Kenmore 767.8541000 Service Manual Download Page 1

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TECHNICAL FLASH

T.F. 22-480

Department 731A Toronto

BASIC SERVICE MANUAL

FOR

MICROWAVE OVEN

MODEL 767.8541000 / 767.8541001

767.8541300 / 767.8541301
767.8541900 / 767.8541901

MARCH, 2005

Summary of Contents for 767.8541000

Page 1: ...TECHNICAL FLASH T F 22 480 Department 731A Toronto BASIC SERVICE MANUAL FOR MICROWAVE OVEN MODEL 767 8541000 767 8541001 767 8541300 767 8541301 767 8541900 767 8541901 MARCH 2005 ...

Page 2: ... proper 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 CSA Standard should be performed on each oven prior ...

Page 3: ...ES 6 1 SERVICE INFORMATION 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 REPLACEMENT PARTS LIST 8 8 FOREWORD Read thi...

Page 4: ... Open at 90 C 5 C Fuse 20A Primary Interlock Switch Secondary Interlock Switch Interlock Monitor 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 Timer Digital up to 99 mim 99 sec in each cooking stage Tray Tempered Safety Glass Overall Dimensions 2915 16 W x167 16 D x153 8 H Oven Cavity Siz...

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 For Model 85410 ...

Page 8: ...to set and start quickly at 100 power level 13 NUMBER Touch number pads to enter cooking time power level quantities or weights 14 TIME Touch this pad to set a cooking time 15 POWER Touch this pad to select a cooking power level 16 CUSTOM SET Touch this pad to change the oven s default settings for sound clock display speed and defrost weight 17 TIME OF DAY Touch this pad to enter the time of day ...

Page 9: ...5 1 OVERALL CIRCUIT DIAGRAM SCHEMATIC DIAGRAM ...

Page 10: ...5 2 MATRIX CIRCUIT FOR TOUCH KEY BOARD ...

Page 11: ...ght 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 Four long beep sound si...

Page 12: ...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 13: ...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 14: ...e not be more than 2 mW cm2 after determining that all parts are in good condition functioning properly and genuine replacement parts which are listed in this manual have 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 o...

Page 15: ...LL 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 connector CN1 and wire leads Relay6 from the circuit board 4 Remove 3 screws securing the circuit board 5 Remove the FPC connector from the...

Page 16: ... 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 hooks on the plastic fastener 3 Lock the level of the plastic fastener into the hook o...

Page 17: ...ove the base plate by removing six 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 and one screw securing it to the ventilation motor ASS Y and cavity 6 Remove the power cord cover from outcase by removing a screw 7 Remove the power cord to the inner of the out case with turning power cord and remove the out case with pus...

Page 18: ...2 Latch Board WH from H V Transformer WH from Monitor S W WH from Oven Thermostat WH from Cooktop lamp Secondary Interlock Switch Monitor Interlock Switch Primary Interlock Switch GN from P C B YL from P C B WH from Secondary switch RD from Ry 7 Figure 9 Latch Board Secondary Interlock Switch Interlock Monitor Switch Primary Interlock Switch Figure 10 WIRE COLOR SYMBOL COLOR WH BK BR RD BL PK GY N...

Page 19: ... 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 7 ...

Page 20: ...k 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 cm2 With a 275 ml water load G DISASSEMBLING DOOR Figure 17 1 Remove the dielectric choke by using knife blade or small screw driver e...

Page 21: ...ed properly microwaves may leak from the clearance between the door and the oven I REMOVING THE VENTILATION FAN ASS Y 1 Remove the mounting plate by removing two screws securing it to the back plate See Figure 18 2 Remove the two screws securing the MOUNT ALL and one screw securing the ventilation fan ASS Y See Figure 19 3 Carefully pull the ventilation motor ASS Y out of the microwave oven See Fi...

Page 22: ...ews securing it to the oven cavity Figure 22 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 23 NOTES Remove the leadwire from the turntable motor VERY CAREFULLY Be sure to grasp the connector not the wires when removing 7 11 Wire Leads Turntable Motor Figure 23 Figure 21 Figure 22 ...

Page 23: ...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 24: ... 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 25: ...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 26: ...leads 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 ...

Page 27: ...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 27 a Ohm meter Figure 27 b Ohm meter Figure 28 a Ohm meter Fig...

Page 28: ...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 Normal Approximately BK RD 4 5 6 2 Kohm RD WH 2 0 3 5 Kohm BK WH 2 0 3 5 Kohm Abnormal Infinite or several FPC CONNECTOR Top Resistance value When touched Less than 400 ohms When not touched More than 1 mega ohm Figure 29 1 2 3 4 5 6 7 8...

Page 29: ...hes 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 White and 5 Red must be correctly connected Relay 6 These two connectors are not Inter changeable POWER LEVEL 1 2 3 4 5 6 7 8 9 10 4 sec 6 sec 8 sec 10 se...

Page 30: ...d Does the unit still operate Replace the circuit board Replace RELAY3 NO NO YES YES GOOD Defective RELAY3 PROBLEM B T T motor and oven lamp turn on When the door is closed and START key is touched Measure the voltage at pin NO 4 of U01 Voltage reading 0 Vdc Replace the circuit board Defective RELAY3 or poor connection of RELAY3 Replace RELAY3 or correct the connection YES NO NO YES GOOD ...

Page 31: ...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 32: ... c f o 3 n i p d n a s n u R s n u R 0 0 2 1 0 0 2 1 V 0 2 1 e c a l p e R d r a o b t i u c r i c l a m r o N e c n a t s i s e r e g a t l o V t c e r r o c n i t c e r r o C s n o i t c e n n o c l a m r o N d r a o b t i u c r i c s n u R s n u R s n u R h c u o t f o e c n a t s i s e r e r u s a e M g n i v o m e r r e t f a d r a o b y e k 1 S r o t c e n n o c 7 1 7 d n a 4 7 e g a p e e S...

Page 33: ... k c e h C 1 S r o t c e n n o c f o t c a t n o c e h t k c e h C 8 1 7 e g a p e e s 6 y a l e r O N y t i u n i t n o c e c n a t s i s e R t c e r r o c n i f o y t i u n i t n o c e h t k c e h C 6 1 7 e g a p e e s C V H T V H l a m r o N e c n a t s i s e R t c e r r o c n i C V H l a m r o N l a m r o n b A D V H e c a l p e R l a m r o N n o r t e n g a M e c a l p e R n o r t e n g a M l...

Page 34: ...No buzzing when touching the key between stages or at end of cooking 1 l a m r o N d r a o b t i u c r i c l a m r o n k c e h C n o i t a r e p o d r a o b t i u c r i c e c a l p e R d r a o b t i u c r i c s n u R ...

Page 35: ...P e c a l p e R d r a o b t i u c r i c l a m r o N d r a o b t i u c r i c K O t c a t n o C l a m r o N t c a t n o c t c e r r o C g n i t a e s t c a t n o c k c e h C 1 S r o t c e n n o c f o 4 7 e g a p e e s e c a l p e R n o i t a l i t n e v S S A r o t o m Y s n u r O N l a m r o N n o i t a l i t n e v r o t o m f o t c a t n o c e h t k c e h C t a t s o m r e h t n e v o Check 1 POWE...

Page 36: ...8 1 EXPLODED VIEW DOOR PARTS 13581A 13552A 13536A 13213A 14890A 13650A 14970A 14026A WTT028 13551A For Model 767 85413 13720D 14760A EV ...

Page 37: ...8 2 CONTROLLER PARTS For Model 767 85410 767 85419 For Model 767 85413 24810P 07 268711 24781M WTP018 23551A 24810P 23572A 23506A 07 268711 24781M WTP018 23551A EV ...

Page 38: ...T022 WTT028 33112U 368771 WTT029 WTT027 34810T 33530A 34890C WTT010 WTT022 35230A 63303A 34810Q 34960A WTT021 02 01 04 05 34930R 33550L For Model 767 85419 767 85413 For Model 767 85410 WTT027 WTT029 8 3 OVEN CAVITY PARTS EV ...

Page 39: ...466001 43500A 466003 466001 44510A 43501A WSZ085 8 4 LATCH BOARD PARTS EV ...

Page 40: ...8 5 INTERIOR PARTS I 56170D 33390G 34370T 35889A WTP013 WTP015 54810C 50CZZH WSZ002 56851D WTT021 WSZ002 33052A 53300B 56324A WSZ002 56201B WTT021 36549S 33740A 53300A WTT021 EV ...

Page 41: ...36549V 56912B 53550L 55262A 55231C 56804A WTT028 WSZ002 56930V 50FZZA 568771 54930F 55892A 53550F 340511 56411A 56201A WSZ002 8 6 INTERIOR PARTS II EV ...

Page 42: ...8 7 INSTALLATION PARTS 63300M 65862D 65862B VINYL BAG 63861A EV ...

Page 43: ...106F R 33052A CANOPY RESIN 3052WRA002A 3052W1A002A R 33112U OUT CASE U BENDING 3112W1U026H 3112W0U052H R 33390G TRAY GLASS 1B71961E 1B71961H R 33530A GRILLE VENT 3530W0A030A 3530W0A030E R 33550L COVER LAMP 3550W3A095A 3550W3A095C R 3550W3A095A 33740A PROTECTOR MECH 3740W1A005A 3740W1A005E R 3740W1A005A 340511 RIVET ASSEMBLY 4051W3A001A 4051W3A001A R 34370T SHAFT TURN TABLE 3B72373A 4370W1A006B R 3...

Page 44: ...ORD ASSEMBLY 6201W2A019D 6411W1A010Z R 56804A SOCKET CIRC LAMP 6804W3A001A 6804W3A001A R 56851D CABLE ASSEMBLY 6021W3B001A 6021W3B001V R 6021W3B001G 56851D CABLE ASSEMBLY 6021W3B001A 6021W3B001V R 6851W1A002B 568771 HARNESS 6877W1A409C 6877W1A004B R 56912B LAMP DRAWING 3B70067A 6912W1Z004A R 56930V THERMOSTAT 6930W1A003E 6930W1A003E R 6930W3A001S 63300M PLATE MOUNTING 3300W0M003A 3300W0A018A R 633...

Page 45: ... GLASS 1B71961E 1B71961H R 33530A GRILLE VENT 3530W0A030D 3530W0A030H R 33550L COVER LAMP 3550W3A095A 3550W3A095C R 3550W3A095A 33740A PROTECTOR MECH 3740W1A005A 3740W1A005E R 3740W1A005A 340511 RIVET ASSEMBLY 4051W3A001A 4051W3A001A R 34370T SHAFT TURN TABLE 3B72373A 4370W1A006B R 34810Q BRACKET MOUNT 4810W3G062A 4810W1A149A R 34810T BRACKET LAMP 4810W3G100A 4810W1A150C R 34890C GLASS 4890W4A001G...

Page 46: ...IRC LAMP 6804W3A001A 6804W3A001A R 56851D CABLE ASSEMBLY 6804W3A001A 6021W3B001V R 6021W3B001G 56851D CABLE ASSEMBLY 6021W3B001A 6021W3B001V R 6851W1A002B 568771 HARNESS 6877W1A409C 6877W1A004B R 56912B LAMP DRAWING 3B70067A 6912W1Z004A R 56930V THERMOSTAT 6930W1A003E 6930W1A003E R 6930W3A001S 63300M PLATE MOUNTING 3300W0M003A 3300W0A018A R 63302A BASE PLATE 3302W0A013H 3302W0A047A R 63303A BASE P...

Page 47: ...A002A R 33112U OUT CASE U BENDING 3112W1U026J 3112W0U052J R 33390G TRAY GLASS 1B71961E 1B71961H R 33530A GRILLE VENT 3530W0A030B 3530W0A030F R 3530W0A030B 33550L COVER LAMP 3550W3A095A 3550W3A095C R 3550W3A095A 33740A PROTECTOR MECH 3740W1A005A 3740W1A005E R 3740W1A005A 340511 RIVET ASSEMBLY 4051W3A001A 4051W3A001A R 34370T SHAFT TURN TABLE 3B72373A 4370W1A006B R 34810Q BRACKET MOUNT 4810W3G062A 4...

Page 48: ...CORD ASSEMBLY 6411W1A010L 6411W1A010Z R 56804A SOCKET CIRC LAMP 6804W3A001A 6804W3A001A R 56851D CABLE ASSEMBLY 6021W3B001A 6021W3B001V R 6021W3B001G 56851D CABLE ASSEMBLY 6021W3B001A 6021W3B001V R 6851W1A002B 568771 HARNESS 6877W1A409C 6877W1A004B R 56912B LAMP DRAWING 3B70067A 6912W1Z004A R 56930V THERMOSTAT 6930W1A003E 6930W1A003E R 6930W3A001S 63300M PLATE MOUNTING 3300W0M003A 3300W0A018A R 63...

Page 49: ...Printed in Korea P NO 3828W5S5159 ...

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