by-Step Troubleshooting by Symptom Diagnosis

Repair Procedures

Burner/Manifold Assembly

Combination Control Valve

Water Heater Leakage Inspection Points

Diagnostic Charts

Formulas and Facts

Electric Water Heaters

Gas Water Heaters

Formula for Mixing Hot Water

Electric Working Formulas That Apply to Water Heaters

Help on the Internet

18 Top Load Automatic Washers

Principles of Operation

Functions and Cycles

Automatic Washers in General

Location and Installation of the Top Load Automatic Washer

Common Installation Problems

Drain Requirements

Step-by-Step Troubleshooting by Symptom Diagnosis

Common Washability Problems

Stains on the Clothing

Yellowing in Fabric

Fabric Softener Stains

Automatic Washer Maintenance

Cleaning the Interior of the Top Load Automatic Washer

Repair Procedures

Electronic Control Board and User Interface Controls

Water Temperature Selector Switch

Washer Motor (Older Models)

Washer Motor (Direct-Drive Models)

Front Serviceable Washer

Water Level Control

Direct-Drive Washer Transmission and Brake/Drive Assembly

Diagnostic Charts

19 Front Load Automatic Washers

Principles of Operation

Functions and Cycles

Automatic Front Load Washers in General

Location and Installation of Automatic Front Load Washers

Common Installation Problems

Drain Requirements

Electrical Requirements

HE (High-Efficiency) Detergent

Step-by-Step Troubleshooting by Symptom Diagnosis

Common Washability Problems

Stains on the Clothing

Yellowing in Fabric

Fabric Softener Stains

Automatic Washer Maintenance

Cleaning the Door Seal Gasket (Boot)

Cleaning the Dispenser Drawer

Maintain Washer Freshness

Winterize Washer

Repair Procedures

Electronic Control Board and User Interface Controls

Dispenser Assembly

Water Level Control

Drain Pump Motor

Heater Assembly

Inverter (Motor Speed Control Board)

Wiring Schematic Diagrams

20 Automatic Electric Dryers

Principles of Operation

Functions and Cycles

Automatic Electric Dryers in General

Electrical Requirements

Electrical Tests for Electric Dryers

Location and Installation of Dryer

Proper Exhausting of the Dryer

Step-by-Step Troubleshooting by Symptom Diagnosis

Common Drying Problems

Static Electricity

Electric Dryer Maintenance

Repair Procedures

Electronic Control Board and User Interface Controls

Temperature Selector Switch

Diagnostic Charts

21 Automatic Gas Dryers

Automatic Gas Dryers in General

Gas Supply Requirements

Gas Tests for Gas Dryers

Principles of Operation

Functions and Cycles

Electrical Requirements and Tests for Gas Dryers

Gas Dryer Maintenance

Proper Exhausting of the Dryer

Step-by-Step Troubleshooting by Symptom Diagnosis

Repair Procedures

Electronic Control Board and User Interface Controls

Temperature Selector Switch

Burner Assembly

Diagnostic Charts

22 Electric Ranges, Cooktops, and Ovens

Principles of Operation

Electric Ranges, Ovens, and Cooktops in General

Location and Installation of Electric Range, Oven, or Cooktop

Step-by-Step Troubleshooting by Symptom Diagnosis

Range, Oven, and Cooktop Maintenance

Repair Procedures

Surface Element (Burner) Control Systems

Standard Infinite (Burner) Switch

Dual Infinite (Burner) Switch

Electronic Element (Burner) Control System

Surface Calrod (Burner) Element

Solid-Disc Elements

Radiant Heating Element

Oven Selector Switch

Oven Thermostat

Oven Temperature Sensor

Oven Cycling Relay

Range/Oven Time Clock

Electronic Control Board and User Interface Controls

Diagnostic Charts and Wiring Diagrams

23 Gas Ranges and Ovens

Principles of Operation

Gas Ranges, Ovens, and Cooktops in General

Location and Installation of Gas Range, Oven, and Cooktop

Step-by-Step Troubleshooting by Symptom Diagnosis

Gas Appliance Maintenance

Repair Procedures

Gas Burner Valve

Surface Burner Ignitor

Glow-Bar Ignitor

Pressure Regulator Valve

Electronic Control Board and User Interface Controls

Oven Temperature Sensor

Thermostat (Standing Pilot)

Range/Oven Time Clock

Flame Adjustments

Diagnostic Charts and Wiring Diagrams

24 Microwave Ovens

Principles of Operation

Microwave High-Voltage Circuit

Location and Installation of Microwave Ovens

Microwave Ovens in General

Step-by-Step Troubleshooting by Symptom Diagnosis

Microwave Oven Maintenance

Recipe for Microwave Oven Odor Removal

Microwave Leakage Testing

Microwave Oven Magnetron Power Output Test

Repair Procedures

Electronic Control Board, Touchpad Panel, or Display Board

High-Voltage Transformer

High-Voltage Diode

High-Voltage Capacitor

Microwave Oven Thermostats

Microwave Oven Door Switches

Temperature Probe

Humidity Sensor

Turntable Motor

Cooling Fan Motor

Exhaust Fan Motor

Diagnostic Chart and Wiring Diagrams

25 Refrigerators

The Refrigeration Cycle

Refrigerator Automatic Defrost Systems

Storage Requirements for Perishable Products

Refrigerators in General

Location and Installation of Refrigerator

What’s That “Different” Sound in Your Kitchen?

Are Refrigerators/Freezers Snowbirds?

“Freezer” in Single-Door Refrigerator Has Limited Function

Refrigerator Maintenance

Food Odors and Molds

Step-by-Step Troubleshooting by Symptom Diagnosis

Troubleshooting Sealed-System Problems

Repair Procedures

Electronic Control Board and Touchpad

Thermostat (Cold Control)

Adaptive Defrost Control

Evaporator Fan Motor

Condenser Fan Motor

Defrost Thermostat

Compressor, Relay, and Overload Protector

Diagnostic Charts

Refrigerator Electrical Schematics

26 Freezers

Upright Freezers

Freezer Storage and Temperatures

Freezers in General

Step-by-Step Troubleshooting by Symptom Diagnosis

Troubleshooting Sealed-System Problems

Repair Procedures

Thermostat (Cold Control)

Power Indicator Light

Defrost Timer (Automatic Defrost Models)

Defrost Heater (Automatic Defrost Models)

Defrost Thermostat (Automatic Defrost Models)

Evaporator Fan Motor (Automatic Defrost Models)

Compressor, Relay, and Overload Protector

Diagnostic Charts

Freezer Electrical Schematics

27 Automatic Ice Makers

Automatic Ice Makers in General

Principles of Operation for Type-1 and Type-2 Automatic Ice Makers

Type-1 Ice Maker

Type-2 Ice Maker

Ice Production Rate

Testing the Type-1 Ice Maker

Testing the Type-1 Electronic Ice Maker

Testing the Type-2 Ice Maker

Water/Temperature Problems

Step-by-Step Troubleshooting Type-1 Ice Makers by Symptom Diagnosis

Step-by-Step Troubleshooting Type-2 Ice Makers by Symptom Diagnosis

Diagnostic Chart

Repair Procedures

Type-1 Ice Maker: Module

Type-1 Ice Maker: Thermostat

Type-1 Ice Maker: Mold and Heater Assembly

Water Fill Valve Adjustment

Type-2 Ice Maker: Head and Tray

Type-2 Ice Maker Tray

Type-1 Ice Maker Cycle Chart and Wiring Schematic

28 Residential Under-the-Counter Ice Cube Makers

Automatic Ice Cube Makers in General

Type 1-Self-Contained Ice Cube Maker

Principles of Operation

Step-by-Step Troubleshooting by Symptom Diagnosis

Treating the Water

Cleaning Instructions for the Type 1-Ice Cube Maker

Prevention of Water-Utilizing System Explosions

Systems at Risk of Explosion

How an Explosion Occurs

Service Procedures

Step 1: Check for a Ground Fault (a Short to Ground)

Step 2: Check for Water in the System

Replacing a Single-Wall Water-Utilizing System

Repair Procedures

Type-1 Ice Cube Maker Compressor, Relay, and Overload Protector

Evaporator Thermostat

Hot Gas Solenoid Valve

Condenser Fan Motor

Cutter Grid Transformer and Fuse

Self-Contained Ice Cube Maker Performance Data

Troubleshooting Water and Its Effect on Ice Making

Type-1 Self-Contained Ice Cube Maker Wiring Diagrams

Type-2 Self-Contained Ice Cube Maker

Principles of Operation

Step-by-Step Troubleshooting by Symptom Diagnosis

Repair Procedures

Adjusting the Ice Cube Thickness

Type-2 Ice Cube Maker Compressor, Relay, and Overload Protector

Electronic Control Board

Condenser Fan Motor

Type-2 Ice Cube Maker Performance Data

29 Room Air Conditioners

Principles of Operation

Room Air Conditioners in General

Electrical Requirements

Location and Installation of Room Air Conditioner

Step-by-Step Troubleshooting by Symptom Diagnosis

Room Air Conditioner Maintenance

Performance Data

Repair Procedures

Electronic Components

Thermostat (Operating)

Thermostat (Defrost)

Compressor and Overload Protector

Electric Heater Element

Reversing Valve Solenoid Coil

Selector Switch

Troubleshooting Sealed-System Problems

Reversing Valve (Heat Pump Models)

Diagnostic Charts

Cooling Capacity

Drain Pan Valve

30 Dehumidifiers

Sizing a Dehumidifier

Principals of Operation

Dehumidifiers in General

Location and Installation of a Dehumidifier

Dehumidifier Maintenance

Step-by-Step Troubleshooting by Symptom Diagnosis

Repair Procedures

Electronic Components

Compressor and Overload Protector

Defrost Thermostat

Wiring Diagrams and Schematics