Kenmore 795.76083.600, 795.76084.600, 795.76093.600, 795.76824.600, 795.76282.600 Service Manual

...

BOTTOM FREEZER REFRIGERATOR

Use & Care Guide

REFRIGERATOR

SERVICE MANUAL

CAUTION BEFORE SERVICING THE PRODUCT READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

MODELS:

795.76082.600

795.76084.600

795.76089.600

795.76092.600

795.76083.600

795.76093.600

795.76282.600

795.76824.600

795.76289.600

795.76292.600

795.76283.600

795.76293.600

Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.

www.sears.com

CONTENTS

SAFETY PRECAUTIONS ..........................................................................................................

1. SPECIFICATIONS ..................................................................................................................

2. PARTS IDENTIFICATION .......................................................................................................

3. DISASSEMBLY ......................................................................................................................

3.1 Door ..................................................................................................................................

3.2 Door switch ........................................................................................................................

3.3 Fan and fan motor ..............................................................................................................

3.4 Defrost control assembly ...................................................................................................

3.5 Lamp .................................................................................................................................

3.6 Refrigerator control box .....................................................................................................

3.7 Multi duct ...........................................................................................................................

3.8 How to remove and reinstall the pullout drawer ...................................................................

3.9 Cover Valve .......................................................................................................................

4. ADJUSTMENT ......................................................................................................................

4.1 Compressor ......................................................................................................................

4.2 PTC-Starter .......................................................................................................................

4.3 OLP (overload protector) ...................................................................................................

4.4 To remove the cover PTC ...................................................................................................

5. CIRCUIT DIAGRAM ...............................................................................................................

6. TROUBLESHOOTING ...........................................................................................................

6.1 Compressor and electrical components .............................................................................

6.2 PTC and OLP .....................................................................................................................

6.3 Other electrical components ..............................................................................................

6.4 Service diagnosis chart ......................................................................................................

6.5 Refrigeration cycle .............................................................................................................

7. ICEMAKER OPERATING PRINCIPLES AND REPAIR ..........................................................

7.1 Operation Principle ............................................................................................................

7.2 Ice maker functions ............................................................................................................

7.3 Defect diagnosis function ...................................................................................................

8. DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM .........................................................

8.1 Function ............................................................................................................................

8.2 PCB function .....................................................................................................................

8.3 Resistance specification of sensor .....................................................................................

8.4 Troubleshooting ................................................................................................................

8.5 Main PWB assembly and parts list .....................................................................................

8.6 PWB diagram ....................................................................................................................

9. EXPLODED VIEW AND REPLACEMENT PART LIST ...........................................................

2 3 5 6 6 6 7 7 7 7 7 8 11 12 12 12 13 13 14 15 15 16 17 18 19 21 21 22 24 25 25 29 37 38 40 43 45

SAFETY PRECAUTIONS

Please read thefollowing instructions before servicing your refrigerator.

1. Check the refrigerator for current leakage.

2. To prevent electric shock, unplug before servicing.

3. Always check line voltage and amperage.

4. Use standard electrical components.

5. Don't touch metal products in the freezer with wet hands. This may cause frostbite.

6. Prevent water from spiling onto electric elements or the machine parts.

7. Before tilting the refrigerator, remove all materials from on or in the refrigerator.

8. When servicing the evaporator, wear gloves to prevent injuries from the sharp evaporator fins.

9. Service on the refrigerator should be performed by a qualified technician. Sealed system repair must be performed by a CFC certified technician.

- 2 -

1. SPECIFICATIONS

1-1 DISCONNECT POWERC ORDB EFORE SERVICING IMPORTANT

RECONNECTALL GROUNDING DEVICES.

All parts of this appliance capable of conducting electrical current are grounded. If grounding wires, screws, straps, clips, nuts or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened.

1-2 IMPORTANT NOTICE

This information is intended for use by individuals possessing adequate backgrounds of electrical, electronic and mechanical experience. Any attempt to repair a major appliance may result in personal injury and property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

ELECTRICAL SPECIFICATIONS

1.3

Temperature Control (Position: MID) ............................................................................................................................................. -6°F to +8°F

Defrost Control ...................................................................................................................................................................................Automatic

Defrost Thermostat .....................................................................................................................................................................................50°F

Electrical Rating : 115VAC, 60Hz...............................................................................................................................................................1- 5 A

Maximum Current Leakage .....................................................................................................................................................................0.5mA

Maximum Ground Path Resistance ..................................................................................................................................................0.14 Ohms

Energy Consumption

....................................................................................................................................

20 cu.ft 482kWh/yr(Energy Star) 22 cu.ft 494kWh/yr(Energy Star)

1-4 NO LOADP ERFORMANCE

Control Position: MID/MID

AndAmbient of: 70°F

Fresh Food, °F...............................................................

Frozen Food, °F..............................................................

Percent Running Time........................................................

33°F to 41°F

-4°F to +4°F 25%-35%

1-5 REFRIGERATIONS YSTEM

Minimum Compressor Capacity Vacuum ...................................21 in

Minimum Equalized Pressure

@70°F......................................................................49PSIG

@90°F......................................................................56PSIG

Refrigerant R134a................................................................. 4.2. oz

Compressor ................................................................... 700 BTU/hr

90°F

......................................................................................

33°F to 41°F

-4°F to +4°F .

...

45%-60%

1-6 INSTALLATION

Clearance must be provided at top, sides and rear of the refrigerator for air circulation.

AT TOP..........................................................................................1 in

AT SIDES.................................................................................. 1/8 in

AT REAR.......................................................................................1 in

- 3 -

PERFORMANCE DATA

(NORMAL OPERATING CONDITIONS)

AMB WATTS

70°F 90°F

110°F

98 (+10 / -10) 98 (+10 / -10) 103 (+5 / -5)

1-8 AIR FLOW / CIRCULATION D’AIR.

SYSTEM PRESSURE (PSIG)

HIGH SIDE LOW SIDE

98 (+5 / -3) 132 (+3 / -3) 180 (+5 / -5)

(-5) to (-2)

(-4) to 1 (-2) to 3

1-7 REPLACEMENT PARTS

Relay........................................

Overload...................................

Defrost Thermostat ..................

Defrost Heater......................

Evaporator Fan Motor...............

Capacitor..................................

Compressor (Hi-Side) ...............

Evaporator (Lo-Side).................

Condenser ................................

Dryer..........................................

Condenser Fan Motor................

Temperature Control

Main Control..............................

..................

(20 cu.ft ) 5300JB1100D (22 cu.ft ) 5300JB1100J

0CZZJB2003H

6748JJ8002A 6750JJ8002A

6615JB2005C

4680JK1002B 2521JJ8004A

5421JJ1001B 5403JJ1007A 5851JJ2002B

4680JK1001B

6871JB2047A 6871JB1215A

EVAPORATORFAN

DRYER

COMPRESSOR

EVAPORATOR

HOTLOOP

CONDENSER

CONDENSER FAN

- 4 -

COLDAIR

MIXEDAIR

AIR RETURN TO EVAPORATOR

EVAPORATOR

FRESHFOOD

Vegetablebox

FREEZER

2. PARTS IDENTIFICATIONS

PARTSANDFEATURES

F G

Use this section to become more familiar with the parts and features.

NOTE:This guide covers several different models. The refrigerator you have purchased may have some or all of the items listed below. The locations of the features shown below may not match your model.

Cool Sense Electronic Temperature

Control System

Refrigerator Light

Refrigerator Shelves

Snack Pan Supra Fresh Crisper with Tilt-Out Compartment

Adjusta Cube Ice Maker

F G

Ice Bin

Durabase Divider

Glide-Out Drawer Basket Freezer Light

Refrigerator Door Rack

L M

Wine Rack*

Egg Box Modular Door Bins

Dairy Corner

On some models

- 5 -

3. DISASSEMBLY

3-1 DOOR

Refrigerator Door

1. Remove the hinge cover by pulling it upwards.

2. Loosen the hexagonal bolts attaching the upper hinge to the body and lift the freezer door.

HINGE COVER BOLT

HINGE

Figure 1

3. Pull out the door gasket to remove from the door foam assembly.

GASKET

Freezer Door

1. Loosen the hexagonal bolts attaching the lower hinge to the body to remove the refrigerator door only.

LOWER HINGE

BOLT

Figure 3

2. Pull out the door gasket to remove from the door foam assembly.

3-2 DOOR SWITCH

1. To remove the door switch, pry it out with a slotted-type driver, as shown in (Figure 4).

2. Disconnect the lead wire from the switch.

Figure 2

LEAD WIRE DOOR SWITCH

Figure 4

3-3 FAN AND FAN MOTOR

1. Remove the freezer shelf. (If your refrigerator has an icemaker, remove the icemaker first)

2. Remove the grille by pulling it out and by loosening a screw.

3. Remove the Fan Motor assembly by loosening 2 screws and disassemble the shroud.

4. Pull out the fan and separate the Fan Motor and Bracket.

5. Pull out the fan and separate the Fan Motor and Bracket.

FAN MOTOR

BRACKET

MOTOR

FAN

GRILLE

Figure 11

3-4 DEFROST CONTROL ASSEMBLY

Defrost Control assembly consists of Defrost Sensor and FUSE–M.

The Defrost Sensor works to defrost automatically. It is attached to the metal side of the Evaporator and senses its Temperature. Fuse-M is a safety device for preventing over-heating of the Heater when defrosting.

At 72°C, it turns the Defrost Heater off.

1. Pull out the grille assembly. (Figure 6)

2. Separate the connector with the Defrost Control assembly and replace the Defrost Control assembly after cutting the Tie Wrap. (Figure 7)

3-5-1 Refrigerator Compartment Lamp

1. Unplug the power cord from the outlet.

2. Remove refrigerator shelves.

3. Release the hooks on both ends of the lamp shield and pull the shield downward to remove it.

4. Turn the lamp counterclockwise.

5. Assemble in reverse order of disassembly. Replacement bulb must be the same specification as the original (Max. 60 W-2EA).

Figure 9

3-5-2 Freezer Compartment Lamp

1. Unplug refrigerator or disconnect power.

2. Reach behind light shield to remove bulb.

3. Replace bulb with a 0-watt appliance bulb.6

4. Plug in refrigerator or reconnect power.

3-6 CONTROL BOX-REFRIGERATOR

1. First, remove all shelves in the refrigerator, than remove the Refrigerator control Box by loosening 2 screws.

CONTROL BOX

COVER LAMP

Figure 10

GRILLE ASSEMBLY

DEFROST-CONTROL ASSEMBLY

Figure 6

3-5 LAMP

Figure 7

Figure 8

2. Remove the Refrigerator Control Box by pulling it downward.

3. Disconnect the lead wire on the right position and separate the lamp sockets.

3-7 MULTI DUCT

1. Remove an upper and lower Cap by using a flat screwdriver, and loosen 3 screws. (Figure 11)

2. Disconnect the lead wire on the bottom position.

Figure 11

- 7 -

3-8 HOW TO REMOVE AND REINSTALL THE PULLOUT DRAWER

3-8-1 FOLLOW STEPS TO REMOVE

Step 1) Open the freezer door.

Step 3) Remove the two screws from the guide rails (one

from each side).

Step 2) Remove the lower basket.

Step 4) Lift the freezer door up to unhook it from the rail

support and remove. Pull both rails to full extension.

Step 5) First: Remove the gear from the left side first by releasing the tab behind the gear, place a screwdriver between the

gear and the tab and pull up on the gear. Second: Remove the center rail. Third: Remove the gear from the right side by following the same steps for the left side.

NOTE: THIS TAB MUST BE PUSHED IN TO RELEASE THE GEAR.

- 8 -

3-8-2 FOLLOW STEPS TO REINSTALL

Step 1) Reinstall the right side gear into the clip.

Step 2) Insert the rail into the right side gear. Gears do not

need to be perpendicular to each other.

Step 4) The rail system will align itself by pushing the rails

all the way into the freezer section. Pull the rails back out to full extension.

Step 3) Insert the rail into the left side gear, and insert the

gear into the clip.

Step 5) Reinstall the freezer door by inserting the rail tabs

into the guide rail.

Step 6) Reinstall the two screws into the guide rails

(one from each side).

Step 7) Reinstall the lower basket, and close the freezer

door.

- 9 -

3.8.3 GLIDE OUT DRAWER BASKET

To remove, lift basket up and pull out straight out.

2.1.To Install, pull both rails out to full extension.

Hook the basket supports into the rail tabs and push to the back of compartment.

- 10 -

3-9 Cover Valve

- Disassemble

1. Push to inside the cover valve.

- Assemble

1. Insert the cover valve as shown in the picture, push to insert (may need force).

2. Push to the right and release.

3. Release hook a & b

4. Turn the cover valve 120° as shown in the picture, then release it.

2. Insert hook a & b

3. Push to the right to insert the cover valve.

4. Then push to inside to assembly.

- 11 -

4. ADJUSTMENT

4-1 COMPRESSOR

4-1-1 Role

The compressor intakes low temperature and low pressure gas from the evaporator of the refrigerator and compresses this gas to high-temperature and high-pressure gas. It then delivers the gas to the condenser.

4-1-2 Composition

The compressor includes overload protection. The PTC starter and OLP (overload protector) are attached to the outside of the compressor. Since the compressor is manufactured to tolerances of 1 micron and is hermetically sealed in a dust and moisture-free environment, use extreme caution when repairing it.

4-1-3 Note for Usage

(1) Be careful not to allow over-voltage and over-current. (2) If compressor is dropped or handled carelessly, poor

operation and noise may result.

(3) Use proper electric components appropriate to the

Particular Compressor in your product.

(4) Keep Compressor dry.

If the Compressor gets wet (in the rain or a damp environment) and rust forms in the pin of the Hermetic Terminal, poor operation and contact may result.

(5) When replacing the Compressor, be careful that dust,

humidity, and soldering flux don’t contaminate the inside of the compressor. Dust, humidity, and solder flux contaminate the cylinder and may cause noise, improper operation or even cause it to lock up.

4-2 PTC-STARTER

4-2-1 Composition of PTC-Starter

(1) PTC (Positive TemperatureCoefficient) is a no-contact

semiconductor starting device which uses ceramic material consisting of BaTiO

(2) The higher the temperature is, the higher the resistance

value. These features are used as a starting device for the Motor.

4-2-2 Role of PTC-Starter

(1) The PTC is attached to the Sealed Compressor and is

used for starting the Motor.

(2) The compressor is a single-phase induction motor.

Durign the starting operation, the PTC allows current flow to both the start winding and main winding.

4-2-3 PTC-Applied Circuit Diagram

Starting Method for the Motor

OVERLOAD PROTECTOR

PTC

Resistance Starter Capacitor Running

PTC STARTER

COMPRESSOR MOTOR

SEALED TERMINAL

Figure 12

4-2-4 Motor Restarting and PTC Cooling

(1) It requires approximately 5 minutes for the pressure to

equalize before the compressor can restart.

(2) The PTC device generates heat during operation.

Therefore, it must be allowed to cool before the compressor can restart.

4-2-5 Relation of PTC-Starter and OLP

(1) If the compressor attempts to restart before the PTC

device is cooled, the PTC device will allow current to flow only to the main winding.

(2) The OLP will open because of the over current

condition. This same process will continue (3 to 5 times) when the compressor attempts to restart until the PTC device has cooled. The correct OLP must be properly attached to prevent damage to the compressor. Parts may appear physically identical but could have different electrical ratings. Replace parts by part number and model number. Using an incorrect part could result in damage to the product, fire, injury, or possibly death.

4-2-6 Note for Using the PTC-Starter

(1) Be careful not to allow over-voltage and over-current. (2) Do not drop or handle carelessly. (3) Keep away from any liquid.

If liquid such as oil or water enters the PTC, PTC materials may fail due to breakdown of their insulating capabilities.

(4) If the exterior of the PTC is damaged, the resistance

value may be altered. This can cause damage to the compressor and result in a no-start or hard-to-start condition.

(5) Always use the PTC designed for the compressor and

make sure it is properly attached to the compressor. Parts may appear physically identical but could have different electrical ratings. Replace parts by part number and model number. Using an incorrect part could result in damage to the product, fire, injury, or possibly death.

- 12 -

4-3 OLP (OVERLOAD PROTECTOR)

4-3-1 Definition of OLP

(1) OLP (OVERLOAD PROTECTOR) is attached to the

Compressor and protects the Motor by opening the circuit to the Motor if the temperature rises and activating the bimetal spring in the OLP.

(2) When high current flows to the Compressor motor, the

Bimetal works by heating the heater inside the OLP, and the OLP protects the Motor by cutting off the current flowing to the Compressor Motor.

4-3-2 Role of the OLP

(1) The OLP is attached to the Sealed Compressor used

for the Refrigerator. It prevents the Motor Coil from being started in the Compressor.

(2) For normal operation of the OLP, do not turn the Adjust

Screw of the OLP in any way.

(OVERLOAD PROTECTORcross section)

Part No. Name

Base, phenolic (UL 94 V-0 rated) Movable armsupport, plated steel Stationary contact support, platedsteel Heater support,plated steel Heater, resistance alloy Disc, thermostaticalloy Movable arm, spring temper copperalloy Contact, movable, silveron copper Contact, stationary, silver on copper Slug, platedsteel Cover, polyester (UL 94 V -0 rated) Pinconnector, platedcopper alloy (To engage 2.33/2.66 mm dia. pin) Quick-connect terminal,brass, conforms to UL 310, MEMA

DC-2, DIN 46344

Figure 13

Electrical

characteristics

part number

12345678

330 FBYY -S1 BOX98

Customer part number

Lot code/ date code

Physical

termination part number

4-4 TO REMOVE THE COVER PTC

1) Remove the Cover Back M/C. (2) Remove the screw on Cover PTC.

(3) Remove two Housings on upper part of Cover PTC. (4) Take out the cover PTC from upper to lower position

like ( 1 ).

(5) Turn 45¡ in the direction of (2)and take it out. (6) Assembly in reverse order of disassembly.

- 13 -

5. CIRCUIT DIAGRAM

Good / Better

GY: GRIS/GRAY

- 14 -

6. TROUBLESHOOTING

6-1 COMPRESSOR AND ELECTRIC COMPONENTS

Power Source.

Remove PTC-Starter from compressor and measure voltage between Terminal C of compressor and

terminal 5 or 6 of PTC.

No voltage.

Applied voltage isn't in acceptable range. (115V ±10%)

(Rated voltage ±10%)?

YES

OLP disconnected?

Advise customer that power supply needs to be checked by an electrician.

YES

Replace OLP.

Check connection condition.

Reconnect.

Check

Check resistance

resistance of

of motor

motor

compressor.

Check resistance of PTC-Starter.

Check OLP.

Check starting state.

Check the resistance

between M-C, S-C and M-S in motor compressor.

Check resistance of two terminals in

PTC-Starter.

Check resistance of two terminals in OL.P

Check the power supply under load. (Compressor attempting to re-start after being off for 5 minutes).

Open or short

Refer to Page 12.

Supply voltage rating with ±10%.

The range of resistance is between 1~50 ? (ok)

Replace compressor

YES

Did

compressor

start?

YES

Compressor is OK

Replace the compressor

- 1 5 -

6-2 PTC AND OLP

Normal operation of compressor is impossible or poor.

Separate PTC-Starter from Compressor and measure resistance

between No. 5 and 6 of PTC-Starter with a Tester. (Figure 19)

Separate OLP from compressor and check resistance value between two terminals of OLP whit a tester. (Figure 20)

Observation value is 115V/60Hz : 6.8 ? ±?0%

The resistance value is 0 ? (short) or 8(open).

Shows continuity

Open

Check another electric component.

Replace OLP

Replace PTCStarter.

Figure 19

Figure 20

- 1 6 -

6-3 OTHER ELECTRICAL COMPONENTS

Not cooling at all

Compressor

doesn't run.

Poor cooling performance

Compressor runs poorly.

Checkfor open short or incorrect resistance readings in the followingcomponents

a. Starting devices b. OLP

c. Compressor coil d. Wiring harness

Check starting voltage.

Check voltage at starting devices.

Cause

Short, open, or broken. Poor contact

or shorted. Coil open or shorted.

Poor contact or shorted.

Low voltage.

Poor or broken or open contact.

Replace indicatedcomponent.

Advise customer that the power supply

needs to be checked

by an electrician.

Replace indicatedcomponent.

Fan motor doesn't run.

Heavy frost buildup on evaporator

Check current flowing in sub-coil of Compressor.

Check rating of OLP.

Check wiring circuit.

Check Fan Motor.

Check current flow in the following components: Sensor Fuse-M

Check current flow in the defrost heater.

Shorted.

Lack of capacity.

Wire is open or shorted.

Coil is shorted or open.

Open.

Replace indicatedcomponent.

Replace defrostheater.

- 1 7 -

6-4 SERVICE DIAGNOSIS CHART

COMPLAINT POINTS TO BE CHECKED REMEDY

No Cooling.

Cools poorly.

Foods in the Refrigerator are frozen.

Condensartion or ice forms inside the unit.

Condensartion forms in the Exterior Case.

There is abnormal noise.

• Is the power cord unplugged from the outlet?

• Check if the power switch is set to OFF.

• Check if the fuse of the power switch is shorted.

• Measure the voltage of the power outlet.

• Check if the unit is placed too close to the wall.

• Check if the unit is placed too close to the stove, gas cooker, or in direct sunlight.

• Is the ambient temperature too high or the room door closed?

• Check if food put in the refrigerator is hot.

• Did you open the door of the unit too often or check if the door is sealed properly?

• Check if the Control is set toWarm position .

• Is food placed in the cooling air outlet?

• Check if the control is set tocolder position .

• Is the ambient temperature below 41°F(5°C)?

• Is liquid food sealed?

• Check if food put in the refrigerator is hot.

• Did you open the door of the unit too often or check if the door is sealed properly?

• Check if the ambient temperature and humidity of the surrounding air are high.

• Is there a gap in the door gasket?

• Is the unit positioned in a firm and even place?

• Are any unnecessary objects placed in the back side of the unit?

• Check if the Tray Drip is not firmly fixed.

• Check if the cover of the compressor enclosure in the front lower side is taken out.

• Plug into the outlet.

• Set the switch to ON.

• Replace the fuse.

• If the voltage is low, correct the wiring.

• Place theunit about 4 inches (10cm) fromthe wall.

• Place the unit away from these heat sources.

• Lower the ambient temperature.

• Put in foods after they have cooled down.

• Don't open the door too often and close it firmly.

• Set the control toRecommended position .

• Place foods in the high-temperature section. (front part)

• Set the control toRecommended position .

• Set the control toWarm position .

• Seal liquid foods with wrap.

• Put in foods after they have cooled down.

• Don't open the door too often and close it firmly.

• Wipe moisture with a dry cloth. It will disappear in low temperature and humidity.

• Fill up the gap.

• Adjust the Leveling Screw, and position the refrigerator in a firm place.

• Remove the objects.

• Fix the Tray Drip firmly in the original position.

• Place the cover in its original position.

Door does not close well.

Ice and foods smell unpleasant.

• Check if the door gasket is dirty with

• Is the refrigerator level?

• Is there too much food in the refrigerator?

• Check if the inside of the unit is dirty.

• Are foods with a strong odor unwrapped?

• The unit smells of plastic.