Bosch HMV9302 Service Manual Download

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MICROWAVE OVEN

SERVICE MANUAL

MODEL: HMV9302

BEFORE SERVICING THE UNIT, READ THE

SAFETY PRECAUTIONS

IN THIS MANUAL.

HMV9305

HMV9303

HMV9306

HMV9307

CAUTION

Summary of Contents for HMV9302

Page 1: ...MICROWAVE OVEN SERVICE MANUAL MODEL HMV9302 BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL HMV9305 HMV9303 HMV9306 HMV9307 CAUTION ...

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: ...ALL CIRCUIT DIAGRAM 5 1 SCHEMATIC DIAGRAM 5 1 MATRIX CIRCUIT FOR TOUCH KEY BOARD 5 2 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 INTERLOCK SYSTEM 7 12 INTERLOCK CONTIN...

Page 4: ...ven Cavity Thermostat Open at 110 C 5 C Fuse 20A Primary Interlock Switch Secondary Interlock Switch Interlock Monitor Magnetron 2M248 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 59 sec in each cooking stage Tray Tempered Safety Glass Overall Dimensions 2915 16 W x167 16 D x155 8 H...

Page 5: ...area 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 Unlike other appliances the microwave oven is high voltage and high current equipment Though it is free from ...

Page 6: ...d 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 BEFORE YOU BEGIN READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY 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 gro...

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

Page 8: ...er frozen foods See page 21 for more information 12 Quick Defrost This pad provides Quick defrosting for 1 0 pound of frozen foods See page 21 for more information 13 Numbers Touch number pads to enter cooking time power level quantities or weights 14 Kitchen Timer Touch this pad to set the kitchen timer See page 10 for more information 15 Clock Touch this pad to enter the time of day See page 10 ...

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

Page 10: ...ENSOR POTATO START PIZZA SENSOR STOP CLEAR QUICK VENT HI LO OFF HI LO OFF LIGHT LESS FAVORITE EASY COOK CLOCK LIGHT SET UP CONTROL TIME N C N C N C HELP N C N C 3 8 REHEAT SENSOR 9 SENSOR VEGETABLE HOLD LEVEL WARM SENSOR COOK 4 6 7 TIMER KITCHEN POWER AUTO DEFROST 2 1 5 PROGRAM 0 12 13 11 10 8 9 1 2 3 4 5 6 7 ...

Page 11: ...y light 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 soun...

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: ...k for microwave leakage after every servicing The power density of the microwave radiation leakage emitted by the microwave 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 beake...

Page 14: ... leakage 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 voltag...

Page 15: ...SPECIALLY 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 terminal socket foll...

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: ...ng 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 Vent Grille Controller Door Mounting Plate 1 or 2 screws Out Case Mount All Figure 8 7 6 ...

Page 18: ... WH from cooktop lamp Secondary Interlock Switch Monitor Interlock Switch Primary Interlock Switch PK from P C B BL from P C B WH from H V Transformer RD from H V Transformer 7 7 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 acc...

Page 19: ...ULLY 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...

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: ...te by loosening mounting plate screws 1 or 2 screws securing it to the back plate See Figure 18 2 Remove MOUNT ALL loosening one screw loosening one screw securing the ventilation Motor and back plate See Figure 19 a 3 Carefully pull the ventilation motor ASS Y out of the microwave oven See Figure 19 b J REPLACING THE HUMIDITY SENSOR For sensor model only 1 Remove the sensor by removing two screws...

Page 22: ...ews 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 NOTES Remove the leadwire from the turntable motor VERY CAREFULLY Be sure to grasp the connector not the wires when removing Wire Leads Turntable Motor 7 11 Figure 20 Figure 21 Figure 22 ...

Page 23: ...justment 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...

Page 24: ...ro 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 prope...

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 a closed circuit in the door open condition When the door is closed the meter sho...

Page 26: ... each filament terminal of the magnetron and the chassis ground with an ohm mater 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 ohm meter on highest scale a Primary winding to ground b Filament winding to ground Normal reading Less than 1 ohm Normal reading Infinite ohms NOTE Repl...

Page 27: ...tinuity 1 Forward Ohm meter Figure 26 a 1 Reverse Ohm meter Figure 26 b Normal reading Momentarily 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 co...

Page 28: ...sistance 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 7 17 COMPONENTS TEST PROCEDURES RESULTS TOUCH KEY BOARD SENSOR For sensor model only Resistance value When When not touched touched Less than More...

Page 29: ... switches and or the interlock monitor switch Malfunction of the high voltage transformer the high voltage capacitor including the diode the magnetron the blower motor or the circuit board PROBLEMS CAUSES 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 sec 14 sec 12 sec 10 sec 8 sec 6 sec 4 sec 2 sec 0 NOTES If the fuse is blown by an i...

Page 30: ...ll operate GOOD Replace the circuit board Replace RELAY1 PROBLEM B FAN motor and 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 0 Vdc 10 of U03 Voltage reading about 15V Replace the circuit board Defective RELAY1 or poor connection of RELAY1 Defective RELAY1 Replace RELAY1 or correct the connection NO NO YES YES NO NO YES ...

Page 31: ...he interlock switches the door sensing and the relay check good 2 The unit with a normal relay continuously 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 t...

Page 32: ...PERATION on page 6 1 DISPLAY Problems A thru C HELP UP Problems D thru E BUZZER Problems F Measure voltage between pin 1 and pin 3 of connector CN1 Measure resistance of touch key board after removing connector S1 See page 7 4 and 7 17 0 120 120V Replace circuit board Normal circuit board Normal resistance Voltage incorrect Normal resistance Resistance incorrect Replace touch key board Normal touc...

Page 33: ... connector S1 Contact OK Replace Circuit board Correct seating Normal circuit board Normal contact Poor contact Normal Primary switch No continuity Adjust or replace door sensing switch Measure resistance of H V capacitor see page 7 16 Resistance incorrect Normal resistance Measure resistance of fan motor Terminal A C 140 to 150 ohm Terminal A B 25 to 40 ohm Resistance incorrect Replace fan motor ...

Page 34: ... 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 16 Replace H V C Normal resistance Replace H V T Normal resistance NO continuity Replace circuit board Normal circuit board Poor contact Replace circuit board Normal circuit board Contact OK Normal contact Correct seating Check contact of connector S1 Check the contact of r...

Page 35: ...7 24 PROBLEM F No buzzing when touching the key between stages or at end of cooking 1 Normal circuit board Check normal operation circuit board Replace circuit board Runs ...

Page 36: ...e magnetron thermal fuse and oven thermostat Poor contact Replace circuit board Normal circuit board Contact OK Normal contact Correct seating Check contact of connector S1 see page 7 4 Replace ventilation motor ASS Y NO runs Normal ventilation motor ASS Y Check the contact of magnetron thermal fuse and oven thermostat Runs Runs Runs Runs ...

Page 37: ...8 1 EXPLODED VIEW DOOR 1005 1002 1004 1006 1007 1009 W200 1000 1381 W201 1701 1702 EV MODEL HMV9302 HMV9303 HMV9305 HMV9306 HMV9307 ...

Page 38: ...8 2 CONTROL PANEL EV 07 2004 2008 2006 W105 W138 2381 W142 For Model HMV9302 HMV9303 HMV9307 For Model HMV9306 HMV9305 ...

Page 39: ... 3 OVEN CAVITY 3038 3010 W108 3031 3029 3001 6001 3014 5038 6000 3033 W121 3028 3026 W121 5036 3032 3018 3036 W109 W121 W142 For Model HMV9302 HMV9303 HMV9307 W138 W142 W138 For Model HMV9306 HMV9305 EV ...

Page 40: ...8 4 LATCH BOARD 4001 4000 4002 4003 4002 4004 W111 EV W102 ...

Page 41: ...5058 5043 5024 8 5 INTERIOR I 3002 5046 5009 5002 5049 5000 5018 5008 5020 5019 5035 W101 W101 W108 3004 3009 5044 W101 W104 W101 W108 3012 3008 3034 EV 3037 W108 ...

Page 42: ...8 6 INTERIOR II W101 W136 5011 5037 5016 5006 5015 5045 5038 5022 3027 5001 5041 5010 5007 5014 5012 W109 W109 W146 W109 W105 W140 EV ...

Page 43: ...8 7 INSTALLATION 6011 6010 6008 6009 EV 01 OWNERS MANUAL 02 SERVICE MANUAL 05 COOKING GUIDE LABEL 06 TEMPLATE 04 INSTALLATION MANUAL ...

Page 44: ...P NO 3828W5S3298 February 2004 Printed in Korea ...

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