Kenmore 795.78402.801, 795.78403.801, 795.78412.801, 795.78413.801, 795.78416.801 Service Manual

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REFRIGERATOR

SERVICE MANUAL

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

MODELS:

795.78402.801

795.78403.801

795.78406.801

795.78409.801

795.78412.801

795.78413.801

795.78416.801

795.78419.801

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

3.9 Dispenser ...........................................................................................................................................................

3.10 Display PWB Replacement .............................................................................................................................

3.11 Funnel Replacement ........................................................................................................................................

3.12 Sub PWB or working dispenser........................................................................................................................

3.13 Duct Door Replacement....................................................................................................................................

3.14 Ice corner door replacement.............................................................................................................................

3.15 Icemaker assembly...........................................................................................................................................

3.16 Auger motor cover ............................................................................................................................................

3.17 How to remove a door ice bin ..........................................................................................................................

3.18 How to insert a door ice bin .............................................................................................................................

3.19 How to remove and reinstall the pull out drawer ..............................................................................................

3.20 Fan and fan motor disassembly method ..........................................................................................................

3.21 Glide out drawer ...............................................................................................................................................

3.22 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. OPERATION PRINCIPLE AND REPAIR METHOD OF ICEMAKER .....................................................................

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 Troubleshooting ................................................................................................................................................

8.4 Main PWB assembly and parts list ...................................................................................................................

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

2 3 6 7 7 9 10 11 11 12 12 12 13 13 13 13 14 14 14 15 16 16 17 19 19 20 21 21 21 22 22 23 24 24 25 26 27 28 30 30 31 32 33 33 39 44 46 48

SAFETY PRECAUTIONS

Please read the following 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 frost bite.

6.Prevent water from spiling on to 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 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.

ELECTRICAL SPECIFICATIONS

1-3.

Freezer temperature control (Middle setting).................................................................

Defrost Control ..............................................................................................................

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

Electrical Rating : 115VAC, 60Hz...................................................................................

Maximum Current Leakage ...........................................................................................

Maximum Ground Path Resistance ..............................................................................

Energy Consumption......................................................................................................

1-4. NO LOAD PERFORMANCE

Control Position: MID/MID

And Ambient of:

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

Frozen Foor, °F........................................................

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

1-5. REFRIGERATION SYSTEM

Minimum Compressor Capacity Vaccum.............................

Minimun Equalized Pressure

@70°F..............................................................

@90°F..............................................................

Refrigerant R134a............................................................

Compressor...............................................................

70°F

33°F to 41°F

-4°F to +4°F 25% - 35%

21 in

49 PSIG 56 PSIG

4.2 oz

957 BTU/hr

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

Frozen Foor, °F.....................................................

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

1-6. INSTALLATION

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

At Top.................................................................................

At Sides............................................................................

At Rear................................................................................

-6°F to +8°F Automatic 50°F 1-5 A

0.5mA

0.14 Ohms

22.5 cu.ft. 670kWh/yr

90°F

33°F to 41°F

-4°F to +4°F 45% - 60%

1 in

1/8 in

1 in

- 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...............................................

Duct Assy Connector..................................

1-8. AIR FLOW

6748C-0004D 6750C-0004R 6615JB2005C 5300JB1100J

4681JK1004E 0CZZJB2012K TCA31748001 5421JJ1001B 5403JJ1007A 5851JA2002F 4681JB1029J EBR43358502 EBR41956106 ADJ36834101

PERFORMANCE DATA

(NORMAL OPERATING CONDITIONS)

SYSTEM PRESSURE (PSIG)

AMB WATTS

HIGH SIDE LOW SIDE

70°F 98 (+10 / -10) 98 (+5 / -3) (-5) to (-2)

90°F 98 (+10 / -10) 132 (+3 / -3) (-4) to 1

110°F 103 (+5 / -5) 180 (+5 / -5) (-2) to 3

EVAPORATOR FAN

DRYER

COMPRESSOR

EVAPORATOR

HOT LOOP

CONDENSER

FAN

COLD AIR

MIXED AIR

AIR RETURN TO EVAPORATOR

EVAPORATOR

FRESH FOOD

Vegetable box

FREEZER

- 4 -

1-8 DIMENSIONS

Description 795.784**

Depth w/ Handles A 34 1/4 in

Depth w/ Handles B 31 3/4 in

Depth w/ o Door C 27 7/8 in

Depth (Total with Door Open) D 46 1/2 in

Height to Top of Case E 68 3/8 in

Height to Top of Door Hinge F 69 3/4 in

Width G 35 3/4 in

Width (door open 90 deg. w/o handle) H 39 1/4 in

- 5 -

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

(Ice Maker

Refrigerator Light

Refrigerator

Egg Box

Snack

Water Tank Cover

Turbo Motor

Ice Bin

Filter (Inside)

and Ice Bucket)

Shelves

Pan

Dairy Corner

Can Rack*

Modular Door Bins

Crisper

Freezer Light

Pull out Drawer

Durabase

Divider

* On some models

- 6 -

Ice Bucket

Ice Room Door

3. DISASSEMBLY

(1)

(2)

(7)

(5)

(6)

(4)

(8)

Figure A

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

Pull out the tube (4).

CAUTION: If a tube end is deformed or worn out, cut the damaged portion away.

Disconnect wire harness (5). Remove the ground screw (6). Loosen screws (7) and lift off the top hinge (8).

Place the door on a non-scratching surface with the inside up.

CAUTION: When removing top hinge, be careful that the door does not fall forward.

Right Door

Loosen the cover screw (1). Disconnect door switch wire (2). Loosen screws (7) and lift off the top hinge (8). Place the door on a non-scratching surface with the inside up.

(1)

- 7 -

(2)

(7)

(8)

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. Make sure the door is straight and the gap between the doors is even.

Connect the door switch wire (2).

Tighten the cover screw (1).

Left Door

Lower the door onto the middle hinge pin (10). 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 tightening. And make sure the door is straight and the gap between the doors is even. Insert the water supply tube (4) into the connector tube until you see only one scale mark. (Fully insert the tube over 5/8”(15 mm)). Install the ground screw (6) and connect the wire harness (5). Connect the door switch wire (2). Tighten the cover screw (1).

- 8 -

3-2 LEVELING AND DOOR ALIGNMENT

1. Leveling

Your refrigerator has two front leveling screws. the right and one on the left. If your refrigerator seems unsteady or you want the doors to close easier, adjust the Refrigerator’s tilt using the instructions below:

1.Plug the refrigerator’s power cord into a 3-prong

grounded outlet. Move the refrigerator into its final Position. Remove the base cover.

2.Turn the leveling screw clockwise to raise that side of

the refrigerator or counterclockwise to lower it. It may take several turns of the leveling screw to adjust the tilt of the refrigerator.

NOTE:Having someone push against the top of the refrigerator takes some weight off the leveling screws. This makes it easier to adjust the screws.

One on

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 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 the refrigerator.)

3.Open both doors again and check to make sure that they close easily. If not, tilt the refrigerator slightly more to the rear by turning both leveling screws clockwise. It may take several more turns, and you should turn both leveling screws the same amount.

4.Re-adjust if necessary.

5.Replace the base cover.

NOTE:Your new refrigerator is uniquely designed with

two fresh food doors. Either door can be opened or closed independently of one another. You may have to exert slight pressure on doors to get them to close completely.

- 9 -

3-3 DOOR GASKET

1. 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

2. 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.

Gasket Bracket Clip

Spring

Figure 1

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

Gasket

Bracket

Figure 2

Door

Frame

4) Push in remaining clip until you hear it 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.

Correct

IncorrectCorrect

Figure 4

3. Remove gasket

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

Figure 3

- 10 -

Incorrect

Figure 5

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

Figure 6

3. Replace door frame cover

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

Figure 7

3-4 FAN AND FAN MOTOR(EVAPORATOR)

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 the grille fan forward.

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

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

* 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

(1) (2)

(3) (4)

3-5 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 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)

FAN MOTOR

BRACKET

MOTOR

GRILLE

FAN

Figure 11

- 11 -

GRILLE ASSEMBLY

Figure 12

DEFROST-CONTROL ASSEMBLY

Figure 13

3-6 LAMP

Figure 14

3-6-1 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 MULTI DUCT

1. Remove the upper and lower Caps by using a flat screwdriver, and remove 2 screws. (Figure 16)

2. Disconnect the lead wire on the bottom position.

Figure 16

3-8 MAIN PWB

1) Loosen the 3 screws on the PWB cover.

Figure 15

3-6-2 Freezer Compartment Lamp

1. Unplug refrigerator power cord form outlet.

2. Gently pry the lamp cover loose in the back as shown. Rotate forward to remove the front 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 front of cover into slots in freezer ceiling. Push cover up to snap back into place.

2) Remove the PWB cover

3) Disconnect wire harness and replace the main PWB in the reverse order of removal.

- 12 -

3-9 DISPENSER

3-11 FUNNEL REPLACEMENT

1) Disconnect funnel and button assembly by pulling down and forward.

2) Remove display frame assembly by making a gap between a display frame assembly and door with a flat blade screwdriver and pulling it forward. The cover dispenser is attached with a hook.

CAUTION: When replacing the dispenser cover in the reverse order of removal, be careful that the lead wire does not come out and the water tube is not pinched by the dispenser cover, as shown in the picture below.

1) Pull up and out on the dispenser cover to remove.

2) Disconnect the wire harness.

3) Replace in reverse order.

3-12 SUB PWB FOR WORKING DISPENSER

1) Loosen the screw on the sub PWB.

3-10 DISPLAY PWB REPLACEMENT

1) Pull up and out on the dispenser cover to remove.

2) Follow the steps in the pictures

2) Pull the sub PWB down.

3) Disconnect the wire harness and replace the sub PWB in the reverse order of removal.

- 13 -

3-13 DUCT DOOR REPLACEMENT

1) Pull up and out on the dispenser cover to remove.

2) Disconnect the wire harness.

3) Remove the funnel

4) Replace in reverse order.

3-14 ICE CORNER DOOR REPLACEMENT

1) Loosen the front screw as shown in the picture.

2) Lift up the hinge with one hand.

3) Pull out the Ice Corner Door with the other hand.

3-15 ICEMAKER ASSEMBLY

1) Loosen two screws as shown in the first picture.

2) Disconnect the wire harness & ground screw replace theIcemaker assembly in the reverse order of removal.

Hinge

3) It separates a ground connection screw.

- 14 -

3-16 AUGER MOTOR COVER

1) After removing the icemaker remove the (5) stainless screws holding the auger motor cover, shown in the picutres below.

2) Grip the bottom of motor cover assembly and pull out it.

3) Disconnect wire harness of motor cover assembly. There is a auger motor on the back, as shown in the picture.

Auger Motor

- 15 -

3-17 HOW TO REMOVE A DOOR ICE BIN

1) Grip the handles, as shown in the picture.

2) Lift the lower part slightly.

3-18 HOW TO INSERT A DOOR ICE BIN

1) Insert the Ice Bin, slightly tilting it to avoid touching the Icemaker. (especially, ice maker lever)

Insert the ice bucket carefully avoid contacing the automatic shut off arm.

3) Take the Ice Bin out slowly.

- 16 -

3-19 PULL OUT DRAWER

1. HOW TO INSTALL PULL OUT DRAWER

IMPORTANT: To avoid possible injury, product or

property damage, you will need two people to perform

the following instructions.

• With both hands, hold the center of the bar and pull it

out to let both rails out to full extension simultaneously.

Fig. 38

• Hook door supports into rail tabs.

Fig. 39

Door Supports

• Align the top holes of the rail cover with the top holes of the door supports to assemble the rail cover.

Fig. 42

•

Verify the hole’s assembly

Fig. 43

Rail tabes

• Lower door into final position and tighten the screws.

Fig. 40

Screws

•

Make sure you have a right rail cover for each side.

Right

Rail cover

Left

Rail cover

Fig. 41

Fig. 44

• With the rails pulled out to full extension, insert the durabase in the rail assembly.

Fig. 45

Durabase

WARNING: To prevent accidental child and pet

entrapment or suffocation risk. DO NOT allow them to play inside of drawer.

WARNING: DO NOT step or sit down on Freezer Door.

- 17 -

+ 38 hidden pages

Kenmore 795.78402.801, 795.78403.801, 795.78412.801, 795.78413.801, 795.78416.801 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual