Troubleshooting and Repairing Major Appliances by Kleinert, Eric -- Read -- Imperial Library of Trantor

Index

Cover Copyright About the Author Contents Acknowledgments Introduction 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 Built-In Ovens 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

Freezers

Checklist for Refrigerator and Freezer Products

Dishwashers

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) Endnotes

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

Screwdrivers Nut Drivers Wrenches Hammers Prying Tools Pliers Cutting Tools Power Tools Specialty Tools Test Meters

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) Paraphrasing 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

Series Circuit Parallel Circuits Series-Parallel Circuits

Types of Shorts in a Circuit Strip Circuits Types of Electric Current

Theory of Current Flow

Ohm’s Law Ohms Amperes Volts Watts Ohm’s Law Equation Wheel Wiring Diagram Symbols Terminal Codes 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 Flowcharts

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 Resistors

Resistance Color Bands

Thermistor Diodes

Testing a Diode

Bridge Rectifier Triac

Testing a Triac

Transistor Integrated Circuits and Circuit Boards LED Multiple Segment Displays Electrostatic Discharge

8 Gas

Gas Safety Types of Gas

Natural Gas Liquefied Petroleum Gas

Combustion Carbon Monoxide

Testing for Carbon Monoxide

Flue Gases The “Flame”

Air Supply Flame Appearance Flame Lifting Flashback Yellow Flame Tips

Appliance Burner Components

Gas Orifice Air Shutter Venturi Throat Mixing Tube Burner Head Burner Ports

Burner Operation Ventilation

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 Matter

Change of State

Law of Thermodynamics It’s All About Heat

Methods of Heat Transfer

Refrigerants Room Air Conditioner vs. Refrigerator/Freezer The Basic Refrigeration Cycle Refrigeration Components

Compressor Compressor Safety Trained Personnel Only Terminal Venting and Electrocution Compressor Motor Starting Relays Current Type Relay PTC Type Relay Compressor Thermal Protectors (Overloads) Condenser Coil Evaporator Coil Metering Device

Other Components Used in the Sealed Refrigeration System Diagnosing Sealed Systems

Part IV Parts

10 Electric Appliance and Air Conditioner Parts

The Switch

Pressure Switch Thermostat Electromechanical Timer The Motor The Cam Switches The Escapement

Relays Solenoids Water Valves Motors Compressors Capacitors

Testing a Capacitor

Heating Elements Mechanical Linkages Wires 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 Transformer Circuit Board

Integrated Circuit Chip Resistors Sensors Temperature Detectors

Thermistor Thermocouple Resistance Temperature Detector

Thermopile Transducer Diode

LED Bridge Rectifier Triac

Transistor Inverter Board Piezoelectric Ignitor

12 Gas Appliance Parts

Controls

Pressure Regulator Controls Water Heater Thermostat/Regulator Combination Control Safety Valve Dryer Gas Valve

Sensing Devices

Resistance Temperature Detector Thermocouple Flame Sensors

Ignition

Glow-Bar Ignitor Spark Electrode Ignitor Spark Module

Part V Error/Fault or Function Codes

13 Error/Fault or Function Codes

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 Safety First Dishwashers in General

Location and Installation of a Dishwasher Functions and Cycles Water Temperature The Detergent

Loading the Dishwasher Types of Dishwasher Systems

Water Fill Cycle Water Circulation Systems Motor/Pump Assemblies Dishwasher Filtering Systems Dispensing Systems Drying Systems

Step-by-Step Troubleshooting by Symptom Diagnosis Common Washability Problems

Poorly Cleaned Dishes Etching Discoloration 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

Types

Continuous Feed Disposers Batch Feed Disposers

Principles of Operation Safety First Garbage Disposers in General

To Free Jams from Foreign Objects Installation of Garbage Disposer

Garbage Disposer Maintenance

Drain Blockage

Step-by-Step Troubleshooting by Symptom Diagnosis Repair Procedure

Garbage Disposer Assembly

Diagnostic Charts

16 Electric Water Heaters

Principles of Operation Safety First 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 Safety First Gas Water Heaters in General Gas Water Heater Maintenance Thermal Expansion Water Hammer Negative Air Pressure Draft Test Step-by-Step Troubleshooting by Symptom Diagnosis Repair Procedures

Burner/Manifold Assembly Combination Control Valve Thermocouple Ignitor

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

Safety First Automatic Washers in General

Location and Installation of the Top Load Automatic Washer Common Installation Problems Water Supply Drain Requirements Detergent

Step-by-Step Troubleshooting by Symptom Diagnosis Common Washability Problems

Stains on the Clothing Yellowing in Fabric Fabric Softener Stains Lint

Automatic Washer Maintenance

Cleaning the Interior of the Top Load Automatic Washer

Repair Procedures

Washer Timer Electronic Control Board and User Interface Controls Water Temperature Selector Switch Water Valve Washer Motor (Older Models) Washer Motor (Direct-Drive Models) Front Serviceable Washer Capacitor Drive Belt Water Level Control Lid Switch Water Pump Inner Basket Hoses Clutch Transmission Direct-Drive Washer Transmission and Brake/Drive Assembly

Diagnostic Charts

19 Front Load Automatic Washers

Principles of Operation

Functions and Cycles

Safety First Automatic Front Load Washers in General

Location and Installation of Automatic Front Load Washers Common Installation Problems Water Supply 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 Lint

Automatic Washer Maintenance

Cleaning the Door Seal Gasket (Boot) Cleaning the Dispenser Drawer Maintain Washer Freshness Winterize Washer

Repair Procedures

Washer Timer Electronic Control Board and User Interface Controls Door Lock Line Filter Dispenser Assembly Water Level Control Water Valve Drive Belt Drain Pump Motor Heater Assembly Inverter (Motor Speed Control Board) Drive Motor

Wiring Schematic Diagrams

20 Automatic Electric Dryers

Principles of Operation

Functions and Cycles

Safety First 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

Lint Shrinkage Stains Static Electricity Wrinkling

Electric Dryer Maintenance Repair Procedures

Dryer Timer Electronic Control Board and User Interface Controls Dryer Motor Drive Belt Heater Element Door Switch Thermostat Thermistor Start Switch Drum Roller Idler Pulley Temperature Selector Switch Belt Switch

Diagnostic Charts

21 Automatic Gas Dryers

Safety First 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

Vent System Proper Exhausting of the Dryer

Step-by-Step Troubleshooting by Symptom Diagnosis Repair Procedures

Electronic Control Board and User Interface Controls Dryer Motor Drive Belt Door Switch Thermostat Thermistor Start Switch Temperature Selector Switch Belt Switch Burner Assembly

Diagnostic Charts

22 Electric Ranges, Cooktops, and Ovens

Principles of Operation Safety First 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 Bake Element Broil 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 Safety First 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 Ignitor Switch Surface Burner Ignitor Spark Module Glow-Bar Ignitor Pressure Regulator Valve Safety 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

Safety First 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 Magnetron High-Voltage Transformer Inverter Board High-Voltage Diode High-Voltage Capacitor Microwave Oven Thermostats Microwave Oven Door Switches Temperature Probe Humidity Sensor Stirrer Motor 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

Safety First 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 Door Gasket Thermostat (Cold Control) Defrost Timer Adaptive Defrost Control Evaporator Fan Motor Condenser Fan Motor Defrost Heater Defrost Thermostat Compressor, Relay, and Overload Protector

Diagnostic Charts Refrigerator Electrical Schematics

Example #1 Example #2 Example #3 Example #4 Example #5

Endnotes

26 Freezers

Upright Freezers Chest Freezers Freezer Storage and Temperatures Safety First Freezers in General Step-by-Step Troubleshooting by Symptom Diagnosis Troubleshooting Sealed-System Problems Repair Procedures

Thermostat (Cold Control) Power Indicator Light Gasket 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 Endnotes

27 Automatic Ice Makers

Safety First 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 Valve 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 Endnotes

28 Residential Under-the-Counter Ice Cube Makers

Safety First 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 Bin Thermostat Evaporator Thermostat Hot Gas Solenoid Valve Water Valve Condenser Fan Motor Water Pump Cutter Grid Cutter Grid Transformer and Fuse Cycle Switch

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 Water Valve Water Pump Thermistor Electronic Control Board Condenser Fan Motor

Type-2 Ice Cube Maker Performance Data

29 Room Air Conditioners

Principles of Operation Safety First 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 Thermistor Thermostat (Operating) Thermostat (Defrost) Capacitor Fan Motor 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 Endnotes

30 Dehumidifiers

Sizing a Dehumidifier Principals of Operation Safety First Dehumidifiers in General Location and Installation of a Dehumidifier Dehumidifier Maintenance Step-by-Step Troubleshooting by Symptom Diagnosis Repair Procedures

Electronic Components Capacitor Fan Motor Compressor and Overload Protector Bucket Switch Defrost Thermostat

Wiring Diagrams and Schematics Endnote

Glossary Index

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