Kenmore 795.78719.801, 795.78729.801, 795.78713.801, 795.78723.801, 795.78722.801 Service Manual

...

CAUTION

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

REFRIGERATOR

SERVICE MANUAL

795.78712.801

795.78713.801

795.78719.801

795.78722.801

795.78723.801

795.78729.801

P/No. MFL47912404 (Last Revision: March. 10. 2008)

Model #s:

- 2 -

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

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

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

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

DOOR.............................................................................................................................................................................. 5-8

TO REMOVE THE DISPENSER .........................................................................................................................................8

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

DEFROST CONTROL ASSEMBLY.................................................................................................................................... 9

LAMP.................................................................................................................................................................................. 9

CONTROL BOX-REFRIGERATOR.................................................................................................................................... 9

MULTI DUCT...................................................................................................................................................................... 9

HOW TO REMOVE AND REINSTALL THE PULLOUT DRAWER.............................................................................. 10-15

4. ADJUSTMENT............................................................................................................................................................. 16-18

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

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

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

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

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

6. TROUBLESHOOTING................................................................................................................................................. 19-23

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

PTC AND OLP.................................................................................................................................................................. 21

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

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

REFRIGERATION CYCLE.......................................................................................................................................... 26-27

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

8. DESCRIPTION OF FUNCTION AND 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 positions, 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 ~ 50 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. 457 kWh/yr (Energy Star)

.......................................25 cu.ft. 476 kWh/yr (Energy Star)

1-4 NO LOAD PERFORMANCE

CONTROL POSITION: MID/MID

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 ....................................................... 52 PSIG

@ 90°F ....................................................... 59 PSIG

Refrigerant R134a ................................................. 4.59 oz.

Compressor ..................................................... 821 BTU/hr

1-6 INSTALLATION

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

AT TOP ......................................................................... 2 in

AT SIDES ...................................................................... 1 in

AT REAR ...................................................................... 1 in

1-7 REPLACEMENT PARTS

21 cuft

795. 78712.801 795. 78722.801

795. 78713.801 795. 78723.801

795. 78714.801 795. 78724.801

Relay EBG44308701 Overload EBG44308701 Defrost Thermostat 6615JB2005H Defrost Heater 5300JK1005D Evaporator Fan Motor 4681JK1004D Capacitor (Running) 0CZZJB2014G Compressor (Hi-Side) 2521JA1006L Evaporator (Lo-Side) 5421JJ1003B Condenser ACG36653801 Dryer 5851JA2008U Condenser Fan Motor 4681JB1029D Temperature Control EBR36499201 Main Control 6871JB1423M

1. SPECIFICATIONS

- 3 -

EVAPORATOR

COLD AIR MIXED AIR AIR RETURN TO

EVAPORATOR

FRESH FOOD

FREEZER

Vegetable box

EVAPORTOR FAN MOTOR

CONDENSER FAN MOTOR

1-9 DIMENSIONS

- 4 -

Description 795.787** Depth w/ Handles A 30 in. Depth w/o Handles B 27 1/2 in. Depth w/o Door C 23 5/8 in. Depth (Total with Door Open) D 42 1/4 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. Width (door open 90 deg. w/ handle) I 44 1/4 in.

- 5 -

2. PARTS IDENTIFICATION

Refrigerator

Light

Refrigerator

Shelves

Humidity

Controlled

Crisper

Adjusta Cube

Ice Maker

Wide Pantry

Drawer

Ice Bin

Freezer

Drawer Bin

Divider

Pull-Out Drawer

Tilt-Out Door Basket

Modular Door Bins

Bottle Holder (795.7855** Models Only)

Dairy Bin

Utility/Egg Box

Door Bins

Water Filter

Water Tank

Cover

3-1 REMOVING AND REPLACING REFRIGERATOR DOORS

- 6 -

3. DISASSEMBLY

(1)

(2)

(4)

(5)

(6)

(3)

To remove the left refrigerator door:

Pull the water tube out of the fitting while pressing the release ring on the fitting. When you pull out the tube, first you have to push the collet by opposite direction of arrow in the upper picture and tube pull out by direction of arrow.

To remove the right refrigerator door:

¥ Open the door. Remove the top hinge cover screw (1).

Lift up the cover (2). ¥ Remove the cover. ¥ Disconnect the wire harness (3). ¥ Rotate the hinge lever (4) clockwise and remove.

Lift the top hinge (5) free of the hinge lever latch (6).

IMPORTANT:

When lifting the hinge free of the latch, be

careful that the door does not fall forward.

Explosion Hazard

WARNING

¥ Disconnect electrical supply to the refrigerator

before installing. Failure to do so could result in death or serious injury.

¥ Do not put hands or feet or other objects into the

air vents, base grille, or bottom of the refrigerator. You may be injured or receive an electrical shock.

¥ Be careful when you work with the hinge, base

grille, and stopper. You may be injured.

¥ Open the door. Remove the top hinge cover screw (1). ¥ Use a flat-head screwdriver to pry back the hooks

(not shown) on the front underside of the cover (2).

Lift up the cover. ¥ Remove the cover. Pull out the tube (3). ¥ Disconnect all the wire harnesses (4). ¥ Remove the grounding screw(5) ¥ Rotate hinge lever (6) counterclockwise and remove.

Lift the top hinge (7) free of the hinge lever latch (8).

IMPORTANT:

When lifting the hinge free of the latch, be careful that the door does not fall forward. ¥ Lift the door from the middle hinge pin and remove

the door.

¥ Place the door, inside facing up, on a nonscratching

surface.

(1)

(2)

(4)

(3)

(6)

(7)

(8)

(5)

CAUTION :

Before you begin, remove food and

bins from the doors.

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.

Inserting the Gasket Assembly into the Bracket Door

- 7 -

Frame Cover

Handle

Door

Frame

Gasket

Bracket Clip

Flat Tip

Screwdriver

Gasket

Bracket

Figure 1

Figure 2

Figure 3

Door

Frame

Gasket Bracket Clip

Spring

IncorrectCorrect

Figure 4

Figure 5

Correct

Incorrect

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.)

- 8 -

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 46°F(8°C), it turns the Defrost Heater off.

Fuse-M is a safety device for preventing over-heating of the Heater when defrosting. At 172.8°F(77°C), it turns the Defrost Heater off. It is attached to the between Eva pipe in the middle Evaporator.

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

- 13 -

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.

7 8

- 14 -

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)

2 3

4 5

6 7

- 15 -

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.

6-4 SERVICE DIAGNOSIS CHART

- 22 -

COMPLAINT POINTS TO BE CHECKED REMEDY

● Other possible problems:

Check if frost forms in the freezer.

check components of the defrosting circuit.

Check the refrigeration system.

Check the thermistor.

Not defrosting

The system is faulty.

Perform sealed system repair.

Replace the thermistor.

The operation of the Thermistor is incorrect.

No Cooling.

Cools poorly.

Foods in the Refrigerator are frozen.

Condensation or ice forms inside the unit.

Condensartion forms in the Exterior Case.

There is abnormal noise.

Door does not close well.

Ice and foods smell unpleasant.

• Is the power cord unplugged from the outlet?

• Check if the power switch is set to OFF.

• Check if the fuse of the power switch is shorted.

• Measure the voltage of the power outlet.

• Check if the unit is placed too close to the wall.

• Check if the unit is placed too close to the stove, gas cooker, or in direct sunlight.

• Is the ambient temperature too high or the room door closed?

• Check if food put in the refrigerator is hot.

• Did you open the door of the unit too often or check if the door is sealed properly?

• Check if the Control is set to Warm position.

• Is food placed in the cooling air outlet?

• Check if the control is set to colder position.

• Is the ambient temperature below 41°F(5°C)?

• Is liquid food sealed?

• Check if food put in the refrigerator is hot.

• Did you open the door of the unit too often or check if the door is sealed properly?

• Check if the ambient temperature and humidity of the surrounding air are high.

• Is there a gap in the door gasket?

• Is the unit positioned in a firm and even place?

• Are any unnecessary objects placed in the back side of the unit?

• Check if the drip tray is not firmly fixed.

• Check if the cover of the compressor enclosure in the lower front side is taken out.

• Check if the door gasket is dirty with an item like juice.

• Is the refrigerator level?

• Is there too much food in the refrigerator?

• Check if the inside of the unit is dirty.

• Are foods with a strong odor unwrapped?

• The unit smells of plastic.

• Plug into the outlet.

• Set the switch to ON.

• Replace the fuse.

• If the voltage is low, correct the wiring.

• Place the unit about 4 inches (10 cm) from the wall.

• Place the unit away from these heat sources.

• Lower the ambient temperature.

• Put in foods after they have cooled down.

• Don't open the door too often and close it firmly.

• Set the control to Recommended position.

• Place foods in the high-temperature section. (front part)

• Set the control to Recommended position.

• Set the control to Warm position.

• Seal liquid foods with wrap.

• Put in foods after they have cooled down.

• Don't open the door too often and close it firmly.

• Wipe moisture with a dry cloth. It will disappear in low temperature and humidity.

• Fill up the gap.

• Adjust the leveling screw, and position the refrigerator in a firm place.

• Remove drip tray.

• Fix the Drip Tray firmly in the original position.

• Place the cover in its original position.

• Clean the door gasket.

• Position in the firm place and level the leveling screw.

• Make sure food stored in shelves does not prevent the door from closing.

• Clean the inside of the unit.

• Wrap foods that have a strong odor.

• New products smell of plastic, but this will go away after 1-2 weeks.

4. ADJUSTMENT

- 16 -

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 TSD STARTER

4-2-3 TSD-Applied circuit diagram

● Starting method for the motor

4-2-4

ELECTRICAL AND DIMENSION DIAGRAM

ELECTRICAL CONNECTION DIAGRAM

TSD

START

MAIN

Ð The TSD must not be applied to refrigeration systems with

defrosting electrical resistance or any other component in parallel to the thermostat. Systems with this configuration can maintain a residual voltage over the compressor when the thermostat is opened, obstructing the proper functioning of the TSD. It is vital for the TSD circuit and compressor to remain completely de-energized after opening the thermostat.

Ð Use of the fixing clamp is essential, as this prevents

disconnection or bad TSD contact in relation to the compressor as well as to running capacitor in relation to the TSD. The ones that assemble it have to guarantee a perfect connection between the parts. Bad contacts and sparking can burn out the electronic circuit.

Ð The electronic circuit was designed taking the mandatory

use of the running capacitor into consideration. The 115V version is rect angular box, assembling directly onto the TSD body.

Ð The plastic box was projected to offer protection against

contamination and mechanical shock normally present in refrigeration system production lines.

Ð The TSD's internal components may undergo degradation

when in contact with chemical elements such as CI

,H2S,

,SOX,NOX. Some plastic isolation of cables may release chemical elements when submitted to high temperature conditions. Thus, check if the isolation of the cables used on the terminal board are in accordance with this recommendation.

Ð The TSD was designed for the operation with a run

capacitor and Embraco domestic compressor; any other application must be previously evaluated by EmbracoÕs technical team.

Ð Embraco reserves the right to check the customer's

handling of the manufacturing / assembly process, indicating possible adjustments should any be required.

Ð After replacement, the compressor and itÕs accessories

must have proper processing, and the components must be recycled according to the material group (ferrous, non-ferrous, polymers, oils, ...) directives. These recomendations are intended to minimize the adverse impacts that may be caused to the environment.

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Kenmore 795.78719.801, 795.78729.801, 795.78713.801, 795.78723.801, 795.78722.801 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual