TECHNICAL EDUCATION TECHNICAL TRAINING SERVICE … · LOKRING Tube Connection System . n . iii....

R-124

TECHNICAL TRAINING MANUAL

LOKRING Tube Connection System

8

TECHNICAL EDUCATION

JOB AID W10329932

L-84

Vertical Modular Washer

SERVICE MANUALLOKRING

Tube Connection System

W11025473

ii n LOKRING Tube Connection System

FORWARD This Whirlpool Technical Training Manual, (Part No. W11025473), provides the In-Home Service Professional with training information for the “LOKRING Tube Connection System.”

The Wiring Diagrams used in this Service Manual are typical and should be used for training purposes only. Always use the Manuals and Literature provided with the individual tools and equipment when performing repairs. Always use the Tech Sheet and Wiring Diagrams supplied with the product when servicing the refrigerator.

For specific operating and installation information on the model being serviced, refer to the “Use and Care Guide” or “Installation Instructions” provided with the refrigerator.

GOALS AND OBJECTIVESThe goal of this Service Manual is to provide information that will enable the In-Home Service Professional to properly use the LOKRING Tube Connection System to repair refrigerator sealed sytems in the Whirlpool family of brands.

The objectives of this Service Manual are to:• Understand and follow proper safety precautions.• Successfully perform necessary repairs.• Successfully return the refrigerator to its proper operational status.

WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on our products by anyone other than authorized In-Home Service Professionals.

Copyright © 2017, Whirlpool Corporation, Benton Harbor, MI 49022

LOKRING is a registered trademark of Lokring Technology, LLC, used with permission.

LOKRING Tube Connection System n iii

TABLE OF CONTENTS

LOKRING Tube Connection System

LOKRING REPAIR PROCEDURE

REFRIGERATOR SAFETY ......................................................................................................................1-1OVERVIEW ..........................................................................................................................................1-2PRINCIPAL OF OPERATION .................................................................................................................1-2TOOLS AND MATERIAL .......................................................................................................................1-3HAND ASSEMBLY TOOL ......................................................................................................................1-8ASSEMBLING A LOKRING FITTING ...................................................................................................1-11ASSEMBLING A LOKRING FITTING ONTO A CAPILLARY TUBE .........................................................1-12ASSEMBLING A LOKRING FITTING ONE SIDE ..................................................................................1-13ASSEMBLING A LOKRING FITTING SHORT STUB..............................................................................1-14QUALITY WORK PROCESSES................................................................................................................1-15

LOKRING Repair Procedure

LOKRING Tube Connection System n 1-1

Refrigerator Safety

You can be killed or seriously injured if you don't immediately

You can be killed or seriously injured if you don't follow

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if theinstructions are not followed.

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.”These words mean:

follow instructions.

instructions.

DANGER

WARNING

1-2 n LOKRING Tube Connection System


OverviewLokring is the only Whirlpool non brazing tool approved for sealed systems. The Lokring Tube Connection System hermetically joins sealed system tubing , without the need for a torch or solder.

The system can make connections anywhere in the refrigerator. It is able to join tubes of any type, including dissimilar metals and thicknesses.

The ability to join sealed system tubing without a flame is critical when working on sealed systems with flammable refrigerant (R600a). Lokring is also beneficial for use with traditional refrigerants, reducing repair time and repair defects. The system is capable of making connections anywhere in the refrigerator and is easy to learn, even for new technicians.

Principle of OperationThe Lokring system uses a fitting consisting of two Lokrings and one Tubular joint to join two tube ends (Figure 1). The hand tool (Figure 2) compresses the fittings over the joint, reducing the diameter ofthe connection creating a hermetic seal between the joint and thetube. Prior to compression, Lokprep, an anaerobic sealant (Figure3), is applied to fill and seal microscopic imperfections in thetubing, ensuring hermetic integrity of the joint (Figure 4).

FIGURE 1: Lokring Fitting

Principle of Operation

FIGURE 2: Lokring Hand Tool

LOKPREP 65G

Metal tubes can have longitudinal grooves on the surface from production. These production-related faults

can be compensated quite easily by moistening the tube ends to be connected with LOKPREP fluid before

assembly. Thanks to its capillary characteristic, it can even flow into microscopic cavities and fill these

out completely. LOKPREP is not an adhesive, rather an anaerobic sealant which hardens under oxygen

exclusion and in contact with free metal ions.

POSSIBILITY A Move the nozzle 360° around the tube to distribute the LOKPREP evenly.

POSSIBILITY B Rotate the moistened tube through 360° inside the joint.

POSSIBILITY C Rotate the joint through 360° around the end of the tube.

12 | LOKPREP

LOKPREP APPLICATION

FIGURE 4: Lokprep Sealing Microscopic Imperfections

Tools and MaterialThe Lokring method requires limited tools and materials.

Required tools:• Tubing Cutter• Tube Caliper• Hand Assembly Tool

Required materials:• Sand Paper• Lokprep Manual• Lokprep Sealant• Appropriately sized fitting

FIGURE 3: Lokprep

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About the Lokring Fittings The Lokring Fittings are composed of a Joint, and two Lokrings. They are shipped with the Lokrings fitted over the Joint. If necessary, the Lokrings can be removed from the Joint using pliers.

How to Select the Correct FittingIt is important to select the appropriate size and material to ensure a long lasting, leak free joint. Lokring fittings are sized and marked using the metric system. Sizes are available to cover all applications, and range from 1.6mm (1/16”) to 35mm (1 3/8”). Fittings are available as Union Connectors to join identical sized tubes, and as Reducing Connectors to join different sized tubing.Brass and aluminum Lokrings are available. Brass Lokrings may have steel or brass rings depending on the size. Aluminum joints always use aluminum rings.

Selecting the Correct MaterialIf either of the tubes being joined is aluminum, always use an aluminum (AL) Lokring. Due to corrosion only

Aluminum Lokring should be used on the interior of the Refrigerator compartments. Use a brass (MS) connector to join any combination of steel or copper tubes (FIGURE

8). It is recommend to use a Heat Shrink covering on the Lokrings inside the Refrigeration compartments.

Select the Correct Lokring Size and Material for Service

Digital Micrometer-CaliperIt is highly recommended that technicians use a digital caliper set in the millimeter mode to determine tubing size.Key steps are highlighted below. Always refer to the instructions provided with your digital calipers for specific instructions.

• Change the batteries regularly, or anytime the calipers indicate a low battery condition.

• Always measure in the millimeter mode.• Ensure the measuring surfaces are clean and free of

debris.• Fully close the calipers, if calipers do not read zero

when fully closed, zero the calipers.

Measuring the TubeUse the center of the inside measuring blades to measure the tube outside diameter (OD). Tubing can often be oblong, or out of round. Taking two readings, 90 degrees apart helps ensure the appropriate size is selected.1. It is critical to zero your calipers before taking any measurements. If you skip this step, your subsequent measurements may not be accurate. Measure the OD of the first tube, and record.2. Rotate the digital calipers, 90 degrees. Measure and record this second reading of the OD.3. Add these numbers and divide by 2 to get the average OD.4. Repeat these steps on the second tube to get the average OD.5. Use the conversion chart on the following pages to select the correct size fitting.6. If the OD measurement is between two sizes, try the smaller size fitting first. Tubes should be measured using a digital caliper set to the millimeter mode.Example 7.8 to 8.2 O.D. Uses a 8mm Lokring connector 8.3 to 8.7 uses a 8.5. Lokring connector

Figure 8: Joint Material Chart

Selecting the correct size

This section covers the proper method to ensure the approriate sized fitting is selected.




On each end of the couplings you will see numbers that Identify the Material and the size. You may need a Magnifying glass to see the numbers embossed on each end of the part.

Material Types MS = Brass ConnectorAL = Aluminum Connector

Connector TypeNK = Union ConnectorNR = Reducing Connector




Inches To Metric Conversion examples

Capulary tubing

1/16” 1.6

5/64” 2.

0.87” 2.2

Connecting tubing

5/32” 4

3/16” 5

1/4” 6

5/16” 8

2MM = No Grooves 1.8 MM = 3 Grooves

The tolerance fit generally built into Lokring connectors is as follows.Lokring capillary tube connectors have a tube O.D. tolerance of plus or minus 0.1 mm and come in sizes 1.8mm, 2mm, 2.2mmThe most popular sizes for US appliances are 1.8 and 2mm.If the O.D. measurement falls between 2 sizes try the smaller size connector first; “if it doesn’t fit”, use the Larger connector

2.2 MM = 2 Grooves

It is suggested to use Heat shrink tubing on all dissimilar tubing inside the refrigerator compartments. Heat Shrink tubing”, not only serves to bundle, protect components and other objects, but also provides an environmental seal that can prevent liquid, gaseous and solid contaminants from reaching sensitive components. The original inside diameter of the Heat Shrink tubing must be large enough to slip over the component to be covered, and the tubing can subsequently be shrunk onto the component by heating the tubing using a heat gun or other source of thermal energy. Step (1) is to choose the proper Shrink tubing to cover the Lokring and connecting tubing. Measure the Lokring and enough to cover the complete fitting. Step (2) Complete the full Lokring process to compress the Lokring. Step (3) move the Heat Shrink tubing over the Lokring and connecting tubing. Step (4) Use the heats source to properly shrink the tubing to seal the complete fitting.



Lokring Coupling Part NumbersWhirlpool single P/N Lokring Identifier Lokring Size Replacement Kit P/N-incl 2 pc

per kit (Couplers Only)

W10894070 Lokprep65G/15 Lokprep65G /15 ml Bottle W10898074 Sealant

W10890087 10.5/8NRMS00 .413"- .313" or 5/16" Brass Reducer W10895710 Coupler

W10890087 8.5/8 NR MS 00 .335" - .313" or 5/16" Brass Reducer W10895713 Coupler

W10890099 8.5/6 NR MS 00 .335"- .250" or 1/4" Brass Reducer W10895716 Coupler

W10890100 8.5/5 NR MS 00 .335"- .197" or 3/16" Brass Reducer W10895720 Coupler

W10890102 8/6 NR MS 00 .313" or 5/16" - .250" or 1/4" Brass Reducer W10895723 Coupler


W10890114 7.5/6 NR MS 00 .295" - .250" or 1/4" Brass Reducer W10895738 Coupler

W10890115 7/6 NR MS 00 .275" - .250" or 1/4" Brass Reducer W10895748 Coupler

W10890117 7/5 NR MS 00 .275" - .197" or 3/16" Brass Reducer W10895750 Coupler



W10890126 6/2 NR MS 00 .250" or 1/4" - .079" Brass Reducer W10896677 Coupler

W10890128 6/1.8 NR MS 00 .250" or 1/4" - .071" Brass Reducer W10896678 Coupler


W10891056 8 NK MS 00 .313" or 5/16" Brass Connector W10896690 Coupler




W10891061 3 NK MS 00 .118" Brass Connector W10896712 Coupler

W10890241 8/2.2NRAL00 .313" or 5/16"- .087" Alum Reducer W10896713 Coupler

W10890290 8/2NRAL00 .313" or 3/8"- .079" Alum Reducer W10897193 Coupler

W10890291 8/1.8NRAL00 .313" or 3/8"- .071" Alum Reducer W10897194 Coupler

W10891067 8 NK AL 00 .313" or 5/16" Alum Connector W10897195 Coupler

W10891719 6 NK AL 00 .250" or 1/4" Alum Connector W10897196 Coupler

W10894058 6 VS MS 00 .250" or 1/4" Brass Stopper W10897197 Coupler

W10592358 6 NF MS SV .250" or 1/4" Charging Tube w/ Schrader Valve

W10913906 Coupler

W10894059 7NAV .275" Ext For Compressor Stub W10897198 Coupler

W10894060 7.5NAV .295" Ext For Compressor Stub W10897199 Coupler

W10894061 8NAV 5/16" Ext For Compressor Stub W10897200 Coupler



Lokring Identifier Number

Lokring Size Whirlpool Part Number

VME5 Pre-Assembly Tool 3/16" W10898067 Tool



NAV11 NAV Assembly Tool W10898071 Tool

NAV-E6 NAV Assembly Tool Insert W10898072 Tool

NAV-E8/7 NAV Assembly Tool Insert W10898073 Tool

Lokprep65G/15 Lokprep65G /15 ml Bottle W10898074 Sealant

HMRK-V Manual Hand Tool Double Hinged Handles

W10898075 Tool

MB8 Assembly Jaws for up to 5/16" W10898076-Need Qty 2 Tool

MB10 Assembly Jaws for up to 3/8" W10898077-Need Qty 2 Tool

CTP 1 Capillary Tube Cutters W10898078 Tool

EMERY Emery Cloth 9x11 W10898079 Cloth

LRSZ 120 Degree Tube Cutter W10898080 Tool

Tool Box-Metal only no tools or fittings

W11026893

Tool Box-Metal, Tools & Coupler Service Kit

W10911009 Tool Kit Complete

Lokring tool kit and kit part numbers



Single Lokring Coupling Part Numbers inside the kit



About the Hand Assembly Tool

The Hand Assembly Tool (Figure 5) is used to joint the two tube ends using the Lokring fittings.

The tool has removable jaws (Figure 6), allowing the appropriately sized jaws to be installed for the job. The majority of the Lokrings used for refrigeration will use the 8mm on both sides of the tool. However we do use the 10mm Jaw on one side of the tool for a few fittings. Recommend to use the jaw that fits the Lokring firmly.

Each handle of the tool has a release lever (Figure 6). The release levers are used to open the jaws to receive the Lokring fitting (Figure 7). Each release lever allows the orientation of the handles to be modified, permitting access to hard to reach places. By releasing the Lever you are setting the Ratchet assembly. Setting the ratchet allows the ratchet device continuous linear or rotary motion in only one direction while preventing motion in the opposite direction. Reminder: after completing every Lokring fitting clean the Lokring and Jaws with a dry cloth.

Figure 5: Hand Assembly Tool

Figure 6: Removable Jaws and Handle Release Levers

Figure 7: Jaws Open to Receive Lokring Fitting

Push Pin Out to Remove Jaw

Swing Out Release Lever to

Open Jaws to

Position Handles

Close-up of the release lever



Service Technician Use Only

Left Handed Operation Right Handed Operation

Hold tool with Release Levers facing towards you.Pull down the ratchet release lever using your left thumb.

Hold the tool with the release levers facing away from you.Pull down the ratchet release lever with your right index finger.

While holding the lever use a pushing motion in direction of arrow to open tool until jaws are fully open.

While holding the lever use a pushing motion in direction of arrow to open tool until jaws are fully open.



Service Technician Use OnlyLeft Handed Operation Right Handed Operation

After the tool is fully open, fold the ratchet handle back against the fixed handle as shown. Place your thumb against the handle to hold the tool open. Grab both handles with your other hand.

After the tool is fully open, fold the ratchet handle back against the fixed handle as shown. Place your thumb against the handle to hold the tool open. Grab both handles with your other hand.

This frees your other hand to hold the tubes and connector.



1. Prepare the Connection1. Use the tubing cutter to separate the tubing if necessary.2. Check for and remove any burs on the tube end.3.Clean the tube end with sandpaper, rubbing around the circumference of the tube.

2. Insert Fitting1. Push Joint onto the tubing until it reaches the inner stop. At this time verify the Lokring you have chosen is a correct fit. 2. If applicable, insert other side of Joint onto the other side of the tubing.

3. Apply Lokprep1. Note; There is a 3 minute curing time of the Lokprep. Do not apply unless the Lokring Fitting will be completed within this time.2. Then back the tubing out about 1/4”before adding Lokprep, Apply one drop of Lokprep. Then fully insert the tubing into the Lokring

4. Rotate fitting

5. Compress Lokrings1. Insert Lokring fitting into jaws of hand tool. Ensure the fitting remains up against the marked line on the tubing. 2. Ratchet the tool closed, compressing the Lokrings until they are flush to the assembly stop of the joint.

6. Important! Wait 3 minutes before applying vacuum, pressure or force. This allows the Lokprep to cure before proceeding. Reminder: after completing every Lokring fitting clean the Lokring and Jaws with a dry cloth.

Assembling a Lokring Fitting

1. Rotate the fitting 360* after fully inserting tubing. This is to evenly distrubute the Lokprep evenly around the complete tubing.



Installing Lokring Fittings onto Capillary Tubes

Lokring reducers for capillary connections such as at the evaporator inlet, or drier outlet, do not have an internal stop at the capillary side of the connector. This section provides additional guidance for installing capillary tubes. Follow guidance on the previous page for the other, non-capillary side of the fitting.

1. Prepare the Connection1. Use the tubing cutter to separate the tubing if necessary.2. Clean the capillary tube end with sandpaper, rubbing

around the circumference of the tube.

2. Insert Capillary Tube1. Pass the capillary tube all the way through the properly

sized Lokring Connector as shown, so that it just emerges from the other end.

3. Bend the Capillary Tube1. Place a slight bend into the capillary tube, as shown,

creating a stop for the capillary tube.2. Complete Steps 1-4 on the previous page, for the other

piece of tubing.

4. Apply Lokprep to Capillary Tube1. Pull the Capillary tube back slightly (about 1/8”)2. Apply only a single drop of Lokprep where the tube meets

the fitting. Too much Lokprep or too close to the end may block the cap tube.

3. Rotate the fitting 360° to disperse Lokprep evenly around the tubing.

Note: Tubing smaller than (1/4’ or 6mm) Apply Lokprep while tubing is partially inserted in the Lokring.



It is possible to Pre-assemble one side of the fitting joint at a time. There are three sizes of drive blocks that will act as a bypass. Figure (1) there are three different sizes. Use the proper size for the fitting you are using. In figure (2) you can see how the block inserts into the Lokring to prevent the Ring from compressing the Joint. Figure (3) is the proper position for the joint to be inserted into the jaws. Figure (4) is a completed one sided joint to be uses as needed at a later date.

Pre-assemble one side of the fitting coupling at a time.

Pre-Assembly Block 3/16” 1/4” and 5/16”

Figure (1)

Insert the block on the side of the joint you will not being crimping. The block prevents the coupling from compressing. This will allow the blocked joint to be available for use as needed.

Figure (3)

In figure (3) the jaws are secured on the end of the block on one side and the end of the fitting to be compressed on the other. This will cause the end with the block the ability to be compressed at a later time.

Figure (4)

This is showing a completed/compressed Lokring.

Notice the joint and Lokring placement. You now will see the joint extended outside the Lokrings. Reminder: after completing every Lokring fitting clean the Lokring and Jaws with a dry cloth.

Figure (2)



Included in the Whirlpool kit you will find a short stub kit. Figure (1) shows the tools and parts needed to extend a compressor stud that is too short to get the compression tool around the Lokring. Figure (2) shows the two sides of the Lokring. One side is tapered and one is larger. On Figure (3) 1. It is very important that after Lokprep is added the tapered side is be inserted first. 2. Then the Compressor Extension insert tool. 3. Last insert the Compressor Extension assembly tool. 4. To secure the joint you need to use a hammer to hit the end of the Compressor Extension assembly tool. When using this method too much force with the hammer can damage the stud. You can remove and reinstall the assembly tool to check the fitting progress.

When you have completed the installation of the Lokring be sure to wipe off any excess Lokprep.



It is very important to fully insert the tool jaws onto the Lokring. This will provide even pressure to the Lokring for proper seal.

Two things can cause this bent coupling. Not inserting the jaws fully or leaving a buildup of Lokprep on the jaws.

Quality work processes.

Restricted tubing can be caused by adding too much Lokprep. If the Lokprep is added too close to the end it will seep into the opening of the tubing and restrict the tubing.

Jaws not installed fully.Causing a bent coupling

This is too close to the opening of the tubing and will cause the Lokprep to seep into the opening.

The best process is to insert the tubing about 50% of the way. Then add the Lokprep then fully insert the tubing. Final process is to turn the coupling 360* to evenly distribute the Lokprep.

This Jaw has a build up of Lokprep due to not cleaning after every use. This will cause the Lokring to move while compressing.

This is a properly cleaned compression jaw

Note: Tubing smaller than (1/4’ or 6mm) Apply Lokprep while tubing is partially inserted in the Lokring.



NOTICE TO THE TECHNICIANIt is the responsibility of the Service Technician to comply with all EPA Regulations and Standards and posses all necessary State and Federal licenses when servicing

refrigerators.

Federal regulations and Standards can be found on the United States Government EPA Web Site.

State Regulations and Standards and licensing requirements, in most cases, can be found on the State Government Web Site.

Notes

PRODUCT SPECIFICATIONS &WARRANTY INFORMATION SOURCES

IN THE UNITED STATES:FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL:

FOR WHIRLPOOL PRODUCTS: 1-800-253-1301

FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL:THE TECHNICAL ASSISTANCE LINE: 1-800-832-7174

HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS ANAUTHORIZED IN-HOME SERVICE PROFESSIONAL

FOR LITERATURE ORDERS (CUSTOMER EXPERIENCE CENTER): PHONE: 1-800-851-4605

FOR TECHNICAL INFORMATION AND SERVICE POINTERS: www.servicematters.com

IN CANADA:FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL

PHONE: 1-800-461-5681

FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL:THE TECHNICAL ASSISTANCE LINE: 1-800-488-4791

HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL

LOKRING TUBE CONNECTION SYSTEM

W11025473

TECHNICAL EDUCATION TECHNICAL TRAINING SERVICE … · LOKRING Tube Connection System . n . iii....

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