Kenmore 795.777297, 795.777197, 795.777137, 795.777127, 795.775536 Service Manual

...

CAUTION

BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

REFRIGERATOR

SERVICE MANUAL

795.77192600

795.77199600

795.77194600

795.77193600

795.77196600

795.77542600

795.77549600

795.77544600

795.77543600

795.77546600

795.77552600

795.77559600

795.77554600

795.77553600

795.77556600

795.77712700

795.77713700

795.77719700

795.77729700

P/No. 3828JL8796A (Last Revision: MARCH. 2. 2006)

Model #s:

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SAFETY PRECAUTIONS....................................................................................................................................................... 2

1. SPECIFICATIONS............................................................................................................................................................... 3

2. PARTS IDENTIFICATION................................................................................................................................................... 4

3. DISASSEMBLY.............................................................................................................................................................. 5-12

DOOR.............................................................................................................................................................................. 5-7

TO REMOVE THE DISPENSER .........................................................................................................................................7

FAN AND FAN MOTOR...................................................................................................................................................... 8

DEFROST CONTROL ASSEMBLY.................................................................................................................................... 8

LAMP.................................................................................................................................................................................. 8

CONTROL BOX-REFRIGERATOR.................................................................................................................................... 8

MULTI DUCT ...................................................................................................................................................................... 8

HOW TO REMOVE AND REINSTALL THE PULLOUT DRAWER................................................................................ 9-12

TRIM KIT ASSEMBLY AND AISASSEMBLY METHOD(795.77719, 77729 models only.............................................13-15

4. ADJUSTMENT............................................................................................................................................................. 16-17

COMPRESSOR................................................................................................................................................................ 16

PTC-STARTER................................................................................................................................................................. 16

OLP (OVERLOAD PROTECTOR).................................................................................................................................... 17

TO REMOVE THE COVER PTC.......................................................................................................................................17

5. CIRCUIT DIAGRAM.......................................................................................................................................................... 18

6. TROUBLESHOOTING................................................................................................................................................. 19-24

COMPRESSOR AND ELECTRIC COMPONENTS.......................................................................................................... 19

PTC AND OLP.................................................................................................................................................................. 20

OTHER ELECTRICAL COMPONENTS ........................................................................................................................... 21

SERVICE DIAGNOSIS CHART........................................................................................................................................ 22

REFRIGERATION CYCLE .......................................................................................................................................... 23-24

7. OPERATION PRINCIPLE & REPAIR METHOD OF ICEMAKER .............................................................................. 25-28

8. DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM ........................................................................................... 29-40

CONTENTS

Please read the following instructions before servicing your refrigerator.

1. Unplug the power before handling any elctrical componets.

2. Check the rated current, voltage, and capacity.

3. Take caution not to get water near any electrical components.

4. Use exact replacement parts.

5. Remove any objects from the top prior to tilting the product.

SAFETY PRECAUTIONS

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 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.

1-3 ELECTRICAL SPECIFICATIONS

Temperature Control (Freezer Compartment)...-6°F to +8°F

Defrost Control.................Total Comp Running Time : 7 hrs

Defrost Thermostat.......................................................46°F

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

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

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

Energy Consumption .....21 cu.ft. 484 kWh/yr (Energy Star)

.......................................25 cu.ft. 499 kWh/yr (Energy Star)

1-4 NO LOAD PERFORMANCE

CONTROL POSITION: MID/MID

And Ambient of: ..................70°F..................................90°F

Fresh Food, °F....................33°F to 41°F.........33°F to 41°F

Frozen Food, °F..................-4°F to +4°F..........-4°F to +4°F

Percent Running Time........35%-45%.................50°F-70°F

1-5 REFRIGERA TION SYSTEM

Minimum Compressor Capacity Vacuum ............... 20 MIN.

Minimum Equalized Pressure

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

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

Refrigerant R134a ................................................. 4.06 oz.

Compressor ..................................................... 830 BTU/hr

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 in

AT REAR ...................................................................... 2 in

1-7 REPLACEMENT PARTS

Relay............................................................. 6748C-0004D

Overload ....................................................... 6750C-0005P

Defrost Thermostat ...................................... 6615JB2005H

Defrost Heater ............................................. 5300JK1005D

Evaporator Fan Motor .................................. 4681JK1004A

Capacitor .................................................... 0CZZJB2012G

Compressor (Hi-Side) .................................. 2521C-A5719

Evaporator (Lo-Side) .................................... 5421JJ0006A

*5421JJ0007A

Condenser .................................................... 5403JJ1004B

Dryer ............................................................ 5851JA2008A

Condenser Fan Motor .................................. 4681JB1029D

Temperature Control .................................... 6871JB1439A

Main Control.................................................. 6871JB1423B

1-8 AIR FLOW / CIRCULATION D’AIR

1. SPECIFICATIONS

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EVAPORATOR

COLD AIR MIXED AIR AIR RETURN TO

EVAPORATOR

FRESH FOOD

FREEZER

Vegetable box

EVAPORTOR FAN MOTOR

CONDENSER FAN MOTOR

1-9 DIMENSIONS

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Description 795.777** 795.775** Depth w/ Handles A 30 in. 34 1/4 in. Depth w/o Handles B 27 1/2 in. 31 3/4 in. Depth w/o Door C 23 5/8 in. 27 7/8 in. Depth (Total with Door Open) D 42 1/4 in. 46 1 /2 in. Height to Top of Case E 68 3/8 in. 68 3/8 in. Height to Top of Door Hinge F 69 3/4 in. 69 3/4 in. Width G 35 3/4 in. 35 3/4 in. Width (door open 90 deg. w/o handle) H 39 1/4 in. 39/1/4 in. Width (door open 90 deg. w/ handle) I 44 1/4 in. 44 1/4 in.

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2. PARTS IDENTIFICATION

Refrigerator Light

Refrigerator

Shelves

Super Fresh

Crisper with

Tilt-Out

Compartment

Adjust Cube

Ice Maker

Glide'N'Serve

Ice Bin

Durabase

Divider

Pull out Drawer

Tilt-Out Door Basket (795.7754*, 7755* Model Only)

Modular Door Bins

Bottle Holder (795.7755*,77729 Models Only)

Dairy Bin

Egg Box

Modular

Door Bins

Filter

Cover Front

3-1 REMOVING AND REPLACING REFRIGERATOR DOORS

● Removing Refrigerator Door

CAUTION: Before you begin, unplug the refrigerator. Remove food and bins from doors.

Left Door

1. Disconnect water supply tube by pushing back on the disconnect ring (4).

2. Open door. Loosen top hinge cover screw (1). Use flat tip screwdriver to pry back hooks on front underside of cover (3). Lift up cover.

3. Disconnect door switch wire harness (2). Remove cover.

4. Attach the tube on the door with door.

5. Pull out the tube.

6. Disconnect the three wire harnesses (5). Remove the grounding screw (6).

7. Rotate hinge lever (7) counterclockwise and remove. Lift top hinge (8) free of hinge lever latch (9).

CAUTION: When lifting hinge free of latch, be careful that door does not fall forward.

8. Lift door up from middle hinge pin (10) and remove door.

9. Place door, inside facing up, down onto a non-scratching surface.

Right Door

1. Open door. Loosen top hinge cover screw (1). Lift up cover (3).

2. Disconnect door switch wire harness (2). Remove cover.

3. Disconnect wire harness (5). Remove the grounding screw (6).

4. Rotate hinge lever (7) clockwise and remove. Lift top hinge (8) free of hinge lever latch (9).

CAUTION: When lifting hinge free of latch, be careful that door does not fall forward.

5. Lift door up from middle hinge pin (10) and remove door.

6. Place door, inside facing up, down onto a non-scratching surface.

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3. DISASSEMBLY

3-2 DOOR

● Door Gasket Removal

1. Remove door frame cover

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

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 snaps out.

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

3. Remove gasket

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

● 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 the spring ends are in the door channel.

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

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.

2. Insert gasket into channel

1) Snap gasket assembly into the door bracket.

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Frame Cover

Handle

Figure 1

Figure 2

Figure 3

Door

Frame

Gasket Bracket Clip

Spring

IncorrectCorrect

Figure 4

Figure 5

Correct

Incorrect

Gasket

Door

Bracket Clip

Frame

Flat Tip

Screwdriver

Gasket

Bracket

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

3. Replace door frame cover

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

3-3 TO REMOVE THE DISPENSER

1. Use fiat tip screwdriver to pry back hooks on botton underside of cover dispenser.

2. Pry off cover dispenser.

Disconnect wire harness.

3. Replace cover dispenser in opposite manner and order of removal.

3-4 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 at middle hinge.

2. With other hand, use pliers to insert snap ring as shown.

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

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Figure 6

Figure 8

Figure 9

Figure 7

Figure 10

3-5 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 pulling it out and by loosening a screw.

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

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

3-6 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. At 161.6°F(72°C), it turns the Defrost Heater off.

Fuse-M is a safety device for preventing over-heating of the Heater when defrosting.

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)

3-7 LAMP

3-7-1 Refrigerator Compartment Lamp

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

2. If necessary, remove top shelf or shelves.

3. Using a flat instrument, gently pry the cover loose in the front as shown. Rotate downward to remove rear tabs.

4. Make sure the bulbs are cool to the touch. Turn bulbs counterclockwise to remove.

5. Assemble in reverse order by snapping the Lamp Cover in, engaging the rear tabs followed by the front tabs. (Max. 60 W-2EA)

3-7-2 Freezer Compartment Lamp

1. Unplug refrigerator power cord form outlet.

2. Using a flat instrument, gently pry the lamp cover loose in the front as shown. Rotate downward to remove the rear tabs.

3. Make sure the bulb is cool to the touch. Turn the bulb counterclockwise to remove.

4. Replace with a new 60-watt appliance bulb.

5. Insert tabs on back of cover into slots in freezer ceiling. Push cover up to snap front into place.

3-8 CONTROL BOX-REFRIGERATOR

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

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

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

3-9 MULTI DUCT

1. Remove an upper and lower Cap by using a flat screwdriver, and loosen 2 screws. (Figure 17)

2. Disconnect the lead wire on the bottom position.

- 9 -

BRACKET

MOTOR

GRILLE

FAN MOTOR

FAN

Figure 11

GRILLE ASSEMBLY

Figure 12

DEFROST-CONTROL ASSEMBLY

Figure 13

Figure 14

Figure 15

CONTROL BOX

COVER LAMP

Figure 16

Figure 17

3-10 HOW TO REMOVE AND REINSTALL THE PULLOUT DRAWER

3-10-1 FOLLOW STEPS TO REMOVE

- 10 -

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.

3-10-2 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 6) Reinstall the two screws into the guide rails

(one from each side).

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 7) Reinstall the lower basket, and close the freezer

door.

- 11 -

3-10-3 PULL OUT DRAWER

To separate the drawer, push the front left and right hooks in

direction to pull up and remove.

Then gently lift the gear part of rear left and right side of the drawer and pull it out in

direction.

To install, reposition the gear part of rear left and right side of the drawer after pulling out both rails as much as possible, and gently push down both left and right side while checking the hook on the front part.

- 12 -

Hook

3-11 TRIM KIT ASSEMBLY AND AISASSEMBLY METHOD (795.77719,77729 MODELS ONLY)

3-11-1 ASSEMBLY AND DISASSEMBLY METHOD OF LEFT DOOR GLASS AND DISPLAY OF THE REFRIGERATOR

1. Remove the 2 screws on the top refrigerator door trim, circled in Photo # 1.

2. Remove the 2 screws on the bottom refrigerator door trim, circled in photo # 2.

3. While holding the door handle (to prevent it from falling) remove the 3 screws on the side trim that holds the handle on.(see photo # 3)

4. Remove the door handle. (see photo # 4)

5. While lifting up on the top door trim, slide the glass front (above the dispenser) to the right to remove it. (see photo # 5)

6. While pulling down on the bottom door trim, slide the glass front (below the dispenser) to the right to remove it. (see photo # 6)

7. Once the glass is removed, the dispenser cover can be removed by pulling it out by the right side and gently pulling out of the left door trim slot. (see photos 7 & 8)

8. The right side door glass is removed

in the same manner as the left. However because it will not have the dispenser the glass will be one piece.

9. Reassemble in reverse order.

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7 8

3-11-2 ASSEMBLY AND DISASSEMBLY METHOD OF FREEZER DOOR AND GLASS

1. Fully open the freezer drawer as shown in photo # 1.

2. Lift out the freezer basket as shown in photo # 2.

3. Remove the 2 screws (one on each side shown in photo # 3.

4. Hold the freezer handle and pull up to remove the door assembly,

as shown in photo # 4.

5. Put the freezer door facing down

(on a clean soft surface to prevent scratching the top trim) as shown in

photo # 5.

6. Remove all the screws hold the bottom door trim in place. (be careful not to

remove the 2 screws circled in photo # 6).

7. Remove the screw at the bottom of each side trim shown in photo # 7.

(continued on the next page)

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2 3

4 5

6 7

3-11-2 ASSEMBLY AND DISASSEMBLY METHOD OF FREEZER DOOR AND GLASS

8. Pull off the bottom cover as shown in photo # 8.

9. Remove one of the side trim pieces by pulling it out slightly the up to remove it from the top door trim. As shown in photo # 9.

10. Carefully pull out the freezer door

glass as shown in photo # 10.

11. Reassemble in reverse order.

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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 performing repairs.

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 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 Compressor Motor.

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

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

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. Use only approved substitute parts.

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. Use only approved substitute parts.

4. ADJUSTMENT

- 16 -

PTC STARTER

SEALED TERMINAL

COMPRESSOR MOTOR

OVERLOAD PROTECTOR

Resistance Starter Capacitor Running

PTC

Figure 18

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