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Kenmore 721.62642, Basic Field Manual

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DIVISION 22

BASIC FIELD MANUAL

FOR

MICROWAVE OVEN

MODEL  

721.62642400 / 721.80592401 / 721.80592402
721.62649400 / 721.80599401 / 721.80599402
721.62644400 / 721.80594401 / 721.80594402
721.62643400 / 721.80593401 / 721.80593402

March, 2005

MODEL 721.62642 / 721.80592 

721.62649 / 721.80599
721.62644 / 721.80594
721.62643 / 721.80593

Summary of Contents for 721.62642

Page 1: ... MODEL 721 62642400 721 80592401 721 80592402 721 62649400 721 80599401 721 80599402 721 62644400 721 80594401 721 80594402 721 62643400 721 80593401 721 80593402 March 2005 MODEL 721 62642 721 80592 721 62649 721 80599 721 62644 721 80594 721 62643 721 80593 ...

Page 2: ...alignment integrity and connections d 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 e A Microwave leakage check to verify compliance with the Federal performance standard should be performed on each ove...

Page 3: ...RMATION 7 1 PRECAUTIONS AND REPAIR SERVICE TIPS 7 1 MICROWAVE LEAKAGE TEST 7 2 POWER OUTPUT MEASUREMENT 7 3 DISASSEMBLY INSTRUCTIONS 7 4 INTERLOCK SYSTEM 7 12 INTERLOCK CONTINUITY TEST 7 14 TEST AND CHECKOUT PROCEDURES AND TROUBLE SHOOTING 7 15 A TEST PROCEDURES 7 15 B CHECKOUT PROCEDURES 7 18 C TROUBLE SHOOTING 7 21 EXPLODED VIEW 8 1 PART REFERENCE LIST 9 1 FOREWORD Read this Manual carefully Fai...

Page 4: ...at 90 C 5 C Fuse 20A Primary Interlock Switch Secondary Interlock Switch Interlock Monitor Switch Magnetron 2M214 161GP High Voltage Capacitor Capacitor 1 0µF 2 1 KV AC High Voltage Diode Diode 350mA 9 0 KV Cook top Lamp 125 V 30 W Cavity Lamp 125 V 30 W or 40 W Timer Digital up to 99 mim 99 sec in each cooking stage Tray Tempered Safety Glass Overall Dimensions 2915 16 W x167 16 H x153 8 D Oven C...

Page 5: ... 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 2 1 CAUTIONS Unlike other appliances the microwave oven is high voltage and high current equipment Though it is free fro...

Page 6: ...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 3 1 INSTALLATIONS BEFORE YOU BEGIN READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY 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 aut...

Page 7: ...4 1 OPERATING INSTRUCTIONS CONTROL PANEL 1 2 6 9 11 15 19 23 26 27 24 12 5 8 10 14 16 17 18 21 20 22 25 29 28 13 7 4 3 ...

Page 8: ...ch this pad followed by Number Pads to thaw frozen meat by weight 15 Number Pads Touch number pads to enter cooking times cook powers quantities weights or food categories 16 Express Defrost Touch this pad to express defrost GROUND BEEF 1 0 LBS TOUCH START will appear in the display 17 Add Minute Touch this pad to cook for 1 minute at 100 cook power or to add extra minutes at the set cook power to...

Page 9: ...5 1 OVERALL CIRCUIT DIAGRAM SCHEMATIC DIAGRAM I Check the Model No ...

Page 10: ...5 2 SCHEMATIC DIAGRAM II Check the Model No ADD Noise filter RY1 O L RY14 C L HIGH RY15 C L NIGHT RY11 V M RY6 T M ...

Page 11: ...5 3 MATRIX CIRCUIT FOR TOUCH KEY BOARD ...

Page 12: ...comes on The 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 Two short and a long beep s...

Page 13: ...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 e...

Page 14: ...icrowave oven should not exceed 4 mW cm2 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 Narda 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 MEASURING MIC...

Page 15: ...ave been used 3 At least once a year have the electromagnetic energy leakage monitor checked for calibration by its manufacturer 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 2 The water is contained in a cylindrical borosilicate glass vessel having a ma...

Page 16: ...RALL CIR CUIT DIAGRAM ESPECIALLY SWITCHES AND HIGH VOLTAGE CIRCUIT A REMOVING POWER AND CONTROL CIRCUIT BOARD Figures 1 2 and 3 1 Remove a screw securing the control panel assembly to the oven cavity 2 Remove the control panel with pushing it upward 3 Remove the connectors CN1 and wire leads Relay2 from the circuit board 4 Remove 3 screws securing the circuit board 5 Remove the FPC connector from ...

Page 17: ...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 pro...

Page 18: ...emove the mounting plate by turning the two screws securing it to the out case 5 Remove the base plate by removing four screws securing it to the out case Remove the Mount All from the out case by removing two screws securing it to the out case 6 Remove four screws from the rear section 7 Remove the outcase with pushing it back 7 6 Vent Grille Controller Mounting Plate Door Out Case Mount All Powe...

Page 19: ...e 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 Latch Board Secondary Interlock Switch Interlock Monitor Switch Primary Interlock Switch Figure 9 Figure 10 7 7 ...

Page 20: ...acent 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 leaka...

Page 21: ... monitor switch operate normally After replacing the door check for microwave energy leakage with a survey meter Microwave energy leakage must be below the limit of 5mW cm2 With a 275 ml water load F DISASSEMBLING DOOR Figure 15 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 ...

Page 22: ...mounted properly microwaves may leak from the clearance between the door and the oven H REMOVING THE VENTILATION FAN ASS Y 1 Remove the mounting plate by removing two screws securing it to the back plate See Figure 16 2 Remove the two screws securing the MOUNT ALL and one screw securing the ventilation fan ASS Y See Figure 17 3 Carefully pull the ventilation motor ASS Y out of the microwave oven S...

Page 23: ...removing eight screws securing it to the oven cavity Figure 20 4 Disconnect the leadwire from the turntable motor terminals 5 Remove a screw securing the turntable motor to the oven cavity ASS Y Figure 21 NOTES Remove the leadwire from the turntable motor VERY CAREFULLY Be sure to grasp the connector not the wires when removing 7 11 Figure 21 Figure 19 Figure 20 ...

Page 24: ...ent 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 Loos...

Page 25: ... 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 seq...

Page 26: ...the secondary switch operation is abnormal make the necessary adjustment or replace the switch only with the same type of switch C 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 in the door open condition When the door is closed meter should ind...

Page 27: ...eads are removed 1 Measure the resistance Across the filament terminals of the magnetron with an ohm meter on Rx1 scale 2 Measure the resistance Between each filament terminal of the magnetron and the chassis ground with an ohm meter on high test scale 1 Measure the resistance With an ohm meter on Rx1 scale a Primary winding b Filament winding c Secondary winding 2 Measure the resistance With an o...

Page 28: ...omentarily indicates several ohms and then gradually returns to infinite ohms Abnormal reading Indicates continuity or infinite ohms from the beginning Normal readings Infinite Abnormal reading Indicates continuity Normal readings continuity Abnormal reading Infinite Normal readings Infinite Abnormal reading continuity Ohm meter Figure 25 a Ohm meter Figure 25 b Ohm meter Figure 26 b Ohm meter Fig...

Page 29: ...nnecting 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 detail matrix circuit of each model refer to page 5 2 FPC CONNECTOR Top Resistance value When touched Less than 400 ohms When not touched More than 1 mega ohm ...

Page 30: ...ck switches and or the interlock monitor switches are adjusted or replaced 7 18 COMPONENTS TEST PROCEDURES RESULTS RELAY2 Check for continuity of relay 2 with an ohm meter Remove wire leads from relay 2 and operate the unit CAUTION The relay connector 2 must be correctly connected Relay 2 POWER LEVEL 1 2 3 4 5 6 7 8 9 10 4 sec 6 sec 8 sec 10 sec 12 sec 14 sec 16 sec 18 sec 20 sec 22 sec 18 sec 16 ...

Page 31: ... Does the unit still operate Replace the circuit board Replace RELAY1 NO NO YES YES GOOD Defective RELAY1 PROBLEM B Oven lamp turn on When the door is closed and START key is touched Measure the voltage at pin NO 35 of U01 Voltage reading 5 Vdc Replace the circuit board Defective RELAY1 or poor connection of RELAY1 Replace RELAY1 or correct the connection YES NO NO YES GOOD ...

Page 32: ...operates 3 Proper temperature measurement is not obtained 4 The buzzer does not sound or continues to sound 5 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 Wrong figures appear 7 The figures of all digits 8 Some of the indicators do no flicker light up 9 The clock does not keep time properly 7 20 NOTE A MICROWAVE ENERGY LE...

Page 33: ...hru E BUZZER Problems F PROBLEM A PLEASE SET TIME OF DAY does not appear in display window when power supply cord is plugged into wall outlet PROBLEM B Display does not show correct numbers and or correct indications when programmed Check 1 POWER SUPPLY 2 FUSE See CHECKOUT PROCEDURES FOR FUSE BLOWING on page 7 18 3 OVEN CAVITY THERMOSTAT 1 1 ...

Page 34: ...7 22 PROBLEM C Unit does not heat up even if display counts down when START key is touched for HIGH POWER cooking Check 1 PRIMARY AND SECONDARY INTERLOCK SWITCHES 2 THERMOSTAT 1 2 ...

Page 35: ...7 23 PROBLEM D No buzzing when touching the key between stages or at end of cooking 1 ...

Page 36: ...7 24 PROBLEM E Ventilation fan does not operate when FAN HIGH LOW key is touched 1 Check 1 POWER SUPPLY 2 FUSE ...

Page 37: ... 1002 1004 1006 1007 1011 1009 1381 For 721 62643 721 80593 1003 1008 W109 EV Model 721 62642400 721 80592401 721 80592402 721 62649400 721 80599401 721 80599402 721 62644400 721 80594401 721 80594402 721 62643400 721 80593401 721 80593402 ...

Page 38: ...8 2 CONTROLLER PARTS 2004 2002 2000 2008 2381 2006 W106 07 2004 2008 2006 W106 07 2381 EV FOR MODEL 721 62642 721 62649 721 62644 721 80592 721 80599 721 80594 FOR MODEL 721 62643 721 80593 ...

Page 39: ...1 3029 3024 3003 3036 3018 3034 3026 3028 5036 3026 3025 3011 6000 5038 3014 6001 W118 W118 05 01 04 W109 3010 FOR MODEL 721 62642 721 62644 721 80592 721 80594 FOR MODEL 721 62649 721 62643 721 80599 721 80593 8 3 OVEN CAVITY PARTS EV ...

Page 40: ...8 4 4000 W102 4001 4002 4003 4002 4004 LATCH BOARD PARTS EV ...

Page 41: ...8 5 INTERIOR PARTS I 3002 3012 3008 W101 5009 W108 5008 5035 W101 5034 5000 5002 5018 W101 W105 3009 W108 3037 EV ...

Page 42: ...4 5011 5058 5044 5043 3004 W136 W101 Check the Model No Check the Model No Check the Model No Check the Model No 8 6 INTERIOR PARTS II I EV Model 721 80592401 721 80599401 721 80594401 721 80593401 Check the rating label of Model and order SVC parts according to the Model No ...

Page 43: ... 5044 5043 3004 W136 W101 Check the Model No Check the Model No Check the Model No 5041 Check the Model No 5001 8 7 INTERIOR PARTS II II EV Model 721 80592402 721 80599402 721 80594402 721 80593402 Check the rating label of Model and order SVC parts according to the Model No ...

Page 44: ...8 8 INSTALLATION PARTS 6008 W109 6011 6010 6009 VINYL BAG EV ...

Page 45: ...Printed in Korea P NO 3828W5S5158 ...

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