Kenmore 796.4102#90# Service Manual Download

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WASHING MACHINE
SERVICE MANUAL

CAUTION

READ THIS MANUAL CAREFULLY TO DIAGNOSE

PROBLEMS CORRECTLY BEFORE SERVICING THE UNIT.

http://www.managemyhome.com

MODEL : 796.4219#90# , 796.4102#90#

Summary of Contents for 796.4102#90#

Page 1: ...WASHING MACHINE SERVICE MANUAL CAUTION READ THIS MANUAL CAREFULLY TO DIAGNOSE PROBLEMS CORRECTLY BEFORE SERVICING THE UNIT http www managemyhome com MODEL 796 4219 90 796 4102 90 ...

Page 2: ...P No MFL30599143 ...

Page 3: ...R LEVEL FREQUENCY 21 8 TROUBLESHOOTING 22 8 1 SAFETY CAUTION 22 8 2 ERROR MODE SUMMARY 22 8 3 TROUBLESHOOTING SUMMARY 24 8 4 TROUBLESHOOTING WITH ERROR 26 8 5 TROUBLESHOOTING ELSE 33 9 COMPONENT TESTING INFORMATION 38 9 1 FILTER ASSEMBLY LINE FILTER 38 9 2 DOOR LOOK SWITCH ASSEMBLY 39 9 3 STATOR ASSEMBLY 41 9 4 PUMP MOTOR ASSEMBLY 44 9 5 INLET VALVE ASSEMBLY 45 9 6 HEATER ASSEMBLY 46 9 7 THERMISTO...

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Page 5: ...ening Tilted drum and extra large opening make it possible to load and unload clothing more easily RollerJets Washing ball enhances the wash performance and reduces damage to the clothing The jets spray and help tumble clothes to enhance washing performance while maintaining fabric care Automatic Wash Load Detection Automatically detects the load and optimizes the washing time Built in Heater Inte...

Page 6: ...m then proceeds Spinning does not proceed until the water in the tub drains to a certain level 2 4 DOOR CONTROL The door can be opened by pulling the door handle whenever washer is not in operation When the cycle is completed the DOOR LOCKED light will turn off If a power failure has occurred while in operation the door will unlock after 5 minutes Clicking sounds can be heard when the door is lock...

Page 7: ...ite the motor is in the process of intertial rotating through the operation is paused 2 6 CONTROL LOCK Use this option to prevent unwanted use of the washer Press and hold CONTROL LOCK button for 5 seconds to lock unlock control When CONTROL LOCK is set CONTROL LOCK lights and all buttons are disabled You can lock the controls of the washer while washing ...

Page 8: ...FICATION ACCESSORIES Wrench Tie strap Option to secure drain hose to standpipe inlet hose or laundry tub Hot Cold 1 each Hose Non skid pads Caps 4 for covering shipping bolt holes Elbow Bracket for securing drain hose ...

Page 9: ... the 4 caps provided into the hole ADJUST THE LEVELING INSTALL THE APPLIANCE ON A FLAT AND FIRM SURFACE 8 Before servicing ask the customer what the trouble is Check the setup power supply is 120V remove the transit bolts level the washer Check with the troubleshooting guide Plan your service method by referring to the disassembly instructions Service the unit After servicing operate the appliance...

Page 10: ...9 ...

Page 11: ...se rotation 4 Check the water supply Check if water is supplied through the detergent dispenser 7 Check the drain and spin functions Power off and the power on Press the SPIN SPEED button Press the START PAUSE button Check the spin and drain functions 8 Press the START PAUSE button 9 Water removal If SERVICE is needed during check remove the remaining water by pulling out the hose cap 2 Press the ...

Page 12: ...XX UGvwlyh pvu TXUGjvu yvs whuls mlh ylz U YX J JJ U XWYJ JJ ...

Page 13: ...DD STEAM button to add steam to the selected cycle for added cleaning power B CYCLE SELECTOR KNOB Turn this knob to select the desired cycle Once the desired cycle has been selected the standard presets will be shown in the display These settings can be adjusted using the cycle setting buttons anytime before starting the cycle C START PAUSE BUTTON Press this button to start the selected cycle If t...

Page 14: ...13 5 2 CYCLE GUIDE 4219 9 ...

Page 15: ...14 4102 9 5 2 CYCLE GUIDE ...

Page 16: ...e This is especially useful for heavily soiled items AUTO SOAK Use the AUTO SOAK option to presoak garments to help remove difficult spots or stains on fabrics This option provides a 30 minute presoak prior to the start of the selected cycle 1 Add detergent only to the Main wash compartment or Liquid Box of the dispenser drawer 2 Select desired cycle 3 Select cycle modifiers 4 Press the START PAUS...

Page 17: ...disable the controls The washer can be locked during a cycle This feature allows you to prevent children from changing cycles or operating the machine Once set the CONTROL LOCK must be turned off before the controls can be used Once the washer has shut off the power button will allow the machine to be turned on but the controls will still be locked When the controls are locked CL will be displayed...

Page 18: ...he drum rotates If water temperature becomes lower than selected because of re supplied water the heating starts again 7 Washing Fuzzy Logic decides washing time according to the laundry load water temperature and other factors 8 Drainage A pump motor drains the water from the drum After sensing drained water amount by water level frequency spin starts When a heating course is selected stay coolin...

Page 19: ...supply Water supply for rinse process E Rinse Rinsing process F Last drainage After spin finishes and power is not supplied to motor the drum rotates by remaining spin power If rinse hold is selected the drainage is not proceeded after rinse finishes G Disentangling The same as item 9 H Intermittent spin The same as item A I Main spin1 The same as item B J Main spin2 At the end of a main spin the ...

Page 20: ...11 20 16 22 34 40 19 75 63 20 97 20 80 59 59 100 25 44 50 Heavy Duty Normal Casual Sanitize Bulky Bedding Whitest Whites Cold Clean Express Wash Kids wear 120 120 120 120 120 NOTE Cycles are different depending on the models ...

Page 21: ...20 53 59 11 26 23 20 58 20 53 100 Handwash wool Rugged Workout wear Steam Refresh 120 120 120 120 120 NOTE Cycles are different depending on the models ...

Page 22: ...E and DELAY S button simultaneously The digits indicate the water level frequency x 1 kHz So for example a display indicating 241 a Water level frequency of 241 x 1 kHz 24 1 kHz None 1 time 2 times 3 times 4 times 5 times 6 times 7 times 8 times 9 times 10 times 11 times Turns on all lamps and locks the door Tumble clockwise Low speed Spin High speed Spin It will be take about 2minits to be high s...

Page 23: ...the preset water level within 25 minutes The load is too small The appliance is tilted Laundry is gathered to one side Non distributable things are put into the drum Door not all the way closed Loose electrical connections at Door switch and PWB Assembly The DOOR SWITCH ASSEMBLY is out of order Not fully drained within 10 minutes The SENSOR SWITCH ASSEMBLY is out of order The THERMISTOR is out ord...

Page 24: ...ntact between the connectors 3 pin male white in the MOTOR HARNESS and 4 pin female white connector in the MAIN PWB ASSEMBLY is bad or unstable The MOTOR HARNESS between the STATOR ASSEMBLY and MAIN PWB ASSEMBLY is cut open circuited The hall sensor is out of order defective EEPROM is out of order Displayed only when the START PAUSE button is first pressed in the QC Test Mode The washer experience...

Page 25: ...24 8 3 TROUBLESHOOTING SUMMARY CIRCUIT DIAGRAM ...

Page 26: ...25 ...

Page 27: ...bly Clean or replace the filter Check the AIR CHAMBER and the tube clogged Yes No No Yes Yes Reconnect or repair the connector Replace the INLET VALVE ASSEMBLY Yes Yes Is the voltage at the inlet valve coil 120VAC with the valve energized Replace the INLET VALVE ASSEMBLY No Yes Yes Is the wiring correct Refer to the wiring diagram for correct connections Refer to 9 5 wiring diagram Replace the MAI...

Page 28: ...tance of the drain pump motor Is the resistance between 101 and 201 Refer to 9 4 Pump motor assembly Replace the DRAIN PUMP ASSEMBLY Yes Yes Check the voltage between the main PCB connectors NA4 1 BN and BL3 1 BK Is the voltage 120 VAC 5 TO TURN ON THE DRAIN PUMP 1 Turn on the washer 2 Press the SPIN SPEED button to select LOW speed 3 Press the START PAUSE button The drain pump will be energized f...

Page 29: ...e the THERMISTOR ASSEMBLY Yes No Are the thermistor terminals dry and free of corrosion Note The temperature sensing circuits on the main PCB are very simple consisting only of resistors and capacitors Problems with wiring or connections in the thermistor circuit are the most likely cause for this error Be sure to check ALL connections and wiring thoroughly The main PCB should only be replaces as ...

Page 30: ...s Motor Drive Is rotor magnet cracked Hall sensor Motor Drive Hall Sensor part of wire part of motor Motor Yes Yes Yes Magnet Replace the STATOR Check the resistance of the stator winding from the main PCB connector RD3 Is the resistance between each pair or wires between 5 and 15 Measure pins 1 2 1 3 and 2 3 No Replace the Hall sensor Is hall sensor out of order Refer to 9 3 Stator assembly Hall ...

Page 31: ...MBLY Replace gasket or hinge Remove foreign objects No No If tested off the stator using the diagram above ohm check the resistors from pin 5 to pin 1 pin 2 Does either test show an open infinity the hall sensor You should measure approximately 10 000 ohms from pin 5 to pin 1 and 10 000 ohms from pin 5 to pin Replace the DOOR SWITCH ASSEMBLY No Yes Yes Is the door closing properly Is the gasket da...

Page 32: ...ing machine installed at an angle Adjust the height of washing machine to be kept horizontally Yes No Is displayed Yes While a cycle is running press the WASH RINSE and DELAY START buttons together to display the water level Is the water level 213 Refer to 7 3 Check the AIR CHAMBER and the tube clogged No Unplug the washer Does the water valve remain on when the power is removed from the washer Re...

Page 33: ...e or disconnected Reconnect or repair the connector No Yes Yes Measure the resistance between pins 1 and 3 of the pressure switch Is the resistance between 211 and 231 Replace the pressure switch No No Is the AIR CHAMBER and the tube clogged Replace the MAIN PWB assembly Fix the air chamber and remove the foreign material Yes ...

Page 34: ...r Yes No Is the current rating of multi outlet power strip enough Avoid connecting several electric devices Is the supplied voltage 120V AC 10 15 Alternate with explanation Yes No No Check the connectors at the main PCB and the line filter Are the connectors loose or disconnected Reconnect or repair the connector Yes Replace the MAIN PWB ASSEMBLY Main LED Yes No Is LED on while the power is on Rep...

Page 35: ...PCB and the line filter Are the connectors loose or disconnected Reconnect or Repair the connector Yes Check the connectors between the main PCB and the display PCB Are the connectors loose or disconnected Replace the main PCB Replace the main PCB Yes No No ...

Page 36: ...Put an unbalance part rubber inside of drum and start QC test mode and run in high spin Refer to section 7 2 When the machine is spinning in high speed verify that it is stable If you do not have the unbalance part put 4 5 to 6 5 lbs 2 to 3 kg of clothing Once loaded press power Rinse Spin and the start pause button in sequence When the machine is spinning in high speed verify that it is stable If...

Page 37: ... the dispenser Put the detergent in the correct place YES YES YES YES NO NO NO Is water supplied Is the detergent caked or hardened Are receptacles correctly connected to the terminals of the INLET VALVE ASSEMBLY Has detergent been put in the correct compartment of the dispenser ...

Page 38: ...tive Then check stator Replace if necessary Check rotor for broken magnets Replace rotor if necessary YES NO YES YES YES YES YES NO NO NO Is water supplied Are the plugs correctly connected to the terminals of the INLET VALVE ASSEMBLY Is liquid detergent softener bleach put in the correct compartment of the drawer Is the liquid detergent softener bleach cap clogged Is the motor bolt loosened Is th...

Page 39: ...e Component be sure to turn the power off and do voltage discharge sufficiently WARNING Circuit diagram Circuit in the MAIN PWB Circuit diagram Vac MAIN PWB ASSEMBLY FUSE RD1 WH1 LI L2 RI CI C2 C3 3 2 1 3 2 1 Test points and Result Test Points Result WH 1 to RD 3 WH 3 to RD 1 0 1 0 1 3 1 WH1 3 1 RD1 ...

Page 40: ...rough terminal 3 4 PTC solenoid will make the door locked Door lock is detected when switches in terminal 4 5 are set closed CAM rotation will forcibly clear off the connection The maximum allowable number of impulse authorizations is 2 Upon the third authorization of the impulse the position of CAM goes back to the door open position Authorizing the impulse occurs in 4 5 seconds upon input for ma...

Page 41: ...40 Test points Result Test Points 2 to 4 3 to 4 4 to 5 2 to 4 Result 700 1500 1 60 90 1 Infinity 120 Vac Remarks At 77 F 25 C At 77 F 25 C Voltage Input 2 3 4 5 ...

Page 42: ...4 5 2 3 4 1 2 3 4 Hb Function Test points Windings Result Windings The DD motor can be driven from stopped to maximum speed in infinite steps in either direction There are 36 poles on the stator 12 permanent magnets spaced around the rotor There are no brushes to wear out Unlike a more traditional brushless motor the rotor surrounds the stator rather than being attached to it Test Points Result 1 ...

Page 43: ...o the Hall Sensor use the following steps 1 Unplug power cord 2 Remove rear washer panel 3 Locate Hall sensor connector on the stator behind the rotor 4 Place meter leads on terminals 5 to 4 white to gray 5 Plug in power cord close door and press power button DO NOT PRESS START 6 You should measure 10 to 15 Vdc If 10 to 15 Vdc is present control board white wire and gray wire are OK If not follow ...

Page 44: ...s but does not pulse or change Hall sensor has failed and must be replaced IF zero 0 voltage is measured on either test check red blue wires for continuity Repair or replace harness as needed Voltage Testing Hall Sensor from the Main PCB Assembly 7 To measure output signal voltage from the hall sensor carefully move test leads to terminals 1 to 4 blue and gray Slowly rotate motor rotor by hand You...

Page 45: ...3 4 1 2 3 4 BL3 SB SB SB BK BN BN DRAIN PUMP CIRCULATION PUMP BK Object Function Test points Result Each circuits of loads in wiring diagram are all same Two pump motors are used to drain the tub and to circulate the water detergent solution Drain Pump Drain Pump Circulation Pump Circulation Pump Test Points Result 1 to 2 10 20 1 Test Points Result 1 to 2 18 30 1 T P For Drain For Circulation 1 2 ...

Page 46: ...t or cold water valve solenoids to meet the selected water temperature After pull out the connector of defective valve check the resistance Test points 1 2 Result 0 8 1 2 k1 Circuit diagram MAIN WASH AG VALVE PRE WASH BLEACH HOT VALVE 1 2 1 2 1 2 1 2 1 2 RD BL BL RD NA WH NA4 VT GY YL BL BL4 BL3 4 3 2 1 1 2 3 1 2 3 4 3 2 1 4 3 2 1 4 3 2 1 COMMON BK MIAN PWB INLET VALVE Each circuits of loads in wi...

Page 47: ...L BK BK Vac WASH HEATER STEAM GENERATOR HEATER YL F U S E F U S E Function Test points Result 1 The Wash Heater is designed to raise the wash water to the desired temperature selection during certain wash cycles Wash Heater Steam Generator Heater Each circuits of loads in wiring diagram are all same Wash Heater Steam Generator Heater Test Points Result 1 to 2 12 18 1 Test Points Result 1 to 2 12 1...

Page 48: ... PWB MICOM NA3 BL BN WH 1 2 1 2 1 2 1 2 WH WASH THERMISTOR STEAM GENERATOR THERMISTOR 1 2 3 4 5 6 1 5V 5V R R R R C C C C 2 3 4 5 6 Function Test points The thermistor temperature sensor is used to monitor water temperature in the tub Wash Thermistor 2 1 Steam generator Thermistor 1 2 1 2 ...

Page 49: ...48 Result Wash Thermistor Test Points 1 to 2 Result tolerance 5 39 5 k1 26 1 k1 12 1 k1 8 5 k1 3 8 k1 2 8 k1 Remarks At 86 F 30 C At 104 F 40 C At 140 F 60 C At 158 F 70 C At 203 F 95 C At 221 F 105 C ...

Page 50: ...evel sensor thermistor or heater cannot be replaced individually Diagnosis is limited to determining malfunction and replacing as an assembly The steam generator does not have to be removed from the machine to be drained Be sure to let the water cool to avoid a burn Have a hose available to slip onto the connector or a large towel to catch the water so it doesn t run down into the machine cabinet ...

Page 51: ...pairing the parts 2 Pull the top plate backward and upward as shown 4 Pull out the drawer and unscrew 2 screws 5 Remove one screw 8 Disassemble the Display PWB Assembly 6 Lift the side the control panel assembly and pull it out 7 Unscrew the 9 screws M4 1 screw M3 from the control panel assembly 3 Disconnect the Display PWB assembly connector from trans cable ...

Page 52: ...51 MAIN PWB ASSEMBLY 1 Disconnect the POWER connector and SENSOR SWITCH ASSEMBLY 2 Remove the Protective cover 3 Disconnect the connectors 4 Unscrew 1 screw on the back 5 Remove the Main PWB ...

Page 53: ... assembly 2 Pull out the drawer 1 Disassemble two or three connectors from the NOISE FILTER 2 Unscrew a screw from the TOP BRACKET 4 Unscrew the Clamp nut at the lower part of the dispenser 5 Disassemble the 4 connectors from the valves 6 Unscrew 2 screws from the back of the cabinet 3 Push out the DISPENSER ASSEMBLY after unscrewing 2 screws 1 2 3 4 ...

Page 54: ...ews from upper of the canbinet cover 2 Unscrew the screw from filter cover 3 Put a flat screwdriver or putty knife into the hinge slots at the bottom of the cover and pry it out 4 Unscrew the screw from the lower side of the cabinet cover ...

Page 55: ... assembly 7 Tilt the cabinet cover 8 Disconnect the door switch connector 9 Lift and separate the cabinet cover 10 Disassemble the clamp assembly 11 Disassemble the gasket NOTE When assembling the CABINET COVER connect the door switch connector ...

Page 56: ...disassemble the CLAMP ASSEMBLY Unscrew the 2 screws DOOR LOCK SWITCH ASSEMBLY NOTE Reconnect the connector after replacing the DOOR SWITCH ASSEMBLY PUMP Disassemble the cabinet cover Separate the pump hose the bellows and the circulation hose assembly from the pump assembly Disassemble the pump assembly in arrow direction CIRCULATION HOSE PUMP HOSE BELLOWS 1 2 3 ...

Page 57: ...isassemble the cabinet cover Separate 2 connectors from the heater Loosen the nut and pull out the heater THERMISTOR Disassemble the cabinet cover Unplug the white connector from the thermistor Pull it out by holding the bracket of the thermistor CAUTION When assembling the heater insert the heater into the heater clip on the bottom of the tub Tighten the fastening nut so the heater is secure 1 2 ...

Page 58: ...tor 1 Unscrew the 2 screws from the tub bracket 2 Remove the 6 bolts on the stator 3 Unplug the 2 connectors from the stator 1 Disassemble the damper hinges from the tub and base NOTE If you pull the dampers apart the must be replaced If you do not separate them they can be re used ...

Page 59: ...tor 1 Unscrew the 2 screws from the tub bracket 2 Remove the 6 bolts on the stator 3 Unplug the 2 connectors from the stator 1 Disassemble the damper hinges from the tub and base NOTE If you pull the dampers apart the must be replaced If you do not separate them they can be re used ...

Page 60: ...A410 A111 A102 A103 A130 A131 A390 A310 A300 A133 A303 A200 A150 A110 F210 A104 A105 A106 F215 A141 A151 A140 A153 A154 M400 Printed materials Description Owner s Manual Energy Label Loc No Tech Sheet Service Manual Quick Start Guides Installation Sheet G001 G002 G003 G004 G006 G007 The following parts are not illustrated ...

Page 61: ...K115 K141 K117 F315 F465 K125 F467 F463 F464 F310 K121 K122 K550 K540 F461 K520 K105 K190 K195 In case of replacing THERMISTOR of HEATER ASSEMBLY K320 replace HEATER ASSEMBLY K320 HEATER ASSEMBLY K320 includes THERMISTOR In case of replacing BEARING BALL K121 K122 and GASKET K125 replace TUB ASSEMBLY OUTER K105 TUB ASSEMBLY OUTER K105 includes BEARING BALL K121 K122 and GASKET K125 Part Assembly K...

Page 62: ...60 11 3 DISPENSER ASSEMBLY F300 F220 A275 A276 F225 F441 F430 F170 F120 F130 F432 F462 F227 F226 F322 F323 F321 F327 F160 ...

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