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7-4

DISASSEMBLY INSTRUCTIONS

IMPORTANT NOTES:

UNIT MUST BE DISCONNECTED FROM ELEC-
TRICAL OUTLET WHEN MAKING REPAIRS,RE-
PLACEMENTS,ADJUSTMENTS AND CONTIN-
UITY CHECKS.
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)

(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

(3 Tap Power Relay, RY7) from the circuit board.

(4) Remove 5 screws securing the circuit board.

Power Transformer

Control Panel

Screw

Circuit Board

(RY7)

3 Tap
Power Relay

(CN1)

Circuit Board

Control Bracket

Circuit Board

FPC Connector(S1)

(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.

Figure 1

Figure 2

Figure 3

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Summary of Contents for AMV4204AAB

Page 1: ...Microwave Oven Service Manual AMV4204AAB AMV4204AAQ AMV4204AAW CAUTION BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ...

Page 2: ...roper 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 ea...

Page 3: ... 2 OVERALL CIRCUIT DIAGRAM 5 1 SCHEMATIC DIAGRAM I 5 1 SCHEMATIC DIAGRAM II 5 2 MATRIX CIRCUIT FOR TOUCH KEY BOARD 5 3 GENERAL INFORMATION FOR SERVICE 6 1 GENERAL PRECAUTIONS IN USE 6 1 TRIAL OPERATION 6 1 FEATURES AND SPECIFICATIONS FEATURES 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 INTE...

Page 4: ...witch Interlock Monitor Switch Magnetron 2M282J Toshiba Cook top Lamp 125 V 30 W or 40 W Cavity Lamp 125 V 30 W or 40 W Timer Digital up to 99 min 99 sec in each cooking stage Tray Tempered Safety Glass Overall Dimensions 2915 16 W x167 16 H x153 8 D Oven Cavity Size 231 2 W x103 16 H x141 2 D Effective Capacity of Oven Cavity 2 0 Cu ft Accessories Owner s Manual Cooking Guide Installation Manual ...

Page 5: ...ng operation BEFORE TOUCHING any parts of the oven always remove the power plug from the outlet 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 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 ...

Page 6: ...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 grounde...

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

Page 8: ...OST Touch this pad to defrost most other frozen foods 13 NUMBER Touch number pads to enter cooking time power level quantities or weights 14 CLOCK Touch this pad to enter the time of day 15 COOK TIME Touch this pad to to set a cooking time 16 CONTROL SETUP Touch this pad to change the oven s default settings for sound clock display speed and defrost weight 17 HOLD WARM Touch this pad to keep hot c...

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 ...

Page 11: ...5 3 MATRIX CIRCUIT FOR TOUCH KEY BOARD 13 12 8 9 10 11 2 1 3 4 5 6 7 KEY MATRIX ...

Page 12: ...l 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 sound signal is heard when the time is up The unit will shut off...

Page 13: ...w the limit of 5 mW cm2 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 th...

Page 14: ...ervicing The power density of the microwave radiation leakage emitted by the microwave oven should not exceed 1mW cm sq And always start measuring of an unknown field to assure safety for operating personnel from radiation leakage NOTE The standard is 5mW cm sq while in the customer s home 1mW cm sq stated here is manufacturer s own voluntary standard for units in customer s home EQUIPMENT TESTER ...

Page 15: ...al have been used 3 At least once a year have the electromagnetic energy leakage monitor checked for calibration by its manufacturer 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 2 The water is contained in a cylindrical borosili...

Page 16: ... 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 3 Tap Power Relay RY7 from the circuit board 4 Remove 5 screws securing the circuit board Power Transformer Control Panel Screw Circuit Board RY7 3 Tap Power Relay CN1 Circuit Board Control Bracket Circuit Board FPC C...

Page 17: ...sert 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 hooks on the plastic fastener 3 Lock the level of the plastic fastener into th...

Page 18: ...1 or 2 screws securing it to the out case 4 Remove two screws on the left central edge and two 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 four screws of the rear cavity 6 Remove the outcase with disconnecting power cord connector Door Mount All Vent Grille Controller Out Case Mounting Plate Power ...

Page 19: ... Latch Board Primary Interlock Switch RD from P C B RD from Fan Motor BK from Cooktop lamp WH from H V T PK from P C B BL from P C B BN from Turntable Motor RD from P C B BK from MGT THERMOSTAT Monitor Interlock Switch Secondary Interlock Switch Latch Board Primary Interlock Switch Interlock Monitor Switch Secondary Interlock Switch Figure 9 Figure 10 WIRE COLOR SYMBOL COLOR WH WHITE BK BLACK BR B...

Page 20: ... 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 cm 2 All service adjustments should be made for minimum microwave energy leakage r...

Page 21: ...ve two screws securing it to the door handle CAUTION Be careful not to damage door seal plate with the screwdriver H ASSEMBLING DOOR 1 When mounting the door assembly to the oven assembly be sure to adjust the door assembly 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 l...

Page 22: ...19 3 Remove the base plate by removing 8 screws securing it to the oven cavity Figure 20 4 Disconnect the leadwire from the turntable motor terminals 5 Remove 1 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 Figure 18 b Figure 19 Figure 20 Figure 21 Wi...

Page 23: ...rd 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 Swi...

Page 24: ...o 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...

Page 25: ... When 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 shou...

Page 26: ...eads 2 Measure resistance ohm meter scale Rx1 Primary winding High Low Secondary winding Filament winding 3 Measure resistance ohm meter scale Rx1000 Primary winding to ground Filament winding to ground 1 Remove wire leads Install the magnetron seal in the correct position Check that the seal is in good condition 2 Measure resistance ohm meter scale Rx1 Filament terminal 3 Measure resistance ohm m...

Page 27: ...le Rx1000 CAPACITOR DIODE Some inexpensive ohm meters may indicate infinite resistance in both directions 1 Measure continuity ohm meter scale Rx1 2 Remove the lead wires and operate oven at power level 1 through power level 10 RELAY 7 1 Remove wire leads 2 Measure resistance ohm meter scale Rx1 Normal Approximately Terminal 35 to 50 ohms Terminal 5 to 15 ohms Abnormal Infinite or several A B C FA...

Page 28: ...ns 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 TOUCH KEY BOARD Resistance value When touched Less than 400 ohms When not touched More than 1 mega ohm FPC CONNECTOR Top 1 2 3 4 5 6 7 8 9 10 11 12 13 13 12 8 9 10 11 2 1 3 4...

Page 29: ... ADJUSTMENT PROCEDURES on page 7 11 when the primary interlock secondary interlock switches and or the interlock monitor switches are adjusted or replaced Fuse blows immediately after the door is closed Fuse blows immediately after the door is opened Fuse blows when the door is closed and START key is touched Improper operation of the primary interlock secondary interlock switches and or the inter...

Page 30: ...without touching START key when the door is closed GOOD Remove the mate connector of I O CON from the circuit board Does the unit still operate Defective Wire Assembly Replace the circuit board Replace Wire Assembly NO NO YES YES GOOD Measure the voltage at pin NO 1 4 of CN1 Voltage reading 120 V AC Replace the circuit board Defective FAN motor YES NO NO YES Replace FAN motor PROBLEM B Oven lamp t...

Page 31: ...t the high voltage Systems the interlock switches the door sensing and the relay check good 3 The unit with a normal relay continuously operates 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 The clock does not keep time p...

Page 32: ... 2 FUSE See CHECKOUT PROCEDURES FOR FUSE BLOWING on page 7 17 3 OVEN CAVITY THERMOSTAT 1 1 Measure voltage between pin 1 and pin 3 of connector CN1 BL WH Runs Runs 0 120 0 120 120V Replace circuit board Normal circuit board Normal resistance Voltage incorrect Correct connections Runs Runs Runs Measure resistance of touch key board after removing connector S1 See page 7 5 and 7 16 Normal resistance...

Page 33: ...orrect seating Normal circuit board Normal contact Poor Normal Secondary switch No continuity Adjust or replace door sensing switch Runs Runs Runs Check operation of fan motor when START key is touched Measure resistance of H V capacitor see page 7 15 Resistance incorrect Measure resistance of fan motor Terminal A C 35 to 50 ohms Terminal A B 5 to 15 ohms Resistance incorrect Replace fan motor Nor...

Page 34: ...ormal circuit board Contact OK Normal contact Correct seating Check contact of connector Check the contact of relay 7 see page 7 15 Resistance incorrect Check the continuity of H V C see page 7 15 Normal H V T Resistance incorrect Normal H V C Abnormal Replace H V D Normal Magnetron Replace Magnetron Normal Normal H V D Check the continuity of H V D see page 7 15 Replace H V C Normal resistance Re...

Page 35: ... when VENT HI LO OFF key is touched 1 Runs Runs Runs Contact OK NO contact Replace magnetron thermostat and oven thermostat Poor contact Replace circuit board Normal circuit board Contact OK Normal contact Correct seating Check contact of connector Runs Replace ventilation motor ASS Y NO runs Normal ventilation motor ASS Y Check the contact of magnetron thermostat and oven thermostat Check 1 POWER...

Page 36: ...8 1 EXPLODED VIEW DOOR PARTS 1002 1004 1000 1003 1008 1009 1011 1005 W109 W150 1007 1006 EV Model AMV4204AAB AMV4204AAQ AMV4204AAW Serial Number ldentification Figure Check First Second ex 1 0 ...

Page 37: ...8 2 CONTROLLER PARTS 2004 2002 2381 2008 2006 2009 W130 2000 07 Check the Serial No EV ...

Page 38: ...8 3 OVEN CAVITY PARTS For Model AMV4204AAB For Model AMV4204AAQ AMV4204AAW 3024 W138 W142 W108 3010 3028 5038 3026 3032 W121 3029 3031 3001 3025 3018 3011 6000 3036 3037 W109 3014 EV ...

Page 39: ...8 4 LATCH BOARD PARTS W111 4004 4003 4002 4002 4001 4000 EV ...

Page 40: ...8 5 INTERIOR PARTS I 5044 3004 W109 3012 3034 3002 3008 5008 3009 W105 5018 W101 5000 5002 3007 5009 W101 5023 W101 W109 5049 5051 5058 5043 5024 EV ...

Page 41: ...006 5007 5014 W204 5045 5015 5038 5037 5016 3027 5412 W110 W101 5012 5017 5010 5001 W109 Check the Serial No Check the Serial No SPECIAL PARTS 5383 EV Check the rating label of Model and order SVC parts according to the Serial No Serial No 10 ...

Page 42: ...6 5007 5014 W204 5045 5015 5038 5037 5016 3027 5412 W110 W101 5012 5041 5010 5001 Check the Serial No Check the Serial No W109 SPECIAL PARTS 5383 EV Check the rating label of Model and order SVC parts according to the Serial No Serial No 11 ...

Page 43: ...8 8 INSTALLATION PARTS VINYL BAG 6011 6009 6010 6008 EV ...

Page 44: ...P NO 3828W5S3657 Printed in Korea ...

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