Kenmore 111.6121 Series User manual

REFRIGERATOR
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT,
READ THE SAFTY PRECAUTIONS IN THIS MANUAL.
Model : 111.6121*,6120*, 7121*
*color number

2
CONTENTS
1. Warnings and Precautions for Safety----------------------------------------------------------- 3
2. Specification
3. External Views
----------------------------------------------------------------------------------------- 6
----------------------------------------------------------------------------------------- 7
4. Compressor Compartment Views --------------------------------------------------------------- 9
5. Wiring Diagram ---------------------------------------------------------------------------------------10
6. Main PCB Circuit Diagram
7. Operation and Functions
------------------------------------------------------------------------ 11
------------------------------------------------------------------------- 12
8. Assemble/Disassemble Procedures for each Parts---------------------------------------18
9. Reverse doors
10. Door Aligning
---------------------------------------------------------------------------------------- 40
---------------------------------------------------------------------------------------- 41
11. Troubleshooting & Repairing Methods -------------------------------------------------------42
12. Cooling Cycle Heavy Repair----------------------------------------------------------------------52
13. Pop-up Drawings & Parts List of SVC ---------------------------------------------------------57

3
For your safety, please certainly keep followings
◆Please read [Caution for Safety] before using refrigerator and operates it correctly.
Warning
It contains contents of possibilityof
severe damage to human body
such as dead or heavy injury etc
when does not followinstructions.
Caution
It contains contents of possibility
of light or light-heavy damage to
human body or damageto mate-
rial when does not follow
instructions.
◆Example of marking
It means prohibition of This marks means [Prohibition]
disassembly. or [Do not attempt to try].
It means certainly disconnect This mark means [Mandatory]
electric source plug from or [Certainly keep Instructions]
socket.
Warning
Do not install refrigerator at wet
area or humid environment.
When throw away refrigerator,
certainly remove packing of door.
◇Children may be trapped and
◇It cause of electric shock or fire
accident by weakening electrical
insulation.
suffocated. It is dangerous thought
if you consider as for “some days”
Insert plug so that electrical cord
face downward.
Make sure there is no shaking
after inserting plug in to socket.
◇It cause of electrical shock or fire
accident by short circuit or over
heating due to irregular condition
when cord is inserted as face up.
◇It cause of electric shock or fire
accident by weakening electrical
Insulation.
Make a call for service if electric
cord is damaged.
◇It cause of fireor electric shock
If you feel there is leakage of
flammable gas, make ventilation
so that refrigeratordoes not
exposed to gas.
◇It cause of explosion, fire or
burning accident by flameat
electrical connection.
or short circuit.
1. Warnings and Precautions for Safety

4
Warning
Do not touch electric source plug
with wet hand.
Do not use distribution socket.
◇It cause of fire by abnormal
heat
◇It cause of electric shock.
When connect with multiple line.
◇Only use single socket with
rated Capacity.
Do not connect to other electric
source except 115~127V.
Do not use damaged cord or
electric source plug, loosened
socket.
◇It cause of fire, electric shock
and out of order.
◇It cause of electric shock or
fire by short circuit or over
heating.
Do not let electric source plug or
wire to be pressed by refrigerator
or other object.
Do not pull plug only with
gripping cord.
◇It cause of electric shock or
◇It cause of fire by damage of
electric source plug or wire.
fire by broken wire and short
circuit.
◇Always pull plug from socket
by gripping body of plug.
Do not let electric source cord
exposed at electric heating source.
Do not put container with water
on the top of refrigerator.
◇It cause of short circuit,
◇It cause of fire or electric shock
by damaging of cord.
◇When cord is damaged, stop
using it and call service center to
replace part.
electric shock or fire by
weakening of electrical
insulation of parts when
water is spilt from container.
Do not spray water at main body or
Inside of refrigerator.
Do not move rack with food
stuffs on the rack.
◇It cause of electric shock or fire
By weakening of electrical insulation
◇It may cause of hurt by
. dropping down of a food stuffs.
Do not pull down door with gripping
It.
◇It may cause of falling down or
Do not climb over refrigerator.
◇It may cause of hurt by falling
hurt such as finger constriction
accident.
Down of a refrigerator.
Never try to Disassemble or
repair or remodeling.
Do not let sheath of electric cord
to be peeled off by pressing of
heavy obstacle or pull or bend
◇It may cause of hurt by fire or
abnormal operation.
electric cord forcefully.
◇It may cause of fire or electric
shock when sheath is damaged.
Do not use flammable spray nearby
refrigerator.
Do not put flammables inside of
refrigerator.
◇It may exist danger of ignition,
◇It may danger of fire at electrical
Connection.
explosion by thinner, benzene, LP
gas or adhesive.

5
Warning
Do not keep medicine or materials
for lecture.
◇Do not keep materials at home
Use same capacity of fuse when
changing fuse.
refrigerator which need strict
temperature control.
◇It is danger of fire when use
inadequate capacity of fuse.
Certainly disconnect plug when
access to the bottom rear side of
machining chamber by hand.
Do not install earth to water line,
gas line, telephone line and
lightening rod.
◇It cause of fire or electric shock.
◇Certainly ask sales agent for
earthing.
◇It cause electric shock or fire.
Change light inside of refrigerator
after disconnecting plug.
Make sure of earthing.
◇It is danger of electric shock
by a short circuit due to out of
ordered part.
◇Certainly ask sales agent for
earthing.
◇It may cause electric shock.
Caution
Wear glove when change light
Inside of a refrigerator because
light may be broken or burning
Do not eat food stuffs with odor or
discolored.
◇Food stuffsmay be spoiled if
accident by hot light bulb.
It is stored for a long time even if
It is stored at freezer or
refrigerator.
Raise adjusting legs when moving
refrigerator.
◇It damage floor when moving
When moving refrigerator, grip
adjustable legs and upper part of
rear side.
refrigerator forcefully.
◇Lay protectiveplate to protect
floor with easily get damaged.
◇Be careful so that hand is not
slipped when gripping upper
part of rear side.
◇It may hurt hand by slippage.
Do not insert hand under of
Refrigerator.
◇It may hurt hand by sharp plate
when inserting hand for cleaning.
Do not touch food or container
at freezer or refrigerator with wet
hand.
Do not touch compressor or
piping at rear bottom side of
refrigerator.
◇It may cause of burning accident
◇It is danger of frostbite.
by hot compressor or piping
during operation or short time after
stopping.
Disconnect electric source plug
when do not use refrigeratorfor a
long time.
Do not store bottle at freezer.
◇It is danger of hurt by broken
◇It cause of fire.
Bottle due to freeze.

6
2. Specification
MODEL NAME
BUYER
111.7121*
111.6121*/6120*
FACTORY
K21SS*****I***
6121* : K21SS*****N***
6120* : K21SS*****R***
VOLUME
(AHAM)
FREEZER CAPACITY
5.8cuft
←
FRESH FOOD CAPACITY
15.0cuft
←
TOTAL CAPACITY
20.8cuft
←
EXTERNAL
DIMENSIONS
WIDTH
32.9”
←
DEPTH WITHOUT HANDLE
32.0”
←
HEIGHT TO TOP OF HINGE
66.7”
←
RATED VOLTAGE
115-127VAC / 60Hz
←
NET WEIGHT
220.5lbs.
←
COMPRESSOR
EMBRACO EM3D60HLT
←
COMP.
ACCESSARY
OVER LOAD PROTECTOR
4TM427KFBYY-53
←
POSITIVE TEMP. COEFFICIENT
TSD2-115V
←
RUNNING CAPACITOR
250VAC/12µF
←
REFRIGERANT / QUANTITY
R134a / 3.53oz
←
EVAPORATORTYPE
FIN
←
CONDENSER
FAN COOLING SYSTEM
←
SENSOR
DEFROST
1pc on Eva. Pipe
←
FREEZER
N/A
←
REFRIGERATOR
1pc on Back Wall of Refrigerator
←
AMBIENT TEMP.
1pc on Top of Cabinet
←
HEATER
DEFROST
SHEATH, AC120V / 250W
←
INNER LINER
CORD, AC120V / 22W
←
DEFROST FUSE TEMP.
2pcs, 77℃
←
FAN MOTOR
FREEZER
115VAC / 60Hz, 0.13A
←
CONDENSER
115VAC / 60Hz, 3.5W
←
LAMP
FREEZER
N/A
←
REFRIGERATOR
DC12V, 5-LED
←
DOOR SWITCH
1pc on Top of Refrigerator
←
WATER VALVE
115/120VAC, 50/60Hz, 35W
N/A (sold separately)
ICEMAKER
115VAC / 60Hz, Total1.4~1.6A
N/A (sold separately)

3. External Views
7
3-1. External Size

3. External Views
8
12
1
5
1
11
2
7
8
6
3
3
9
3
3
10
10
4
3-2. Name of Each Parts
*This instruction manual refers to several models. Features may vary according to model.
1. Freezer door bin
2. Dairy compartment
for spreadable food items such as butter
or margarine.
3. Adjustable half width door bin
4. Full width door bin
5. Adjustable wire shelf
6. Adjustable half width shelf
7. djustable half width
shelf with deli
drawer
8. Deli drawer
9. Adjustable full width shelf
10. Humidity controlled crisper drawer
for storage of fruits and vegetables
11. Ice tray (optional)
12. Ice maker / Ice storage bin
(optional)

9
3
10
4
5
10
11
4. Compressor Compartment Views
※Features may vary according to model.
1. Compressor
2. OLP, PTC, CLAMP
3. POWER CORD
4. DRYER
5. SUCTION PIPE
6. SUCTION PIPE CONNECTOR
7. CONDENSOR
8. CONDENSOR PIPE CONNECTOR
9. CONDENSOR FAN MOTOR
10. PIPE HOT
11. WATER VALVE (OPTIONAL)
1
2
6
8
7
9

5. Wiring Diagram
10

6. Main PCB Circuit Diagram
11
CN3
CN4
CN5
CN2
CN1
CN1 : [AC]
Heater Sheath, Compressor, Power
CN2 : [AC]
Heater Inner Liner
CN3 : [DC]
Door Switch, LED Light
CN4 : [DC]
RT-Sensor
CN5 : [DC]
R-Sensor, D-Sensor, Volume PCB(Dial)

7. Operation and Functions
12
7-1. Control Temperature
INPUT
A. Turn Dial Knob on “Box Control”
B. Turn Dial Knob on “Louver F”
CONTROL OBJECT
A. PCB Volume
B. Airflow
CONTENTS REMARKS
A. Fresh Food TemperatureControl
-The temp. control is located at the top front of the refrigerator compartment.
-The temp. control dial is calibrated in a range from 1 (least cold) to 7 (coldest).
Max Mid Min
B. Freezer Temperature Control
- The airflow control is located on the back wall of the freezer compartment.
- The temp. control dial is calibrated in a range from “Coldest” to “Cold”.

7. Operation and Functions
13
7-2. Compressor Control
INPUT
CONTROL OBJECT
- R-Sensor
- Defrost Mode
- Accumulated Compressor Off Time
- Compressor ON/OFF Operation
CONTENTS
REMARKS
A. Normal Control
1) Defrost Mode
Defrost Heater On Compressor OFF
Pause Compressor OFF
2) Other Mode
2-1) At normal operation :
compressor ON/OFF controlled by R-Sensor.
2-2) If R-Sensor Error has occurred :
compressor ON/OFF controlled by RT-Sensor.
B.Prevention of Compressor Restart :
6 minutes after compressor off

7. Operation and Functions
14
7-3. Defrost Mode
INPUT
CONTROL OBJECT
- Defrosting Cycle
- Compressor
- F/C Fan Motor
- Defrost Heater
CONTENTS
REMARKS
A. Normal Defrost Mode
1) Steps
Comp, C Fan Motor F Fan Motor Defrost Heater
STEP1. Heater On OFF OFF ON
STEP2. Pause OFF OFF OFF
2) Defrost Mode Start Condition
2-1) In case accumulated compressor run times: 6, 8, 12hrs,
- when there occur any errors (R1, D1, C1, RT, DR error etc.)
※See “7-5. Error Mode”
- or, running rate of compressor per 2hrs of accumulated operation time is
more than 90%
- or, accumulated door open time is over 2 minutes
2-2) Even if the above condition is not satisfied, defrost mode starts immediately
when accumulated compressor run time is 14hrs .
3) Defrost Heater OFF Condition
3-1) Heater off after 30 minutes in case D-Sensor error.
3-2) Heater off after 60 minutes at normal control .
3-3) Heater off when D-Sensor is over 10℃.
4) Pause :
Comp, F/C Fan Motor and Heater OFF for 10 minutes at normal control.
B. Forced Defrost Mode
- How to start : turn the fresh food temp control dial from step1 to step 7
while pushingdoor switchsimultaneously.
※If any errors have occurred, the forced defrost mode doesn’t start.

7. Operation and Functions
15
7-4. Control of Interior Lights
INPUT
CONTROL OBJECT
- Fresh food compartment door switch
- LED LAMP
CONTENTS
REMARKS
- Fresh food compartment lights turn ON/OFF by door switch ON/OFF
- For 10 minutes after sensing door open, the lights turn off automaticallyeven
though door close is not sensed.

7. Operation and Functions
7-5. Error Mode
16
INPUT
CONTROL OBJECT
- Error
- LED LAMP on Main PCB
CONTENTS
REMARKS
A. Error Display
※All the error codes are reset if they turn to be normal.
B. Control way of Error (if any)
1) “R1” error
•Cause : R-Sensor disconnection or short
•Check Point :
- Measure the voltage between terminal PIN 7 and 8
after separating CN5 on the Main PCB.
- If the sensor is disconnected, the voltageis under 0.5V. Change the sensor.
- If the sensor is shorted, the voltage is over 4V. Change the sensor.
2) “RT” error
•Cause : RT-Sensor disconnectionor short
•Check Point :
- Measure the voltage between terminal PIN 1 and 2
after separating CN4 on the Main PCB.
- If the sensor is disconnected, the voltageis under 0.5V. Change the sensor.
- If the sensor is shorted, the voltage is over 4V. Change the sensor.
Priorities
Error Code
Main PCB LED
Cause
1
R1
Flickering 1 time
R-Sensor disconnection
or short
2
RT
Flickering 2 times
RT-Sensor disconnection
or short
3
D1
Flickering 3 times
D-Sensor disconnection
or short
4
DR
Flickering 4 times
Sensing door open
for more than 1hr
5
C1
Flickering 6 times
compressor runs over 3hr
when D-Sensor temp. ≥-5℃
6
F3
Flickering 7 times
Defrosting return is done
by time limit

7. Operation and Functions
7-5. Error Mode
17
INPUT
CONTROL OBJECT
- Error
- LED LAMP on Main PCB
CONTENTS
REMARKS
B. Control way of Error (if any) *continued
3) “D1” error
•Cause : D-Sensor disconnection or short
•Check Point :
- Measure the voltage between terminal PIN 5 and 6
after separating CN5 on the Main PCB.
- If the sensor is disconnected, the voltageis under 0.5V. Change the sensor.
- If the sensor is shorted, the voltage is over 4V. Change the sensor.
4) “DR” error
•Cause : In case it senses that door is open for more1hr.
•Check Point :
- Make sure that the door fully stays closed , and then
measure the voltage between terminal PIN 5 and 6
after separating CN3 on the Main PCB while pushing door switch.
- If the voltage is 5V, change the door switch.
- If the voltage is 0V, change the mainPCB.
5) “C1” error (Cycle : abnormal or defective)
•Cause : In case comp. works for over 3 hours when D-sensor temp. is over -5℃(23F)
•Check Point :
- Refrigerant leakage.
•Release condition: D sensor temperature is under -5℃with compressor off.
6) “F3” error
•Cause : In case defrosting return is done by time limit.
•Check Point :
- Measure the resistance between terminal PIN 1 and 7
after separating CN1 on the Main PCB.
- If the resistance is out of range from 50Ωto 70Ω , change the defrost heater.
•Release condition: Defrost is completed by D sensor.

8. Assemble / Disassemble Procedures for each parts
18
Freezer Compartment
8-1. Icemaker (optional)
No
Figure
Description
1
- Unplug the refrigerator.
2
- Loosen the two mounting screws
in the side freezer wall with a Phillipsscrewdriver.
3
- Lift the icemaker and remove it.
4
- Unplug the icemaker with a flat blade screwdriver.

8. Assemble / Disassemble Procedures for each parts
19
Freezer Compartment
8-2. Freezer Wire Shelf
No
Figure
Description
1
- Lift up left side of shelf slightly and slide it left
as far as it will go into the center of the left shelf
support holes.
The right side of the shelf will release from the
support holes on the right.
2
- Raise up right side of shelf and remove the shelf
from freezer compartment.

8. Assemble / Disassemble Procedures for each parts
20
Freezer Compartment
8-3. Louver F
No
Figure
Description
1
- Unscrew 4pcs with a Phillips screwdriver.
2
- Tilt down the “Louver F” to remove it
from the back of the freezer wall.
3
- Unplug the connector and remove the “Louver F”.