Kenmore 795.77319.600, 795.77316.600, 795.77314.600, 795.77312.600, 795.77309.600 Service Manual

...

BOTTOM FREEZER REFRIGERATOR

REFRIGERATOR

SERVICE MANUAL

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

ENGLISH

795.77302.600/601

795.77304.600/601

795.77306.600/601

795.77309.600/601

795.77312.600/601

795.77314.600/601

795.77316.600/601

795.77319.600/601

Sears, Roebuck and Co., Hoffman Estates, IL60179 U.S.A.

www.sears.com

CONTENTS

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

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

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

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

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

3.2 Door alignment ............. ....................................................................................................

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. COMPRESSOR ELECTRICAL .............................................................................................

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

795.773**.600 .........................................................................................................................

795.773**.601 .........................................................................................................................

2 3 5 6 6 7 8 8 8 8 8 9 12 13 13 13 14 14 15 17 17 18 19 20 21 23 23 24 25 26 26 31 32 33 35 37 41 46 54

SAFETY PRECAUTIONS

Please read the following instructions before servicing your refrigerator.

1.Check the refrigerator forcurrent 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 frost bite.

6.Prevent water from spiling onto electrical components Machine parts.

Or the

-2-

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.

1. SPECIFICATIONS

1-1 DISCONNECT POWER CORD BEFORE SERVICING IMPORTANT: RECONNECT ALL 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 background 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.

ELEC TRICAL SPEC IFICATIONS

1.3

Freezer Temperature Control (Middle setting)

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

1-4 NO LOAD PERFORMANCE

Co ntrol Po s ition: M ID/MID

And Ambient of: 70°F

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

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

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

1-5 REFRIGERATION SYSTEM

....................................................................................................................................22 cu.ft. 493kWh/yr (Energy Star)

................................................................................................................... -6°F

33°F to 41°F

-4°F to +4°F 25%-35%

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

1-6 INSTALLATION

33°F to 41°F

-4°F to +4°F .

...

45%-60%

90°F

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

Minimum Equalized Pressure

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

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

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

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

- 3 -

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

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 ...................................EBG32606502

Overload ...............................6750C-0004S

Defrost Thermostat ...............6615JB2005C

Defrost Heater .......................5300JB1100J

Evaporator fan motor ............4681JK1004A

Capacitor ..............................0CZZJB2012J

Compressor (Hi-Side) ..........2521CRA5715

Evaporator (Lo-Side) .............5421JJ1001B

Condenser ............................5403JJ1007A

Dryer ......................................5851JJ2002F

Condenser fan motor .............4681JB1029J

Temperature Control .............6871JB1374C

Main Control ..........................6871JK1011A

EVAPORATOR FAN

DRYER

COMPRESSOR

EVAPORATOR

HOT LOOP

CONDENSER

CONDENSER FAN

COLD AIR

MIXED AIR

AIR RETURN TO EVAPORATOR

EVAPORATOR

FRESH FOOD

Vegetable box

FREEZER

- 4 -

2. PARTS IDENTIFICATION

K O

N M

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

Modular Door Bins

Egg Box

M N

Can Rack* Dairy Corner

*On some models

- 5 -

3. DISASSEMBLY

3-1 DOOR

Left Door

Loosen the cover screw (1). Disconnect door switch wire (2). Loosen hinge bolts (3). Lift off the top hinge (4). Place the door on a non-scratching surface with

the inside up.

Right Door

Loosen the cover screw (1). Disconnect door switch wire (2). Disconnect wire harness (3).

Loosen hinge bolts (4). Loosen ground screw (5). Lift off the top hinge (6).

Place the door on a non-scratching surface with

the inside up.

2. Remove gasket bracket clips

There are two clips on each door. Start bracket removal near one of the middle clips.

1) Pull gasket back to expose gasket bracket clip and door frame.

2) Insert a flat tip screwdriver into seam between gasket bracket and door frame and pry back until clips snap out.

3) Continue prying back along seam until all clips snap out.

Door

Frame

Flat Tip

Screwdriver

Gasket

Bracket Clip

Figure 3

Gasket

Bracket

3. Remove gasket

Pull gasket free from gasket channel on the three remaining sides of door.

Left

Figure 1

Right

Door Gasket Removal

1. Remove door frame cover

Starting at top of cover and working down, snap cover out and away from door.

Frame Cover

Handle

Figure 2

Figure 4

Door Gasket Replacement

1. Insert gasket bracket clips

1) Insert gasket bracket edge beneath door frame edge.

2) Turn upper gasket bracket spring so that both spring ends are in the door channel.

3) Push in clip until you hear it snap securely into place.

Gasket Bracket Clip

Spring

Door

Frame

4) Push in remaining two clips until you hear each snap securely into place.

Note: Make sure that no part of gasket bracket edge

Protrudes from beneath door frame edge.

Correct Incorrect

Figure 5

- 6 -

2. Insert gasket into channel

1) Snap gasket assembly into the door bracket.

Inserting the Gasket Assembly into the Bracket Door.

Correct

Incorrect

Figure 6

3-2 DOOR ALIGNMENT

If the space between your doors is uneven, follow the instructions below to align the doors:

1. With one hand, lift up the door you want to raise near the middle hinge.

2. With other hand, use pliers to insert snap ring at the

middle hinge as shown.

3. Insert additional snap rings until the doors are aligned. (Three snap rings are provided with the product.)

2) Press gasket into channel on the three remaining sides of door.

Figure 7

3. Replace door frame cover

Starting at top of cover and working down, snap the cover back into door.

Figure 9

Figure 8

- 7 -

3-3 FAN AND FAN MOTOR

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

2. Remove the plastic guide for slides on left side by unscrewing phillips head screws.

3. Remove the grille by removing one screw and pulling the grille forward.

4. Remove the Fan Motor assembly by loosening 2 screws.

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 evaporator area when defrosting.

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

1. Pull out the grille assembly. (Figure 12)

2. Separate the connector with the Defrost Control assembly and replace the Defrost Control assembly

after cutting the tie wrap. (Figure 13)

3. Be sure to retie the wires when reassembling after service.

GRILLE ASSEMBLY

Figure 12

3-5 LAMP

DEFROST-CONTROL ASSEMBLY

Figure 13

3-5-1 Refrigerator Compartment Lamp

1. Unplug Refrigerator, or disconnect power at the circuit breaker.

2. If necessary, remove top shelf or 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. Assembly is the reverse of disassembly. Replacement bulb must be the same specification as the original (Max. 60 W, 2 EA).

Figure 15

3-5-2 Freezer Compartment Lamp

1. Unplug Refrigerator, or disconnect power at the circuit breaker.

2. Release the hooks at back of light cover and pull the cover down to remove it. (Figure 15)

3. Turn the lamp counterclockwise.

4. Assembly is in the reverse order. Replacement bulb must be the same specification as the original. (Max 60W)

3-6 REFRIGERATOR CONTROL BOX

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

CONTROL BOX

COVER LAMP

Figure 16

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 the upper and lower caps by using a flat screwdriver, and remove 2 screws. (Figure 17)

2. Disconnect the lead wire on the bottom position.

Figure 14

Figure 17

- 8 -

3-8 HOW TO REMOVE AND REINSTALL THE PULL OUT 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.

- 9 -

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.

- 10 -

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.

- 11 -

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.

- 12 -

4. COMPRESSOR ELECTRICAL

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.

If the hermetic connector rusts out or fails, refrigerant and oil will be expelled into the contact area, probably resulting in smoke and fire.

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

humidity, and soldering flux don’t contaminate the inside of the compressor. Contamination in the cylinder 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 Temperature Coefficient) 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.

3) As the compressor starts, the current through the PTC causes its temperature to rise, and so the resistance also rises. When the resistance reaches a high enough level, only a trickle current will be running through the start winding. This small current then keeps the PTC hot and the resistance high.

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 17

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 overcurrent

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.

- 13 --

4-3 OLP (OVERLOAD PROTECTOR)

4-4 TO REMOVE THE COVER PTC

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 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 PROTECTOR cross section)

Customer part number

12345678

Lot code/ date code

Physical

termination part number

Electrical

characteristics

part number

330 FBYY -S1 BOX98

1) Remove the back cover of the mechanical area.

Figure 18

- 14 -

5. CIRCUIT DIAGRAM

PCB main, 6871JB1375

Air Damper Motor

- 15 -

PCB main, 6871JK1011

F-FAN

C-FAN

LG Electronics

CIRCUIT DIAGRAM

PWB(PCB) ASSEMBLY,DISPLAY

YL/BK

WH/RD

R-DOOR S/W

PUMP S/W

RT-SENSOR

CON4

POWER

SUPPLY

CORD

CON1

GN/YL

(GN)

GN/YL

(GN)

HEATER,

ICE SENSOR

CON5

CON3

CON4

PWB (PCB) ASSEMBLY, ICE MAKER

ICE MAKER PART

DISPENSER

CON6

WH/RD

1544

CON6

YL/BK

BASIC

PWB(PCB) ASSEMBLY, MAIN

SHEATH

CON2

GN/YLNYL

GN/YL

MOTOR

ICE MAKER

WH 1

CON1

610

CAPACITOR PART

CON2

(98 C)

FUSE-M

S/W

POWER

CON6

I/MAKER W/VALVE IN THE MACHINE ROOM

*PLUG TYPE,ICE MAKER PART,CAPACITOR PART,

PWB(PCB) ASSEMBLY DISPLAY, PUMP S/W, DISPENSER W/VALVE PART AND COMP' EARTH PART ON CIRCUIT DIAGRAM ARE SUBJECT TO CHANGE IN DIFFERENT LOCALITIES AND MODEL TYPE.

4 3

P.T.C STARTER

5 6

S M

COMP' EARTH

CON7

CON3

CON5

WH WH

8 7

6 5

4 3

YL BK

F-SENSOR

R-SENSOR

DEF-SENSOR

F-DOOR S/W

STEPPING

MOTOR

BNBL

(72 C)

FUSE-M

OLP

/YL

(GN)

PART

R-LAMPS

F-LAMP

DISPENSER W/VALVE PART

HEATER,SHEATH

DOOR HEATER

BK:BLACK BN:BROWN RD:RED BO:BRIGHT ORANGE YL:YELLOW GN:GREEN BL:BLUE WH:WHITE PK:PINK GY:GREY PR:PURPLE SB:SKY BLUE

- 16 -

6. TROUBLESHOOTING

6-1 COMPRESSOR AND ELECTRIC COMPONENTS

Power Source.

Check

Check resistance

resistance of

of motor

motor

compressor.

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%)

Check the resistance between M-C, S-C and M-S in motor compressor. Check each pin to ground.

(Rated voltage ±10%)?

OLP disconnected?

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

Open or short

or short to ground

Replace compressor

YES

The resistance between pins should be between 1 and 50 ohms. The resistance to ground should be infinite.

Replace OLP.

Check connection condition.

Reconnect.

Check resistance of PTC-Starter.

Check OLP.

Check starting state.

Check resistance of two terminals in

PTC-Starter.

Check resistance of two terminals in OLP.

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

Refer to Page 13.

Supply voltage rating with ±10%.

YES

Did

compressor

start?

YES

Compressor is OK

Replace the compressor

- 17 -

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 with a tester. (Figure 20)

Observation value is 115V/60Hz : 6.8 ?±30%

at room temperature

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

Shows continuity

Open

Check another electric component.

Replace OLP.

PTC OK

Replace PTCStarter.

OLP OK

Figure 19

Figure 20

- 18 -

6-3 OTHER ELECTRICAL COMPONENTS

•Not cooling at all

Compressor

doesn't run

•Poor cooling performance

Compressor runs poorly.

Check for open short or incorrect resistance readings in the following components

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 indicated component.

Advise customer that the power supply

needs to be checked

by an electrician.

Replace indicated component.

Fan motor doesn't run.

Heavy frost buildup on evaporator

Check current flowing

In run winding of

Compressor.

Check rating of OLP.

OLP: 4TM293RFB Temp. 130°C

Check wiring circuit.

13 - 15 V

Check Fan Motor .

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

Check resistance flow in

the defrost heater.

Shorted.

Lack of capacity.

Wire is open or shorted.

Coil is shorted or open.

Open.

Replace indicated component.

Replace defrost heater.

- 19 -

+ 43 hidden pages

Kenmore 795.77319.600, 795.77316.600, 795.77314.600, 795.77312.600, 795.77309.600 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual