Kenmore 800 Series Dryer Repair Manual

The Kenmore 800 Series Dryer is a high-capacity electric or gas dryer featuring multiple cycles, temperature settings, and advanced moisture sensing for efficient drying. This manual provides essential information for troubleshooting, maintenance, and repair of common issues. Below are key sections covering safety, components, diagnostics, disassembly, part replacement, and testing procedures.

1. Safety Precautions 2. Model Identification & Specifications 3. Tools Required 4. Common Symptoms & Diagnostics 5. Component Locations & Access 6. Disassembly Instructions 7. Testing Electrical Components 8. Replacing Common Parts 9. Reassembly & Final Testing 10. Error Codes 11. Preventive Maintenance

Safety Precautions

Before attempting any repair, ensure personal safety and prevent damage to the appliance.

PrecautionDescription
Disconnect PowerUnplug dryer from electrical outlet or shut off gas supply and circuit breaker.
Allow to CoolLet dryer cool completely before handling internal components.
Use Proper ToolsEmploy insulated tools and wear safety glasses when working.
Avoid MoistureKeep work area dry to prevent electrical shock.
Secure DryerEnsure dryer is stable and will not tip during service.

Model Identification & Specifications

Locate model number on label inside door or rear panel.

Tools Required

  1. Phillips and Flat-head Screwdrivers.
  2. Nut Drivers (1/4" and 5/16").
  3. Multimeter for continuity and voltage testing.
  4. Pliers (Needle-nose and Slip-joint).
  5. Putty Knife or Trim Removal Tool.
  6. Socket Set.

WARNING! Use tools properly to avoid injury or damage to components.

Common Symptoms & Diagnostics

SymptomPossible CauseDiagnostic Step
Dryer won't startPower supply, door switch, thermal fuse, start switchCheck outlet voltage; test door switch continuity; inspect thermal fuse.
No heat (Electric)Heating element, thermostat, high-limit thermostatTest heating element for continuity; check thermostats.
No heat (Gas)Igniter, gas valve coils, thermal fuseObserve igniter glow; test valve coils; check thermal fuse.
Drum not turningDrive belt, motor, idler pulley, motor capacitorInspect belt for breakage; test motor windings; check idler pulley.
Excessive noiseRollers, glides, blower wheel, foreign objectsListen for source; inspect rollers and blower; remove obstructions.
OverheatingBlocked vent, cycling thermostat, lint buildupCheck venting; test cycling thermostat; clean lint filter and duct.

Component Locations & Access

Key components and their typical locations:

ComponentLocation
Heating Element (Electric)Rear panel behind drum.
Igniter & Gas Valve (Gas)At the burner assembly at rear bottom.
Thermal FuseOn blower housing or near heating element.
ThermostatsOn heating element housing or exhaust duct.
Drive MotorUnder drum at rear.
Door SwitchInside front panel near door latch.
Start SwitchOn control panel.
Moisture SensorInside drum at front or rear.
BeltAround drum and motor pulley.
Idler PulleyUnder drum, tensions drive belt.

Disassembly Instructions

General steps to access internal components:

  1. Unplug Dryer: Disconnect power and gas (if applicable).
  2. Remove Top Panel: Insert putty knife at rear corners to release clips; lift top and prop forward.
  3. Remove Front Panel: Open door; remove screws at lint filter opening and along bottom edge; tilt panel forward and lift off.
  4. Access Drum: Remove belt from motor pulley; lift front of drum and slide forward.
  5. Remove Rear Panel: Remove screws around perimeter to access heating element, motor, and thermostats.
  6. Remove Control Panel: Remove screws at back or underneath; disconnect wiring harnesses carefully.

CAUTION! Label wires and take photos during disassembly for easier reassembly.

Testing Electrical Components

Use multimeter set to ohms (Ω) for continuity tests (power disconnected).

  1. Heating Element (Electric): Disconnect wires; test between terminals. Should read 10-50 Ω. Infinite reading indicates open element.
  2. Thermal Fuse: Test across terminals. Should read 0 Ω (continuity). Infinite reading indicates blown fuse.
  3. Thermostats: Test for continuity at room temperature. Should have continuity. If open, replace.
  4. Door Switch: Press button; test for continuity. Should show continuity when pressed.
  5. Motor Windings:Test between common, start, and run terminals per wiring diagram. Look for appropriate resistance values.
  6. Igniter (Gas): Should read 50-400 Ω. If open or shorted, replace.
  7. Gas Valve Coils: Each coil should read 500-3000 Ω.

Replacing Common Parts

Follow disassembly steps to access part.

PartReplacement Procedure
Drive BeltRemove front panel and drum; route new belt around drum and idler; attach to motor pulley.
Heating ElementRemove rear panel; disconnect wires; remove mounting screws; install new element.
Thermal FuseLocate fuse on housing; disconnect wires; remove mounting clip or screws; install new fuse.
Dryer Drum RollersRemove drum; unclip or unbolt old rollers from rear bulkhead; press new rollers into place.
Igniter (Gas)Remove rear panel; disconnect wires; remove mounting bracket; install new igniter.
Door SwitchRemove front panel; disconnect wires; unclip or unscrew old switch; install new switch.
Start SwitchRemove control panel; disconnect harness; release tabs or remove screws; replace switch.

Reassembly & Final Testing

  1. Reverse disassembly steps, ensuring all components are securely fastened.
  2. Reconnect all wiring harnesses and ground wires.
  3. Verify drum rotates freely and belt is properly aligned.
  4. Reinstall panels and secure all screws.
  5. Test: Reconnect power/gas. Run dryer empty on air fluff cycle. Listen for unusual noises. Test heat on a timed dry cycle. Verify all controls function.

Tip: Perform a final safety check for loose parts or exposed wires before operating.

Error Codes

Some models may display fault codes via blinking lights.

Code PatternLikely IssueAction
F1 / 1 FlashThermal fuse open / Overheat conditionCheck venting, replace thermal fuse, test thermostats.
F2 / 2 FlashesMotor circuit faultTest motor, motor relay, and associated wiring.
F3 / 3 FlashesHeater circuit fault (Electric)Test heating element, thermostats, and high-limit.
F4 / 4 FlashesIgnition failure (Gas)Check igniter, gas valve coils, flame sensor, gas supply.
F5 / 5 FlashesMoisture sensor faultClean sensor bars; test sensor continuity and wiring.

Preventive Maintenance

Regular maintenance prevents common failures.

  1. Clean Lint Filter: Before every load.
  2. Vent System: Inspect and clean duct at least annually.
  3. Inspect Drum: Check for sharp edges or damage that can tear clothes.
  4. Check Vent Hood: Ensure exterior flap opens freely.
  5. Inspect Power Cord: Look for fraying or damage.
  6. Clean Moisture Sensor: Wipe with rubbing alcohol every few months.

WARNING! Never operate dryer without lint filter. Accumulated lint is a fire hazard.

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