Kenmore 795.78402.804 Service Manual
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Kenmore 795.78402.804 Service Manual

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BOTTOM FREEZER REFRIGERATOR
REFRIGERATOR
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE PRODUCT
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
MFL53274410
Printed in Mexico
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
MODELS:
795.78402.804
795.78403.804
795.78406.804
795.78409.804
795.78412.804
795.78413.804
795.78416.804
795.78419.804
www.sears.com

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Summary of Contents for Kenmore 795.78402.804

  • Page 1 BOTTOM FREEZER REFRIGERATOR REFRIGERATOR SERVICE MANUAL CAUTION BEFORE SERVICING THE PRODUCT READ THE SAFETY PRECAUTIONS IN THIS MANUAL. MODELS: 795.78402.804 795.78403.804 795.78406.804 795.78409.804 795.78412.804 795.78413.804 795.78416.804 795.78419.804 MFL53274410 www.sears.com Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A. Printed in Mexico...
  • Page 2 ECN (Engineering Change Number) Rev.803 •Change Cover Lower (improve structure) & Change Cover PCB (improve) Rev.804 •Change model to Barrierless type Accomplish DOE...

  • Page 3: Table Of Contents

    CONTENTS ..2 SAFETY PRECAUTIONS ..........................1. SPECIFICATIONS ..............................2. PARTS IDENTIFICATION ............................3. DISASSEMBLY ..............................3.1 Doors.................................. 3.2 Leveling and Door Alignment..........................3.3 Door Gasket................................ 3.4 Fan and fan motor (evaporator).......................... 3.5 Defrost control assembly............................. 3.6 Lamp .................................. 3.7 Multiduct................................3.8 Main PCB................................

  • Page 4: Specifications

    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.

  • Page 5: Replacement Parts

    1-7. REPLACEMENT PARTS PERFORMANCE DATA (NORMAL OPERATING CONDITIONS) Relay............EBG42993601 EAF39584205 Overload............. SYSTEM PRESSURE (PSIG) WATTS Defrost Thermostat........6615JB2005C HIGH SIDE LOW SIDE 5300JB1100J Defrost Heater..........70°F 98 (+10 / -10) 98 (+5 / -3) (-5) to (-2) Evaporator Fan Motor......... 4681JB1027C 0CZZJB2012K Capacitor............
  • Page 6 DIMENSIONS Description 7840* / 7841* Depth w/ Handles Depth w/o Handles Depth w/o Door 28 ¼ Depth (Total with Door Open) 45 ½ Height to Top of Case Height to Top of Door Hinge Width 32 ¾ Width (door open 90 deg. w/o handle) 36 ¼...

  • Page 7: Parts Identification

    2. PARTS IDENTIFICATION 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. Ice Room Dairy Corner (Ice Maker and Ice Bucket)

  • Page 8: Disassembly

    3. DISASSEMBLY 3-1 DOORS 1. Removing Refrigerator Door NOTE: Handle appearance may vary. IMPORTANT: Before you begin, turn the refrigerator OFF and unplug it. Remove food and any bins from doors. Left Door Loosen the screws and remove the cove on back side (see figure A). Disconnect water supply tube by pushing back on the disconnect ring (3).

  • Page 9: Replacing Refrigerator Door

    2.Replacing Refrigerator Door Right Door Lower the door onto the middle hinge pin (9). Make sure the door is aligned with the cabinet. Replace the top hinge (8) installing hinge screws (7) to secure it. Make sure the gasket on the door is flush against the cabinet and is not folded. Support the door on the handle side while securing hinge.

  • Page 10: Leveling And Door Alignment

    3-2 LEVELING AND DOOR ALIGNMENT 1. Leveling 2. Door Alignment Your refrigerator has two front leveling screws. One on If the space between your doors is uneven, follow the the right and one on the left. If your refrigerator seems instructions below to align the doors: unsteady or you want the doors to close easier, adjust the 1.With one hand, lift up the door you want to raise at...

  • Page 11: Door Gasket

    3-3 DOOR GASKET 2. Door Gasket Replacement 1. Door Gasket Removal 1. Remove door frame cover 1. Insert gasket bracket clips Starting at top of cover and working down, snap cover 1) Insert gasket bracket edge beneath door frame edge. out and away from door.

  • Page 12: Fan And Fan Motor(Evaporator)

    2) Press gasket into channels on the three remaining sides of door. * Ice Fan Scroll Assembly Replacement 1) Remove the plastic guide for slides on left side by unscrewing phillips head screws. 2) Pull the grille forward as shown in the second picture. 3) Disconnect wire harness of the grille 4) Remove the scroll assembly by loosening 3 screws Fig.

  • Page 13: Lamp

    3-6 LAMP 3-7 MULTI DUCT 1. Remove the upper and lower Caps by using a flat screwdriver, and remove 2 screws. 2. Disconnect the lead wire Fig. 11 on the bottom position. 3-6-1 Refrigerator Compartment Lamp 1. Unplug Refrigerator, or disconnect power at the circuit breaker.

  • Page 14: Dispenser

    3-11 FUNNEL REPLACEMENT 3-9 DISPENSER 1) Disconnect funnel and 1) Pull up and out on the dispenser cover to remove. button assembly by 2) Disconnect the wire harness. pulling down and 3) Replace in reverse order. forward. 2) Remove display frame assembly by making a gap 3-12 SUB PWB FOR WORKING DISPENSER between a display frame...

  • Page 15: Duct Door Replacement

    3-13 DUCT DOOR REPLACEMENT 3-15 ICEMAKER ASSEMBLY 1) Pull up and out on the dispenser cover to remove. 1) Loosen two screws as shown in the first picture. 2) Disconnect the wire harness. 3) Remove the funnel 4) Replace in reverse order. 2) Disconnect the wire harness &...

  • Page 16: Auger Motor Cover

    3-16 AUGER MOTOR COVER 3-17 HOW TO REMOVE A DOOR ICE BIN 1) After removing the icemaker remove the (5) stainless 1) Grip the handles, as shown in the picture. screws holding the auger motor cover, shown in the picutres below. 2) Lift the lower part slightly.

  • Page 17: Pull Out Drawer

    3-19 PULL OUT DRAWER 1. HOW TO INSTALL PULL OUT DRAWER • Align the top holes of the rail cover with the top holes of IMPORTANT: To avoid possible injury, product or the door supports to assemble the rail cover. property damage, you will need two people to perform the following instructions.

  • Page 18: How To Remove And Reinstall The Pull Out Drawer

    2. HOW TO REMOVE PULL OUT DRAWER IMPORTANT: To avoid possible injury, product or CAUTION: When removing drawer door, do not hold it by the handle. Door could fall down and you may be property damage, you will need two people to perform Injured.

  • Page 19: Fan And Fan Motor Disassembly Method

    3-20 FAN AND FAN MOTOR DISASSEMBLY 3-21 GLIDE OUT DRAWER METHOD To remove, lift basket up and pull out straight out. 1) Using a short screwdriver, loosen one SCREW in DRAIN PIPE ASSEMBLY and one connected to the MOTOR COVER. MOTOR COVER To Install, pull both rails out to full extension.

  • Page 20: Adjustment

    4. ADJUSTMENT 4-1 COMPRESSOR 4-2-3 PTC-Applied Circuit Diagram Starting Method for the Motor 4-1-1 Role The compressor intakes low temperature and low pressure gas from the evaporator of the refrigerator and compresses OVERLOAD PROTECTOR this gas to high-temperature and high-pressure gas. It then delivers the gas to the condenser.

  • Page 21: To Remove The Cover Ptc

    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 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...

  • Page 22: Circuit Diagram

    5. CIRCUIT DIAGRAM CIRCUIT DIAGRAM DUCT-HTR DISPENSER LEVEL S/W F-LAMP F-FAN FRONT-HTR ICING F-FAN OUT PLATE-HTR C-FAN FD-HTR 10 GY THERMOSTAT R-DOOR S/W R-LAMPS CON4 SHEATH-HTR FUSE-M CON3 CON2 STEPPING PWB ASSEMBLY, DISPENSER CAPACITOR MOTOR CR PART CON1 CON3 COMP' F-DOOR S/W D-SENSOR P.T.C...

  • Page 23: Troubleshooting

    6. TROUBLESHOOTING 6-1. COMPRESSOR AND ELECTRIC COMPONENTS (Rated voltage Remove PTC-Starter Power Source. from compressor and measure voltage between T erminal C of compressor and terminal 5 or 6 of PTC. No voltage. Replace OLP . Check connection condition. Reconnect. Applied voltage isn't Advise customer that in acceptable range.

  • Page 24: Ptc And Olp

    6-2. PTC AND OLP Separate PTC-Starter Observation value is Normal operation of compressor is impossible from Compressor and ±20% 115V/60Hz : 6.8 or poor. measure resistance between No. 5 and 6 of PTC-Starter with a T ester. (Figure 1) Replace PTC- The resistance value Starter.

  • Page 25: Other Electrical Components

    6-3. OTHER ELECTRICAL COMPONENTS Not cooling at all Check for open short or Compressor Cause doesn't run. incorrect resistance readings in the following components a. Starting devices Short, open, or broken. Poor contact b. OLP or shorted. Coil open or shorted. c.
  • Page 26 6-4. SERVICE DIAGNOSIS CHART COMPLAINT POINTS TO BE CHECKED REMEDY No Cooling. • • Plug into the outlet. • Check if the power switch is set to OFF . • Set the switch to ON. • Check if the fuse of the power switch is shorted. •...

  • Page 27: Service Diagnosis Chart

    6-5. REFRIGERATION CYCLE * Troubleshooting Chart TEMPERATURE STATE OF STATE OF THE CAUSE REMARKS OF THE THE UNIT EVAPORATOR COMPRESSOR - Refrigerant level is low due to a Freezer Low flowing sound of A little higher than PARTIAL leak. ¥ compartment and refrigerant is heard and frost ambient...
  • Page 28 6-5-1 SEALED SYSTEM DIAGNOSIS “Not Cooling” Complaint All components operating, No airflow problems, Not frosted up as a defrost problem problem has been isolated to sealed system area Frost None Partial Pattern? Equalization Equalization Test Test Very Fast Very Slow Very Slow Very Fast Fast...

  • Page 29: Refrigeration Cycle

    7. OPERATION PRINCIPLE AND REPAIR METHOD OF ICEMAKER 7-1 OPERATION PRINCIPLE 7-1-1 Operation Principle of IceMaker Power On Start Position • Adjusts EJECTOR to Start Position with power on. Icemaking • Waits until water becomes ICE after starting the Mode icemaking operation.

  • Page 30: Ice Maker Functions

    7-2 ICE MAKER FUNCTIONS 7-2-1. Icemaking Mode 1. Icemaking refers to the freezing of supplied water in the ice tray. Complete freezing is assured by measuring the temperature of the Tray with Icemaking SENSOR. 2. Icemaking starts after completion of the water fill operation. 3.

  • Page 31: Defect Diagnosis Function

    7-2-5 Function TEST 1. This is a forced operation for TEST , Service, cleaning, etc. It is operated by pressing and holding the Fill Key for 3 seconds. 2. The test works only in the Icemaking Mode. It cannot be entered from the Harvest or Fill mode. 3.

  • Page 32: Description Of Function & Circuit Of Micom

    8. DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM 8-1 FUNCTION 8-1-1 Function 1. When the appliance is plugged in, it is set to 37°F for Refrigerator and 0°F for freezer. You can adjust the Refrigerator and the Freezer control temperature by pressing the ADJUST button. 2.
  • Page 33 8-1-5 Ultra Ice selection Please select this function for quick freezing. • Function is repeat Ultra Ice Icon whenever pressing Ultra Ice button. • Ultra Ice function automatically turns off after a fixed time passes. “Ultra Ice” “Ultra Ice” 8-1-6 Dispenser use selection Function OFF Function ON You can select water or ice.
  • Page 34 8-1-11 Ultra Ice 1. The purpose of this function is to intensify the cooling speed of freezer and to increase the amount of ice. 2. Whenever selection switch is pressed, selection/release, the LED will turn ON or OFF . 3. If there is a power outage and the refrigerator is powered on again, Ultra Ice will be canceled. 4.
  • Page 35 8-1-14 Defrosting (removing frost) 1. Defrosting starts each time the accumulated COMPRESSOR running time is between 7:30 and 50 hours. This time is determinated by how often and how long the doors are opened. 2. For initial power on or for restoring power, defrosting starts when the compressor running time reaches 4 hours. 3.
  • Page 36 ERROR CODE on display panel ERROR CODE ITEM CONTENTS REMARKS FRZ TEMP REF TEMP Failure of Freezer Cut or short circuit wire. sensor Failure of Cut or short circuit wire. Refrigerator sensor Failure of defrost Inspect Connecting Cut or short circuit wire. sensor wires on each sensor Failure of Room...
  • Page 37 8-1-17 TEST Mode 1. The T est mode allows checking the PCB and the function of the product as well as finding out the defective part in case of an error. 2. The test mode is operated by pressing two buttons at Display panel. 3.

  • Page 38: Pcb Function

    8-2 PCB FUNCTION 8-2-1 Power Circuit 1. Power is supplied to the control board at pin1 and 3 of connector #1. - 37 -...
  • Page 39 8-2-2 Load / Fan & Open Door Detection Circuit 1. Load Drive Condition Check Water Circuit Voltage between A & B LAMP-R CON 3 PIN 9 CON 3 PIN 4 115 Vac LAMP-F CON 3 PIN 7 CON 3 PIN 4 115 Vac FD-HTR CON 3 PIN 8 CON 3 PIN 4...
  • Page 40 To measure putput of the fans on the control board check voltages between the pins for the following components: OUTPUT VOLTAGE PIN NUMBER PIN NUMBER MOTOR ON MOTOR OFF Freezing compartment fan Con4 Pin1 Con4 Pin2 13 VDC - 15 VDC 2 VDC or less Machine compartment fan Con4 Pin7...
  • Page 41 3. Open Door Detection Circuit Check Measurement Pin 10 & 11 of con4 Ref.Door Location Freezer/ Pin 5 & 6 of con6 Fre.Door Refrigerator Door Closed Open CONNECTOR 4 CONNECTOR 6 F-FAN ICING-FAN C-FAN R-DOOR S/W Stepping Motor F-Door S/W D-SNR R-SNR F-SNR...
  • Page 42 8-2-4 Refrigeration Compartment Stepping Motor Damper Circuit A reversible DC motor is used to open and close the damper. T o open the damper, push test button once. T o close the damper, push test button twice. To see connector 6 picture, refer to page 42 8-2-5 Dispenser Drive Circuit CON2 MAIN PCB...

  • Page 43: Troubleshooting

    8-3 TROUBLESHOOTING PROBLEM INDICATED BY CHECK CHECKING METHOD CAUSE SOLUTION POWER 1. The whole 1. FREEZER/ Check if POWER SOURCE is Replace Main PWB SOURCE is REFRIGERATOR. FREEZER/REFRIGERA poor. poor. TOR DOOR IS OPEN and check display. 2. If LAMP is dim. Check visually.
  • Page 44 PROBLEM INDICATED BY CHECK CHECKING METHOD CAUSE SOLUTION COOLING is 1. If FREEZER Check is FREEZER Make sure the DOOR poor. REFRIGERATOR TEMPERATURE is TEMPERATURE is too isattached. TEMPERATURE normal. low. is too low. 2. If amount of cool air Make sure that the FAN MOTOR is poor.

  • Page 45: Main Pwb Assembly And Parts List

    8-4 MAIN PWB ASSEMBLY AND PARTS LIST 8-4-1 Main PWB Assembly - 44 -...
  • Page 46 8-4-2 Dispenser Drive PWB Assembly - 45 -...

  • Page 47: Exploded View And Replacement Part List

    #EV# 9. EXPLODED VIEW CASE PARTS Caution: Use the part number to order part, not the position number. Caution: Use the part number to order part, not the position number. 281A 603B 402A 611D 103B 611C 103A 271C 282E 410A 409D 104E 501F...
  • Page 48 #EV# FREEZER PARTS Caution: Use the part number to order part, not the position number. 136B 131A 145C 248E 248F 145F 136A -47-...
  • Page 49 #EV# REFRIGERATOR PARTS Caution: Use the part number to order part, not the position number. 143E 140D 140B 143E 140D 140E 140B 143E 140D 140B 140E 143F 142D 140B 140E 142E 128A 103E 170A 128B 103E 167B 154A 151C 151A 151A 305D 155B...
  • Page 50 #EV# DOOR PARTS Caution: Use the part number to order part, not the position number. 241F 230B 230A 231B 233B 233C 233D 233A 231A 233F 212G 233G 233H 233E 233F 244A 241C 237A 244A 212J 212J 241G 241C 147A 286A 286A 147C 262E...
  • Page 51 #EV# DISPENSER PARTS Caution: Use the part number to order part, not the position number. 278A 282G 113E 405H 278D 500B 113F 617A 280A -50-...
  • Page 52 #EV# ICE MAKER PARTS Caution: Use the part number to order part, not the position number. 606A 630J 600A 600B 630F 630C 630A 614A 630K 630H 630G -51-...
  • Page 53 #EV# VALVE & WATER PARTS Caution: Use the part number to order part, not the position number. 616B 617B 623B 623C 616K 616A 625A 627C 619D -52-...

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