Kenmore 795.787698, 795.787648, 795.787638, 795.787628, 795.787598 Service Manual

R

REFRIGERATOR

SERVICE MANUAL

CAUTION

BEFORE SERVICING THE UNIT,

READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

Model #s:

795.78752800

795.78753800

795.78754800

795.78759800

795.78762800

795.78763800

795.78764800

795.78769800

P/No. MFL48179001 (Last Revision: M. 25. 2008)

CONTENTS

SAFETY PRECAUTIONS .......................................................................................................................................................	2
1. SPECIFICATIONS ...........................................................................................................................................................	3-4
2. PARTS IDENTIFICATION ...................................................................................................................................................	5
3. DISASSEMBLY..............................................................................................................................................................	6-14
REMOVING AND REPLACING REFRIGERATOR DOORS ...............................................................................................	6
DOOR ..............................................................................................................................................................................	7-8
TO REMOVE THE DISPENSER .........................................................................................................................................	8
DOOR ALIGNMENT ............................................................................................................................................................	8
FAN AND FAN MOTOR(Evaporator) ..................................................................................................................................	8
ICE FAN SCROLL ASSEMBLY REPLACEMENT ..............................................................................................................	9
DEFROST CONTROL ASSEMBLY ....................................................................................................................................	9
LAMP ..................................................................................................................................................................................	9
CONTROL BOX-REFRIGERATOR ....................................................................................................................................	9
MULTI DUCT ....................................................................................................................................................................	10
MAIN PWB, DISPLAY PWB REPLACEMENT, FUNNEL REPLACEMENT......................................................................	10
SUB PWB FOR DISPENSER, DUCT DOOR REPLACEMENT, ICE CORNER DOOR
REPLACEMENT, ICE MAKER ASSEMBLY.......................................................................................................................	11
AUGER MOTOR COVER, AUGER MOTOR REPLACEMENT.........................................................................................	12
DOOR ICE BIN ..................................................................................................................................................................	13
HOW TO REMOVE AND REINSTALL THE PULLOUT DRAWER...............................................................................	14-15
WATER VALVE DISASSEMBLY METHOD........................................................................................................................	16
FAN AND FAN MOTOR DISASSEMBLY METHOD ..........................................................................................................	16
PULL OUT DRAWER ........................................................................................................................................................	17
4. ADJUSTMENT..............................................................................................................................................................	18-19
COMPRESSOR ................................................................................................................................................................	18
PTC-STARTER .................................................................................................................................................................	18
OLP(OVERLOAD PROTECTOR)......................................................................................................................................	19
TO REMOVE THE COVER PTC .........................................................................................................................	19
5. CIRCUIT DIAGRAM..........................................................................................................................................................	20
6. TROUBLESHOOTING.................................................................................................................................................	21-25
COMPRESSOR AND ELECTRIC COMPONENTS..........................................................................................................	21
OTHER ELECTRICAL COMPONENTS ...........................................................................................................................	22
SERVICE DIAGNOSIS CHART........................................................................................................................................	23
REFRIGERATION CYCLE ...........................................................................................................................................	24-25
7. OPERATION PRINCIPLE & REPAIR METHOD OF ICEMAKER ..............................................................................	26-28
8. DESCRIPTION OF FUNCTION, CIRCUITS & ERROR CODES..................................................................................	29-43

SAFETY PRECAUTIONS

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.

- 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 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 (F) ...-6°F to +8°F Defrost Control......Total Comp Running Time: 7 hrs~50 hrs

Defrost Thermostat .......................................................	46°F
Electrical Rating : 115VAC, 60Hz.................................	7.2 A
Maximum Current Leakage.......................................	0.5 mA
Maximum Ground Path Resistance ....................	0.14 Ohms
Energy Consumption .....25 cu.ft. 547 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 REFRIGERATION SYSTEM

Minimum Compressor Capacity Vacuum	............... 21 MIN.
Minimum Equalized Pressure
@ 70°F .......................................................	49 PSIG
@ 90°F .......................................................	56 PSIG
Refrigerant R134a .................................................	4.76 oz.
Compressor .....................................................	956 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

	25 cuft
	795.78752.800	795.78762.800
	795.78753.800	795.78763.800
	795.78754.800	795.78764.800
	795.78759.800	795.78769.800
Relay..............................................................	6748C-0004D
Overload ........................................................	6750C-0004R
Defrost Thermostat........................................	6615JB2005H
Defrost Heater ...............................................	5300JK1005D
Evaporator Fan Motor....................................	4681JK1004E
Capacitor (Running) ...................................	0CKZZJB2012K
	(0CKZZJB2014B)
	(0CKZZJB2012H)
Compressor (Hi-Side)	TCA31748001
Evaporator (Lo-Side)......................................	5421JJ1007A
Condenser....................................................	ACG36653801
Dryer..............................................................	5851JA2002P
Condenser Fan Motor ...................................	4681JB1029D
Temperature Control.............................	ACQ36820501( )
	ACQ36820503(WB)
	ACQ36820504(BI)
	ACQ36820505(STS)
Main Control .................................................	EBR41956402
Ice Fan Motor ................................................	4681JB1029E

1-8 AIR FLOW / CIRCULATION D’AIR

EVAPORTOR FAN MOTOR

CONDENSER FAN MOTOR

ICE

ROOM

Glide'N'Serve

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Description		795.787**
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

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2. PARTS IDENTIFICATION

	A
	B	P
	F	Q
	G	C
	S
	D	E
	R	L
		M
	H
		N
	I
	J
		O
	K

Use this page to become more familiar with the parts and features. Page references are included for your convenience. 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.

A	Refrigerator Light	K	Extra Ice Bin	Ice Bucket
B Filter (Inside)		L	Pull out Drawer	Ice Room
C Modular Door Bins		M	Durabase	Door
D Tilting door bin		N	Divider
E Fixed door bin		O	Tilt-Out Door Basket
F	Refrigerator Shelves	P	Dairy Bin
G Ice Room		Q	Bottle Holder
	(Ice Maker and Ice Bucket)		(795.7876 *Model Only)
	Humidity Controlled Crisper	R	Water Tank Cover
I	Glide‘N’Serve	S	Egg Box
J	Cube Ice Maker

- 5 -

3. DISASSEMBLY

3-1 REMOVING AND REPLACING REFRIGERATOR DOORS

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.

3

CAUTION : Before you begin, remove food and bins from the doors.

	(2)	(1)
(3)
	(5)	(4)
(6)
(7)	(8)

•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.

To remove the right refrigerator door:

(2)

(1)

(4) (5)

(6)

(3)

•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.

WARNING

Explosion Hazard

•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.

- 6 -

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.

Frame Cover

Handle

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.

Gasket

Door Bracket Clip

Frame

Flat Tip

Screwdriver

Gasket

Bracket

Figure 2

3.Remove gasket

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

Figure 3

● 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

Door

Frame

Correct

Incorrect

Figure 4

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.

<Inserting the Gasket Assembly into the Bracket Door>

	Correct
Incorrect	Figure 5

- 7 -

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

.

3-3 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.)

Figure 10

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 removing one screw and pulling the grille 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.

FAN MOTOR

BRACKET

FAN

Figure 11

- 8 -

*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 2 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 10)

2.Separate the connector with the Defrost Control assembly and replace the Defrost Control assembly after cutting the Tie Wrap. (Figure 11)

GRILLE ASSEMBLY		DEFROST-CONTROL
		ASSEMBLY

Figure 10	Figure 11

3-6 LAMP

Unplug Refrigerator, or disconnect power at the circuit breaker.

If necessary, remove top shelf or shelves.

3-6-1 Refrigerator Compartment Lamp

1)Release 2 screws.

2)Hold both ends with your both hands and pull it downward to remove it.

3)Use a flat tool as shown below to remove the cover lamp.

Figure 12

4)As shown below, use a flat tool to remove the cover lamp.

Figure 13

			LED, Assembly
	Cover, Lamp			Case Lamp

Figure 14

3-6-2 Freezer Compartment Lamp

1.Unplug refrigerator power cord form outlet.

2.Remove screw with direver.

3.Grasp the cover Lamp,pull the cover downward.

Figure 15

- 9 -

3-7 MULTI DUCT

1. Remove the upper and lower Caps by using a flat screwdriver, and remove 2 screws. (Figure 17)

2. Disconnect the lead wire on the bottom position.

Figure 17

3-8 MAIN PWB

1) Loosen the 3 screws on the PWB cover.

2) Remove the PWB cover

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

3-9 DISPENSER

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.

wCAUTION: 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.

3-10 DISPLAY PWB REPLACEMENT

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

2) Follow the steps in the pictures

3-11 FUNNEL REPLACEMENT

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

2)Disconnect the wire harness.

3)Replace in reverse order.

- 10 -

3-12 SUB PWB FOR WORKING DISPENSER

1) Loosen the screw on the sub PWB.

2)Pull the sub PWB down.

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

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.

hinge

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.

3) It separates a ground connection screw.

- 11 -

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

- 12 -

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) Take the Ice Bin out slowly.

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)

1

2

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

- 13 -

3-19 HOW TO REMOVE AND REINSTALL THE PULLOUT DRAWER

3-19-1 Follow Steps to Remove

Step 1) Open the freezer door.

Step 2) Remove the lower basket.

Step 3) Remove the two screws from the guide rails (one from each side).

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.

- 14 -

3-19-2 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.

- 15 -

3-20. WATER VALVE DISASSEMBLY METHOD

1)Turn off the water. Then separate the water line from the valve.

2). Separate the Mechanical Cover and Valve Screw.

Mechanical Cover

3) Separate the housing and pull out the valve.

Housing

4)Lay a dry towel on the floor and get ready to spill water from the water filter. Pull out the Cilp. Then press te collet to separate the tube from the connector and pour out the water until emptied.

Collet

Tube

Insert Line

Clip

3-21. FAN AND FAN MOTOR DISASSEMBLY METHOD

1)Using a short screwdriver, loosen one SCREW in DRAIN PIPE ASSEMBLY and one connected to the MOTOR COVER.

MOTOR COVER

→

2)Pull and separate the FAN ASSEMBLY and MOTOR turning counterclockwise based on the MOTOR SHAFT.

FAN ASSEMBLY

MOTOR

→

The assembly is in the reverse order of the disassembly and take special care for the following details.

1.Be careful not to bend the tube during assembly.

2.Press the WATER DISPENSER button until water pours out and check for leakage in the CONNECTOR TUBE (It differs by the water pressure but usually takes about 2 minutes until water pours out.)

- 16 -

3-22 PULL OUT DRAWER

o 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.

1

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.

Hook

- 17 -