Amana AMV4204AAB User manual

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

CAUTION
WARNING TO SERVICE TECHNICIANS
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPOSURE
TO EXCESSIVE MICROWAVE ENERGY
a. Do not operate or allow the oven to be operated with the door open.
b. 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.
c. 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.
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 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.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.
MODEL AMV4204AAB
AMV4204AAQ
AMV4204AAW
TABLE OF CONTENTS
(Page)
SAFETY PRECAUTIONS ................................................................................................................Inside front page
SPECIFICATIONS................................................................................................................................................ 1-1
CAUTIONS ........................................................................................................................................................... 2-1
INSTALLATIONS.................................................................................................................................................. 3-1
OPERATING INSTRUCTIONS............................................................................................................................. 4-1
CONTROL PANEL ............................................................................................................................................... 4-1
CONTROL PANEL INSTRUCTIONS.................................................................................................................... 4-2
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
INTERLOCK SYSTEM ....................................................................................................................................... 7-11
INTERLOCK CONTINUITY TEST ...................................................................................................................... 7-13
TEST AND CHECKOUT PROCEDURES AND TROUBLESHOOTING............................................................. 7-14
A.TEST PROCEDURES..................................................................................................................................... 7-14
B.CHECKOUT PROCEDURES.......................................................................................................................... 7-18
C.TROUBLESHOOTING .................................................................................................................................... 7-20
EXPLODED VIEW ................................................................................................................................................ 8-1
REPLACEMENT PARTS LIST ............................................................................................................................. 8-9

1-1
SPECIFICATIONS
Rated Power Consumption ................................1700W maximum (Microwave oven+Cook top lamps+Ventilation fan)
Microwave Output ...............................................1150W (IEC 60705)
Frequency ..........................................................2,450 MHz ±50 MHz
Power Supply .....................................................120 VAC,60 Hz
Rated Current ....................................................14.5 Amp.(Microwave oven+Cook top lamps+Ventilation fan)
Magnetron Cooling .............................................Forced Air Cooling
Rectification .......................................................Rectification Voltage Double Half-Wave
Door Sealing ......................................................Choke System
Safety Devices ...................................................Magnetron Thermostat: Open at 150 °C ±5 °C
Close at 0 °C ±5 °C
............................................................................Oven Thermostat: Open at 110 °C ±5 °C
Close at 0 °C ±5 °C
............................................................................Fuse(20A)
............................................................................Primary Interlock Switch
............................................................................Secondary Interlock Switch
............................................................................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,
............................................................................Exhaust Adapter, Exhaust Damper, Mounting Kit and Filter,
............................................................................Rotating Ring Assembly, Glass Tray, Metal Rack.
SWITCH CHART
SWITCH MODE
CONDITIONS
DOOR OPEN OPEN OPEN CLOSE
CLOSE CLOSE OPEN
DOOR CLOSED
PRIMARY
INTERLOCK
SWITCH
SECONDARY
INTERLOCK
SWITCH
INTERLOCK
MONITOR
SWITCH
COM
NO
COM
NO
COM
NC
NOTE: Use the above switch chart with circuit diagram on page 5-1.

2-1
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.
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.
• 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.
• 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 on the magnetron.
• NEVER put anything into the latch hole and the interlock
switches 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.
THE OVEN IS TO BE SERVICED ONLY
BY PROPERLY QUALIFIED SERVICE
PERSONNEL.
Gasket
ANTENNA
COOLING FIN
MAGNETRON
CHASSIS GROUND FILAMENT
TERMINALS
MAGNETRON

3-1
INSTALLATIONS
BEFORE YOU BEGIN, READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY.
PRECAUTIONS ON INSTALLATION
A. Plug the power supply cord into a 120V AC,60Hz,
single-phase power source with a capacity of at
least 20 amperes.
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 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.
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.
Plug with Ground
Prong
Properly Polarized
and Grounded
Outlet

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

4-2
CONTROL PANEL INSTRUCTIONS
1. DISPLAY: The Display includes a clock and indicators
to tell you time of day, cooking time setting and
cooking functions selected.
2. POPCORN: Touch this pad when popping popcorn in
your microwave oven.
3. BAKED POTATO: Touch this pad to cook potatoes.
4. BEVERAGE: Touch this pad to reheat one or two
cups of a bev-erage.
5. COOK: Touch this pad to cook Fresh Vegetable,
Frozen Vegetable, Casserole, Rice, Oatmeal, Bacon,
Scrambled Eggs, and Frozen Entrée.
6. REHEAT: Touch this pad to reheat Pizza Slice, Dinner
Plate, Soup/Sauce, Casserole, and Roll/ Muffin.
7. POULTRY: Touch this pad to cook chicken wings,
chicken nuggets, Spicy Chicken and Mexican
Chicken.
8. SOFTEN: Touch this pad to soften Butter, Ice Cream,
Cream Cheese and Frozen Juice.
9. MELT: Touch this pad to melt Butter/Margarine,
Chocolate, Cheese and Marshmallows.
10. AUTO DEFROST: Meat, poultry, fish and bread.
Touch this pad to select food type and defrost food by
weight.
11. RAPID DEFROST: This pad provides RAPID defrost
for 1.0 pound of frozen food.
12. TIME DEFROST: 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, cooked
foods warm in your microwave oven for up to 90
minutes.
18. POWER LEVEL: Touch this pad to select a cooking
power level.
19. ADD 30 SEC.: Touch this pad to
set and start quickly at 100% power level.
20. STOP/CLEAR: Touch this pad to stop the oven or to
clear all entries.
21. ENTER/START: Touch this pad to start a function. If
you open the door after oven begins to cook, touch
ENTER/START again.
22. CUSTOM PROGRAM: Touch this pad to recall one
cooking instruction previously programmed into
memory.
23. KITCHEN TIMER: Touch this pad to set the kitchen
timer.
24. LIGHT TIMER: Touch this pad to set the light timer.
25. VENT HI/LO/OFF: Touch this pad to turn the fan on or
off.
26. TURNTABLE ON/OFF: Touch this pad to turn off the
turntable. OFF will appear in the display.
27. LIGHT HI/LO/OFF: Touch this pad to turn on the
cooktop/countertop light.

5-1
OVERALL CIRCUIT DIAGRAM
SCHEMATIC DIAGRAM (I) *Check the Model No.

5-2
SCHEMATIC DIAGRAM (II) *Check the Model No. (ADD Noise filter)