Service Manual - Appliance Factory Parts
Contents
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3. OVEN OVEN LAMP RD WH BL BK THERMOSTAT 513747576 TRANSFORMER 230 o 2131415 WH N BL H BK WH Ro D CAPACITOR 10U RY6 q Q WH RY14 BL C L HIGH H WH WH BASE WH RY15 THERMOSTAT COOKTOP CA Low YL 56 153 LAMPS 2 BK BK VM HI Bye SECONDARY LOW 108 CN1 YL 1 TURNTABLE 8 4 MOTOR 2 oo SENSOR MONITOR SWITCH CN2 1 MIDDLE juo Lm 0000000000000 ul BL C 5 PRIMARY UE RIMAR Bess TRANSFORMER BOTTOM H V CAPACITOR OPTIONAL FUNCTION MAGNETRON FOR SENSOR MODEL ONLY WIRE COLORS CONTROL MODULE SYMBOL COLOR WH WHITE WH RD BR GY Y BK PK PK BL WH RD BK BLACK 1 3 5 7 9 1 13 15 YL YELLOW 321 PK PINK BL BLUE BR BROWN 15 PIN CONNECTOR CN1 3PIN CN2 3PIN CN5 GN GREEN CONNECTOR CONNECTOR CY CREY FOR SENSOR ONLY 5 1 WH NO WH MATRIX CIRCUIT FOR TOUCH KEY BOARD For Model 85130 85138 85139 112 313 14 415 461 VENT HELP COOK POPCORN O HI LOW OF A A A A J 8 LIGHT CUSTOM HI LOW OFF SET REHEAT QUICK Less MP TOUCH peverace KIICHEN 7 2 A PLUS A A CUSTOM LIGHT 11 T TABLE STOP START 4 ON OFF CLEAR 12 2 2 2 MORE N C N C N C T For Model 85140 LIGHT CUSTOM y n c
4. 8 7 SCHEMATIC DIAGRAM OF P C B CN1 P NO 6630WSVO12A YW 15AV RECTIFIER H V C TRANSFORMER MONITOR SWITCH SYNCH MOTOR E FAN MOTOR pno A py DOS 1N4002 20 FAN MOTOR OVEN LAMP X pee Jv Jet 0 55 12 OVEN LIGHT APAA SECONDARY ME 20W2D01 032 INTERROCK OVER essa RYG E Epio Li SWITCH SWITCH C LAMP_HIGH uP Fa 8 OU SS 112LM COOKTOP LIGHT BASE THERMAL PROTECTOR OJ SS 112LM EEE P NG 9820620010 Ry q 41 ets D38 N4004 Bynoseozowa0010A Ry 34 LOW VENT FAN HIGH n VENT FAN LOW P33 1 WER ll D36 MOTOR pEi RY12 i 12V MICRO WWE __ T T ne 211 638 FUSE E 1 ON vos THERMAL THERMAL YW396 O3 2void 120V 6092 protector PROTECTOR 2 si p C25 DOOR W R 9 3 1 xv 2 R28 R29 5V R140 47 141 3 26 1 43 PEE Po2 RESET Test vss vss b
5. 7 24 ASSY ASSY uolye JUBA jeuuoNn suni ON MO 198100 225 jeuuoNn joejuoo IeuuoN 1991102 LS Joloeuuoo jo joejuoo yooyo joejuoo 100d jeisouueuy pue Ileuuedl Yo loeluo0D ON N lelsouuedl pue asny Ieuuedl Joloeluoo y 4oedO asnd AlddNS H3MOd 9eu5 s NV USym sleledo jou seop 6 WaTHOHd 7 25 EV EXPLODED VIEW DOOR PARTS Model 767 8513000 767 8513800 767 8513900 767 8514000 CONTROLLER PARTS EV OVEN CAVITY PARTS LATCH BOARD PARTS INTERIOR PARTS 1 EV INTERIOR PARTS Il EV INSTALLATION PARTS
6. 4 SENSOR OPTION wss 4 R55 j ICR1 TM 1 LI xin LI LS 4 5V ei mE ss 8 LCD meal i 75 m pas 87 H NA pup um P32 Poo RO Po1 18 R81 19 RB2 1 150Ke7 1 4W 0215050810 P54 P NO ODLZWSAD10A 610175 Vbz R130 44 Eu SENSOR MODEL OPTION R131 i ex E 5v CN3 6630W5YA19E FCZ254 13D 8 16 PRINTED CIRCUIT BOARD P NO 3828W5S1807 Printed in Korea
7. Secondary Winding Filament Winding Winding Figure 24 A TEST PROCEDURES COMPONENTS TEST PROCEDURES RESULTS 1 Measure the resistance Across the filament terminals of the magnetron Normal reading with an ohm meter on Rx1 scale Less than 1 ohm 2 Measure the resistance Between Normal reading MAGNETRON each filament terminal of the Infinite ohms Wire leads are magnetron and the chassis ground removed with an ohm mater on high test scale NOTE Replace the magnetron if the magnetron checks and all of the high voltage component tests are good but the unit still does not heat a load 1 Measure the resistance HIGH VOLTAGE a Primary winding TRANSFORMER b Filament winding Wire leads are c Secondary winding removed With an ohm meter on Rx1 scale 2 Measure the resistance With an ohm meter on highest scale a Primary winding to ground b Filament winding to ground Normal readings Approx 0 2 to 0 5 ohm Less than 0 1 ohm Approx 50 to 120 ohms Normal readings Infinite ohms Infinite ohms NOTE A MICROWAVE ENERGY LEAKAGE TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS SERVICED FOR ANY REASON COMPONENTS TEST PROCEDURES RESULTS HIGH VOLTAGE CAPACITOR Measure the resistance 1 Terminal to terminal Figure 25 a Normal reading Momentarily indicates several ohms and then gradually returns to infinite ohms Abnormal r
8. BR BROWN RD RED BL BLUE Figure 9 PINK GY N P Not Provided Latch Board Secondary Interlock Switch Interlock Monitor Switch Primary Interlock Switch REMOVING MAGNETRON Figures 11 Through 13 Remove the vent grille by loosening two screws Figure 11 Remove the outcase See page 7 6 Remove three tap tite screws securing the magnetron to the wave guide Remove the magnetron VERY CAREFULLY Figure 11 Figure 13 NOTES When removing the magnetron make sure that its dome does not hit any adjacent parts or it may be damaged When replacing the magnetron be sure to install the magnetron gasket in the correct position and be sure that the gasket is in good condition After replacing the magnetron check for microwave energy leakage with a survey meter Check microwave energy leakage must be below the limit of 5 mW cm2 All service adjustments should be made for minimum microwave energy leakage readings Mount All screws Mounting Plate Controller 3 screws Figure 12 E REMOVING STIRRER FAN F REMOVING DOOR Figure 16 Figures 14 and 15 1 Remove the vent grille by two screws securing it to 1 Remove one rivet ASS Y securing it to the oven the outcase loosening upper plate by using knife blade 2 Lift up and draw the door 2 Rotate slightly and pull out the stirrer fan cover NOTES 3 Re
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11. 4 mW cm Always start measuring of an unknown field to assure safety for operating personnel from radiation leakage EQUIPMENT TESTER VOLTS DC AC Ohmmeter Microwave survey meter Holaday HI 1500 HI 1501 8100 8200 600 cc non conductive material beaker glass or plastic inside diameter approx 8 5 cm 31 2 in Glass thermometer 100 C or 212 F 1 deg scale Narda MEASURING MICROWAVE ENERGY LEAKAGE Pour 275 15cc of 20 5 C 68 9 F water a beaker which is graduated to 600 cc and place the beaker on the center of the turntable Set the energy leakage monitor to 2 450 MHz and use it following the manufacturer s recommended test procedure to assure correct result When measuring the leakage always use the 2 inch 5cm spacer supplied with the probe Operate the oven at its maximum output Measure the microwave radiation using and electromagnetic radiation monitor by holding the probe perpendicular to the surface being measured Move probe along shaded area Probe scanning speed Less than 2 5 cm sec 1 in sec MEASUREMENT WITH THE OUTER CASE REMOVED 1 When you replace the magnetron measure for microwave energy leakage before the outer case is installed and after all necessary components are replaced or adjusted Special care should be taken in measuring the following parts Around the magnetron The waveguide WARNING AVOID CONTACTIN
12. 4 7 1 MICROWAVE LEAKAGE TEST 7 2 POWER OUTPUT MEASUREMENT nennen 7 3 DISASSEMBLY 5 7 4 INTERLOCK SYSTEM isidro 7 12 INTERLOCK CONTINUITY TEST 7 14 TEST AND CHECKOUT PROCEDURES AND TROUBLE 7 15 iere ea 7 15 B CHECKOUT PROCEDURES diced ea E a e ee Lea 7 18 C TROUBLE 5 7 21 EXPLODED VIEW deer RES Rest gi ue ae De eet pr To e ehe e nd 8 1 PARTS EIST cocida A 8 8 SCHEMATIC DIAGRAM OF PCB tdi Ee ep E deoa 8 16 PRINTED CIRCUIT 9 8 17 PARTS LS ea ESCHER GH 8 18 Rated Power Consumption Microwave Output Power Supply Rated Current Magnetron Cooling Rectification Door Sealing Safety Devices High Voltage Capacitor High Voltage Diode Cook top Lamp Cavity Lamp eere ede Tray c Overall Dimensions Effective Capacity of Oven Cavity Accessories SPECIFICATIONS 1 500W maximum Microwave oven Cook top lamps Ventilation fan 1000W IEC 60 705 Adjustable 100W through 1000W 10 steps 120 60 Hz 18 Amp Microwave oven Cook top lamps Ventilation fan Forced Air Cooling Rectification Vol
13. P C B NEVER operate the oven with no load NEVER injure the door seal and front plate of the oven cavity NEVER put iron tools on the magnetron NEVER put anything into the latch hole and the interlock switches area MICROWAVE RADIATION Personnel should not be exposed to the microwave energy which may radiate from the magnetron or other microwave generating device if it is improperly used or connection All input and output microwave connections waveguide flange and gasket must be secure never operate the device without a microwave energy absorbing load attached Never look into an open waveguide or antenna while the device is energized Proper operation of the microwave oven requires that the magnetron be assembled to the waveguide and cavity Never operate the magnetron unless it is properly installed Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron ANTENNA Gasket COOLING FIN FILAMENT TERMINALS MAGNETRON CHASSIS GROUND MAGNETRON THE OVEN IS TO BE SERVICED ONLY BY PROPERLY QUALIFIED SERVICE PERSONNEL INSTALLATIONS PRECAUTIONS ON INSTALLATION A Plug the power supply cord into a 120V AC 60Hz single phase power source with a capacity of 15A or 20A B Avoid placing the unit in a location where there is direct heat or splashing water C Install the unit on the mounting plate firmly D Place the
14. is the time in seconds and AT is the temperature rise The initial and final water temperatures are selected so that the maximum difference between the final water temperature and the ambient temperature is 5 K NOTE WHEN MEASURING 1 Do not exceed meter full scale deflection 2 The test probe must be removed no faster than 1 inch sec 2 5cm sec along the shaded area otherwise a false reading may result The test probe must be held with the grip portion of the handle A false reading may result if the operator s hand is between the handle and the probe When testing near a corner of the door keep the probe perpendicular to the surface making sure the probe horizontally along the oven surface this may possibly cause probe damage 3 RECORD KEEPING AND NOTIFICATION AFTER MEASUREMENT 1 After adjustment and repair of any microwave energy interruption or microwave energy blocking device record the measured values for future reference Also enter the information on the service invoice Should the microwave energy leakage not be more than 2 mW cm after determining that all parts are in good condition functioning properly and genuine replacement parts which are listed in this manual have been used At least once a year have the electromagnetic energy leakage monitor checked for calibration by its manufacturer 55 9 The microwave power output P in watts is calculated from the following formula 4
15. SWITCH TEST When the door is opened slowly an audible click should be heard at the same time or successively at intervals and the latches should activate the switches with an audible click If the latches do not activate the switches when the door is closed the switches should be a adjusted in accordance with the adjustment procedure Disconnect the wire lead from the primary switch Connect the ohmmeter leads to the common COM and normally open NO terminal of the switch The meter should indicate an open circuit in the door open condition When the door is closed the meter should indicate a closed circuit When the primary switch operation is abnormal make the necessary adjustment or replace the switch only with the same type of switch COMPONENTS TEST PROCEDURE B SECONDARY INTERLOCK SWITCH TEST Disconnect the wire lead from the secondary switch Connect the ohmmeter leads to the common COM and normally open NO terminals of the switch The meter should indicate a open circuit in the door open condition When the door is closed meter should indicate an closed circuit When the secondary switch operation is abnormal make the necessary adjustment or replace the switch only with the same type of switch MONITOR SWITCH TEST Disconnect the wire lead from the monitor switch Connect the ohmmeter leads to the common COM and normally closed NC terminals of the switch The meter should indicate closed circuit i
16. lt HI LOW OFF CONTROL PANEL INSTRUCTIONS DISPLAY The Display includes a clock and indicators to tell you time of day cooking time settings and cooking functions selected QUICK TOUCH REHEAT For model 85130 85138 85139 only Press these keys let you cook foods easily QUICK SENSOR For model 85140 only Used to cook common microwave prepared foods without needing to program times and cook powers MORE Touch this pad to add ten seconds of cooking time each time you press it LESS Touch this pad to subtract ten seconds of cooking time each time you press it HELP Touch this pad to learn how to use each oven function 14 15 16 17 18 19 20 HOLD WARM Touch this pad to keep hot cooked foods safety warm in your microwave oven for up to 99 minutes 99 seconds TIME OF DAY Touch this pad to enter the time of day CUSTOM COOK Touch this pad to recall one cooking instruction previously programmed into memory LIGHT TIMER Touch this pad to set the light timer KITCHEN TIMER Touch this pad to set the kitchen timer STOP CLEAR Touch this pad to stop the oven or clear all entries START Touch this pad to start a function If you open the door after oven begins to cook retouch START 21 ON OFF Touch this pad to turn off the turntable EXPRESS DEFROST Meat poultry fish Touch on pad OFF will appear in the display to select food type and defrost f
17. unit as far away as possible from TV radio etc to prevent interference GROUNDING INSTRUCTIONS For personal safety this appliance must be fully grounded at all times In the event of an electrical short circuit grounding reduces the risk of electrical shock The plug must be plugged into an outlet that is properly installed and grounded CAUTION This unit is equipped with a 3 prong plug for your safety If the wall outlet is a grounded 3 hole type the unit will be grounded automatically Plug with Ground Properly Polarized and Grounded Outlet WARNING Improper use of the grounding plug can result in a risk of electric shock Do not under any circumstances cut or remove the third ground prong from the power cord plug 3 1 OPERATING INSTRUCTIONS CONTROL PANEL For Model 85130 85138 85139 1000 WATT Quick Touch Reheat POPCORN POTATO MORE EXPRESS DEFROST CUSTOM SET CUSTOM COOK ON OFF COOK REHEAT LESS QUICK TOUCH PLUS 2 5 8 9 es HI LOW OFF PIZZA BEVERAGE HELP QUICK DEFROST 3 6 9 TIME OF DAY KITCHEN TIMER lt LOW OFF For Model 85140 1000 WATT Quick Sensor POPCORN POTATO MORE EXPRESS DEFROST CUSTOM SET CUSTOM COOK ON OFF COOK REHEAT LESS QUICK TOUCH PLUS e Ko HI LOW OFF VEGETABLE HELP QUICK DEFROST TIME OF DAY KITCHEN TIMER
18. 187 x AT T P is measured while the microwave generator is operating at full power Magnetron filament heat up time is not included about 3 sec The water is stirred to equalize temperature throughout the vessel prior to measuring the final water temperature Stirring devices and measuring instruments are selected in order to minimize addition or removal of heat x WATER LOAD gt TURNTABLE DISASSEMBLY INSTRUCTIONS IMPORTANT NOTES UNIT MUST BE DISCONNECTED FROM ELEC TRICAL OUTLET WHEN MAKING REPAIRS RE PLACEMENTS ADJUSTMENTS AND CONTIN UITY CHECKS WAIT AT LEAST ONE MINUTE UNTIL THE HIGH VOLTAGE CAPACITOR IN THE HIGH VOLTAGE POWER SUPPLY HAS FULLY DISCHARGED THE CAPACITOR SHOULD BE DISCHARGED BY USING INSULATED WIRE I E TEST PROBE CONNECTED TO 10K OHM RESISTOR IN SERIES TO GROUND WHEN RECONNECTING THE WIRE LEADS TO ANY PART MAKE SURE THE WIRING CONNE CTIONS AND LEAD COLORS ARE CORRECTLY MATCHED ACCORDING TO THE OVERALL CIR CUIT DIAGRAM ESPECIALLY SWITCHES AND HIGH VOLTAGE CIRCUIT A REMOVING POWER AND CONTROL CIRCUIT BOARD Figures 1 2 and 3 Remove a screw securing the control panel assembly to the oven cavity Remove the control panel with pushing it upward Remove the three connectors CN1 CN2 CN5 and wire leads Relay2 from the circuit board 9 Control Panel CN5 For the sensor model only Power Transformer CN2 Relay 2 Relay
19. 2 a d em Figure 1 74 4 Remove 3 screws securing the circuit board EM gt Mb y Circuit Board Figure 2 5 Remove the FPC connector from the terminal socket following HOW TO REMOVE THE FPC CONNECTOR on the next page 6 Remove the circuit board from the control bracket carefully Control Bracket FPC Connector S1 Circuit Board Figure 3 HOW TO REMOVE THE F P C CONNECTOR Follow the steps below as illustrated in Figures 4 and 5 to remove the F P C connector 1 Hold the edges of the plastic fastener with thumb and forefinger Figure 4 2 Lift up the lever of the plastic fastener from the terminal socket by lightly pressing the lever end with forefinger Figure 5 3 Remove the F P C connector from the terminal socket Plastic fastener Connector Terminal socket Figure 4 Plastic fastener Connector Terminal socket Figure 5 HOW TO INSERT THE F P C CONNECTOR Follow the steps below as illustrated in Figures 6 and 7 to insert the F P C connector 1 Insert the F P C connector into the terminal socket securely with the fingers 2 Hold the plastic fastener with thumb and forefinger of the other hand and push it slowly into the terminal socket Figure 6 NOTE When reconnecting the F P C connector make sure that the holes on the F P C connector are properly engaged with the ho
20. EXPRESS HI LOW OFF SET pp DEFROST QUICK Mes TIME OF Touch N C EN 7 DAY PLUS 7 A A CUSTOM LIGHT TIMER N C POWER 8 T TABLE STOP QUICK HOLD I CLEAR idi WARM 9 4 N C 5 12 2 MORE SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR PIZZA POTATO POPCORN ae COOK gh AS 5 2 GENERAL INFORMATION FOR SERVICE GENERAL PRECAUTIONS IN USE A Never operate the unit when it is empty Operating the oven with no load may shorten the life of the magnetron Whenever cooking dry foods dried fish bread etc or a small amount of food be sure to put a glass of water into the cooking compartment The glass turntable may become hot after operating be careful when touching it B Aluminum foil should be avoided because it will disrupt cooking and may cause arcing However small pieces may be used to cover some parts of food to slow the cooking Any aluminum foil used should never be closer than 2 5 cm to any side wall of the oven TRIAL OPERATION After installation the following sequences and results should be checked carefully A Put a container filled with water about 1 liter into the oven and close the door tightly B Set cooking time for 10 minutes by touching 1 and then 0 three times 1 0 0 0 appears in the display window C Touch the START key Make sure the cavity light comes on Th
21. G ANY HIGH VOLTAGE PARTS MEASUREMENT WITH A FULLY ASSEMBLED OVEN 1 After all components including the outer panels are fully assembled measure for microwave energy leakage around the door viewing window the exhaust opening and air inlet openings Microwave energy leakage must not exceed the values prescribed below NOTES Leakage with the outer panels removed less than 5 mW cm2 Leakage for a fully assembled oven Before the latch switch primary is interrupted with the door in a slightly opened position less than 2 mW cm2 55 POWER OUTPUT MEASUREMENT 1 Microwave power output measurement is made with the microwave oven supplied at its rated voltage and operated at its maximum microwave power setting with a load of 1000 5 g of potable water The water is contained in a cylindrical borosilicate glass vessel having a maximum material thickness of 1 8 3 mm and an outside diameter of approximately 7 6 190mm The oven and the empty vessel are at ambient temperature prior to the start of the test The initial temperature T1 of the water is 10 2 C 50 F It is measured immediately before the water is added to the vessel After addition of the water to the vessel the load is immediately placed on the center of the turntable which is in the lowest position and the microwave power switched on The time T for the temperature of the water to rise by a value A T of 10 2 K is measured where
22. Never operate the magnetron unless it is properly installed Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron Routine service safety procedures should be exercised at all times Untrained personnel should not attempt service without a thorough review of the test procedures and safety information contained in this manual FOREWORD Read this Manual carefully Failure to adhere to or observe the information in this Manual may result in exposing yourself to the Microwave Energy normally contained within the oven cavity TABLE OF CONTENTS Page SAFETY PRECAUTIONS Nt Inside front page SPECIFICATIONS 1 1 EE 2 1 INSTALLATION Sit e en bep ecd ee b Fede do eee 3 1 OPERATING INSTRUCTIONS conan 4 1 CONTROL PANEL redd a ep e 4 1 CONTROL PANEL INSTRUCTIONS Ne 4 2 OVERALL CIRCUIT DIAGRAM at Top eee 5 1 SCHEMATIC DIAGRAM Nt 5 1 MATRIX CIRCUIT FOR TOUCH KEY 5 2 GENERAL INFORMATION FOR SERVICE pp 6 1 GENERAL PRECAUTIONS IN USE din nenn kenne 6 1 TRIAL OPERATION 4 elei este tede dudit beds Ged eee 6 1 FEATURES AND SPECIFICATIONS FEATURES pp 6 1 SERVICE INFORMATION cota ree rette P A de ERR ag ve ee Y Ege aa ads 7 1 PRECAUTIONS AND REPAIR SERVICE TIPS
23. OM and NC of the Interlock Monitor must close when the door is opened After adjusting the Interlock Monitor Switch make sure that it is correctly connected Mounting of the primary monitor secondary switches to the latch board Latch Board Secondary Interlock Switch Primary Interlock Switch Figure 23 a LATCH Figure 23 b LATCH BOARD 0 1 64 CHECK THE DOOR LATCH AND SWITCH CLOSING NOTE The outer cover of the microwave oven is removed 1 Set the microwave oven on its side so that you can see the latch board and the switches as shown in Figure 23 a 2 Close the door tightly and check gaps A and B to be sure they are no more than 1 64 0 5 mm See Figure 23 b for close up view of gaps A and B door latches If all gaps are less than 1 64 0 5 mm adjustment of the latch board may not be necessary Go to Steps 5 and 6 to check the sequence of the switches NOTE To correct sequence of the Primary Interlock Switch Secondary Interlock Switch and the Interlock Monitor Switch is very important If any gap is larger than 1 64 0 5 mm you will need to adjust the latch board Go to step 3 and follow all steps in order ADJUST THE LATCH AND SWITCH CLOSING 3 Loosen the two screws holding the plastic latch board as shown 4 With the oven door closed tightly move the latch board upward toward the top of the oven and or away from the door latch until the gaps ar
24. R ANY REASON MAKE SURE THE WIRE LEADS ARE IN THE CORRECT POSITION WHEN REMOVING THE WIRE LEADS FROM THE PARTS BE SURE TO GRASP THE CONNECTOR NOT THE WIRES B CHECKOUT PROCEDURES 1 CHECKOUT PROCEDURES FOR FUSE BLOWING CAUTION REPLACE BLOWN FUSE WITH 20 AMPERE FUSE PROBLEMS CAUSES Fuse blows immediately after the door is closed Improper operation of the primary interlock secondary Fuse blows immediately after interlock switches and or the interlock monitor switch the door is opened Fuse blows when the door is closed and START Malfunction of the high voltage transformer the high key is touched voltage capacitor including the diode the magnetron the blower motor or the circuit board NOTES If the fuse is blown by an improper switch operation replace the all Interlock switches PCB Ass y and the fuse at the same time After replacing the the all Interlock switches PCB Ass y Fuse with new ones make sure that they are correctly connected Check for microwave energy leakage according to INTERLOCK ADJUSTMENT PROCEDURES on page 7 12 when the primary interlock secondary interlock switches and or the interlock monitor switches are adjusted or replaced 7 18 2 CHECKOUT PROCEDURES FOR RELAY FAN motor and oven lamp turn on without touching START key when the door is closed PROBLEM A pe ps GOOD Remove the mate connector of I O CON from the cir
25. cuit board Does the unit still operate la Replace the circuit board Defective RELAY1 Replace RELAY1 PROBLEM B FAN motor and oven lamp turn on When the door is closed and START key is touched Ie GOOD 7 19 35 of UO1 Measure the voltage at pin NO Voltage reading 0 Vdc 10 of U03 Voltage reading about 15V Replace the circuit board Defective RELAY1 or poor connection of RELAY1 Replace RELAY 1 or correct the connection 3 CHECKOUT PROCEDURES FOR CIRCUIT BOARD The following symptoms indicate a defective circuit board The start function fails to operate but the high voltage Systems the interlock switches the door sensing and the relay check good The unit with a normal relay continuously operates Proper temperature measurement is not obtained The buzzer does not sound or continues to sound Some segments of one or more digits do not light up or they continue to light up or segments light when they should not 6 7 8 9 Wrong figures appear The figures of all digits Some of the indicators do no flicker light up The clock does not keep time properly 2 NOTE MICROWAVE ENERGY LEAKAGE TEST MUST ALWAYS PERFORMED WHEN THE UNIT IS SERVICED FOR ANY REASON 7 20
26. d Never plug the unit into a power source to determine which component is defective in high voltage section TO AVOID POSSIBLE EXPOSURE TO MICROWAVE ENERGY LEAKAGE THE FOLLOWING PRECAUTIONS MUST BE TAKEN BEFORE SERVICING 1 Before the power is applied a Make sure the primary interlock switch the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several by opening and closing the door several times Make sure the perforated screen and the dielectric choke of the door are correctly and firmly mounted S 2 After power is applied a Make sure the interlock switch mechanism is operating properly by opening and closing the door b Check microwave energy leakage must bebelow the limit of 5 mW cme All service adjustments should be made for minimum microwave energy leakage readings 3 Do not operate the unit until it is completely repaired if any of the following conditions exist The unit must not be operated a The door does not close firmly b The hinge is broken c The door seal is damaged d The door is bent or warped or there is any other visible damage on the unit that may cause microwave energy leakage NOTE Always keep the seal clean e Make sure that there are no defective parts in the interlock mechanism Make sure that there are no detective parts in the microwave generating and transmission assembly especia
27. e less than 1 64 0 5 mm Hold the latch board tightly in this position until you check the sequence of the switches in steps 5 and 6 TEST THE LATCH AND SWITCH SEQUENCE 5 Open the oven door slowly Watch the door latch the Secondary Switch Release Rod and Lever on the switches to make sure they are zero to the body of the switches in the following sequence Primary Interlock Switch Secondary Interlock Switch Interlock Monitor Switch Adjust the latch board until the switches operate in this sequence See Steps 3 and 4 Close the oven door slowly and be sure it is tightly closed Watch the three switches to make sure they are zero to the body of the switches in the following sequence Interlock Monitor Switch Primary Interlock Switch Secondary Interlock Switch NOTE The Interlock Monitor Switch is an added safety check on the Primary and Secondary Interlock Switches If the Primary and Secondary Interlock Switches allow the oven to operate with the door open the Monitor Switch will blow the fuse 7 When you achieve the proper sequence of switches in Steps 5 and 6 tighten the latch board screws at that point TEST THE MICROWAVE ENERGY LEAKAGE Make sure the microwave energy leakage is below the limit of 1mW cm2 with 275 ml water load and 5mW cm with 275 ml water load without the cabinet when measured with a survey meter 7 13 INTERLOCK CONTINUITY TEST A PRIMARY INTERLOCK
28. e unit will begin cooking and the display window will show the time counting down by seconds D After about 5 minutes make sure the primary interlock switch the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several times Touch the START key each time the door is closed E Continue operating the unit Four long beep sound signal is heard when the time is up The unit will shut off automatically F Confirm the water is hot G Finally measure the output power according to POWER OUTPUT MEASUREMENT on page 7 3 FEATURES AND SPECIFICATIONS FEATURES A The safety systems incorporated in this model are 1 Primary interlock switch 2 Secondary interlock switch 3 Interlock monitor switch 4 Choke system 5 Magnetron thermal fuse 6 Oven cavity thermostat Note This thermostat located on the oven cavity will open and stop the unit from operation only if a high temperature is reached such as a fire created by overcooking food Any one of 10 power output levels ranging 100W to 1000W can be selected by the touch control and electronic computer system A SERVICE INFORMATION PRECAUTIONS AND REPAIR SERVICE TIPS PRELIMINARY SINCE NEARLY 2 100 VOLTS EXISTS IN SOME CIRCUITS OF THIS UNIT REPAIRS SHOULD BE CARRIED OUT WITH GREAT CARE The filament leads of magnetron carry High Voltage with respect to ground Extreme caution must be exercise
29. eading Indicates continuity or infinite ohms from the beginning 2 Terminal to case Figure 25 b Normal readings Infinite Abnormal reading Indicates continuity HIGH VOLTAGE DIODE Measure the continuity 1 Forward Figure 26 a Normal readings continuity Abnormal reading Infinite 1 Reverse Figure 26 b Normal readings Infinite Abnormal reading continuity 7 16 COMPONENTS TEST PROCEDURES RESULTS TOUCH KEY BOARD SENSOR For sensor model only Measure the resistance between terminal pins of connector KEY CONNECTOR NOTE When reconnecting the FPC connector make sure that the holes on the FPC connector are properly engaged with hooks on the plastic fastener MATRIX CIRCUIT FOR TOUCH KEY BOARD CONNECTOR KEY CON For Model 85130 85138 85139 1 2 3 4 5 6 7 HELP COOK POPCORN TIME 5 0 A A A 4 A REHEAT POTATO 6 1 AFA A A TIME OF QUICK KITCHEN Less yay TOUCH BEVERAGE 7 2 JA APSA ACTA AA VENT CUSTOM Ener PIZZA power 8 3 11 ESTAS TA MAU E VM A T TABLE STOP START QUICK HOLD 9 4 ON OFF CLEAR DEFROST WARM AA RETRATA A A MORE N C N C N C N C N C N C 13 A A A A Y For Model 85140
30. it to the back plate 2 Mount the new humidity sensor to the air duct See Figure 18 2 Remove MOUNT ALL loosening one screw loosening one screw securing the ventilation Motor and back plate See Figure 19 a Figure 19 c MOUNT ALL Figure 19 a 7 10 K REMOVING THE TURNTABLE MOTOR NOTES 1 Remove the turntable Remove the leadwire from the turntable motor 2 Remove the turntable shaft VERY CAREFULLY VERY CAREFULLY with a slotted screwdriver Figure 20 Be sure to grasp the connector not the wires when 3 Remove the base plate by removing 7 screws removing securing it to the oven cavity Figure 21 4 Disconnect the leadwire from the turntable motor terminals 5 Remove the 2 screws securing the turntable motor to the oven cavity ASS Y Figure 22 N Figure 20 Wire Leads e Turntable Motor Figure 22 INTERLOCK SYSTEM INTERLOCK MECHANISM The door lock mechanism is a device which has been specially designed to eliminate completely microwave activity when the door is opened during cooking and thus to prevent the danger resulting from the microwave leakage ADJUSTMENT PROCEDURES To avoid possible exposure to microwave energy leakage adjust the door latches and interlock switches using the following procedure The Interlock Monitor and Primary Interlock Switch act as the final safety switch protecting the user from microwave energy The terminals between C
31. lly waveguide f The following items should be checked after the unit is repaired a The interlock monitor switch is connected correctly and firmly b The magnetron gasket is properly positioned and mounted c The waveguide and the oven cavity are intact no microwave energy leakage d The door can be properly closed and the safety switches work properly e The unit must stop when the door is opened or the time is up The unit must not be operated with any of the above components removed or by passed MICROWAVE LEAKAGE TEST CAUTIONS Be sure to check microwave leakage prior to servicing the oven if the oven is operative prior to servicing The service personnel should inform the manufacture importer or assembler of any certified oven unit found to have a microwave emission level in excess of 5 mW cm and should repair any unit found to have excessive emission levels at no cost to the owner and should ascertain the cause of the excessive leakage The service personnel should instruct the owner not to use the unit until the oven has been brought into compliance If the oven operates with the door open the service personnel should Tell the user not to operate the oven The service personnel should check all surface and vent openings for microwave leakage Check for microwave leakage after every servicing The power density of the microwave radiation leakage emitted by the microwave oven should not exceed
32. m M LL 731A Toronto Kenmore BASIC SERVICE MANUAL FOR MICROWAVE OVEN MODEL 767 8513000 767 8913800 767 8913900 767 8514000 FEBRUARY 2001 CAUTION SAFETY PRECAUTIONS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY Do not operate or allow the oven to be operated with the door open Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source and make repairs as necessary 1 Interlock operation 2 proper door closing 3 seal and sealing surfaces arcing wear and other damage 4 damage to or loosening of hinges and latches 5 evidence of dropping or abuse Before turning on microwave power for any service test or inspection within the microwave generating compartments check the magnetron wave guide or transmission line and cavity for proper alignment integrity and connections Any defective or misadjusted components in the interlock monitor door seal and microwave generation and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner A Microwave leakage check to verify compliance with the CSA Standard should be performed on each oven prior to release to the owner Proper operation of the microwave ovens requires that the magnetron be assembled to the wave guide and cavity
33. move the stirrer fan After replacing the door be sure to check that the primary interlock switch the secondary interlock switch and the interlock monitor switch is in good operating normally After replacing the door check for microwave energy leakage with a survey meter Microwave energy leakage must be below the limit of 5mW cm With a 275 ml water load Figure 14 Figure 16 G DISASSEMBLING DOOR Figure 17 1 Remove the dielectric choke by using knife blade or small screw driver etc 2 Remove two screws securing it to the door handle CAUTION Be careful not to damage door seal plate with the screwdriver Figure 15 Door Screen Figure 17 H ASSEMBLING DOOR 1 When mounting the door assembly to the oven 3 Carefully pull the ventilation motor ASS Y out of assembly be sure to adjust the door assembly the microwave oven See Figure 19 b parallel to the chassis Also adjust so the door has no play between the inner door surface and oven frame assembly If the door assembly is not mounted properly microwaves may leak from the clearance between the door and the oven Space i t Figure 19 b J REPLACING THE HUMIDITY SENSOR REMOVING THE VENTILATION MOTOR For sensor model only 1 Remove the mounting plate by loosening 1 Remove the sensor by removing two screws mounting plate screws 1 or 2 screws securing it to the air duct See Figure 19 c securing
34. n the door open condition When the door is closed meter should indicate an open circuit When the monitor switch operation is abnormal replace with the same type of switch NOTE After repairing the door or the interlock system it is necessary to do this continuity test before operating the oven RESULTS SWITCHES Wire leads removed Check for continuity of the switch with an Ohm meter Door open Primary Switch en Monitor Switch Ep Secondary Switch prs NOTE After checking for the continuity of switches make sure that they are connected correctly WARNING FOR CONTINUED PROTECTION AGAINST EXCESSIVE RADIATION EMISSION REPLACE ONLY WITH IDENTICAL REPLACEMENT PARTS TYPE NO SZM V16 FA 63 OR VP 533A OF OR V 5230Q FOR PRIMARY SWITCH TYPE NO SZM V16 FA 62 OR VP 532A OF OR V 5220Q FOR MONITOR SWITCH TYPE NO SZM V16 FA 63 OR VP 533A OF OR V 5230Q FOR SECONDARY SWITCH TEST AND CHECKOUT PROCEDURES AND TROUBLE SHOOTING CAUTIONS DISCONNECT THE POWER SUPPLY CORD FROM THE WALL OUTLET WHENEVER REMOVINGING THE CABINET FROM THE UNIT PROCEED WITH THE TESTS ONLY AFTER DISCHARGING THE HIGH VOLTAGE CAPACITOR AND REMOVING THE WIRE LEADS FROM THE PRIMARY WINDING OF THE HIGH VOLTAGE TRANSFORMER SEE FIGURE 24 ALL OPERATIONAL CHECKS WITH MICROWAVE ENERGY MUST BE DONE WITH A LOAD 1 LITER OF WATER IN CONTAINER IN THE OVEN
35. oks on the plastic fastener Lock the level of the plastic fastener into the hook of the terminal socket securely by releasing the fingers Figure 7 Plastic fastener Connector Terminal socket Figure 6 Plastic fastener C Connector Terminal socket Figure 7 B REMOVING THE OUT CASE Figure 8 1 Remove the vent grille by removing two screws securing it to the out case 2 Remove two screws securing it to the air duct 3 Remove the mounting plate by turning the screws 1 or 2 screws securing it to the out case 4 Remove two screws on the left central edge and one screws on the right central edge of Base plate Remove the Mount All from the out case by removing one screw securing it to the out case 5 Remove the outcase with disconnecting power cord connector Mount All Mounting Plate B di Out Case Vent Grille Controller amp 3 screws Figure 8 C REMOVING THE DOOR INTERLOCK SWITCHES Figures 9 10 1 Disconnect the wire leads from the interlock switches 2 Remove two screws securing the Latch Board 3 Make necessary replacements and check microwave energy leakage according to ADJUSTMENT PROCEDURE on page 7 12 44 2 Latch Board _RD from H V Transformer _ _ 10 WIRE COLOR SYMBOL COLOR WH WHITE BK
36. ood by weight 22 59 HI LOW OFF Touch this pad to turn the fan on or QUICK TOUCH PLUS Touch this pad to set and start off quickly at 100 power 23 Touch this pad to turn on the QUICK DEFROST This pad provides you with the quick defrosting method for 1 0 pounds frozen foods cooktop countertop light 10 NUMBER Touch number pads to enter cooking time power level quantities or weights 11 TIME Touch this pad to set a cooking time 12 POWER Touch this pad to select a cooking power level 13 CUSTOM SET Touch this pad to change the oven s default settings for sound clock display speed defrost weight and demo mode operations 4 2 OVERALL CIRCUIT DIAGRAM Note SCHEMATIC DIAGRAM 1 DOOR OPENED amp COOK OFF MODE 2 BLUE MARK ON LAMP SOCKET MUST BE CONNECTED TO LIVE PART BLACK WIRE MICRO COMPUTER BOARD B a 3 ONLY CERTAIN MODELS USE THE ABSOLUTE HUMIDITY SENSOR FUSE 20A il THERMAL 109 C 228 F 120 VAC 60Hz SINGLE PHASE ONLY VENT MOTOR 7 C Low
37. tage Double Half Wave 2 450 MHz 50 MHz Choke System Magnetron Thermal Fuse Open at 109 C 4 C Oven Cavity Thermostat Open at 110 C 5 Fuse 20A Primary Interlock Switch Secondary Interlock Switch Interlock Monitor 2M246 050GF or 2M248J Capacitor 1 0uF 21 KV AC Diode 350mA 9 0 KV 125 30 W 125 V 30 W Digital up to 99 mim 99 sec in each cooking stage Tempered Safety Glass 291516 W x167 16 D x155 8 H 21 8 Cu ft Owner s Manual 8 Cooking Guide Installation Manual Exhaust Adapter Exhaust Damper Mounting Kit and Two Filters Rotating Ring Assembly Metal Rack CAUTIONS Unlike other appliances the microwave oven is high voltage and high current equipment Though it is free from danger in ordinary use extreme care should be taken during repair DO NOT operate on a 2 wire extension cord during repair and use NEVER TOUCH any oven components or wiring during operation BEFORE TOUCHING any parts of the oven always remove the power plug from the outlet For about 30 seconds after the oven stops an electric charge remains in the high voltage capacitor When replacing or checking you must discharge the high voltage capacitor by shorting across the two terminals with an insulated screwdriver Remove your watches whenever working close to or replacing the Magnetron DO NOT touch any parts of the control panel circuit A resulting static electric discharge may damage this
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