Whirlpool AVM585/IX User manual

WHIRLPOOL PRODUCTS DEVELOPMENT LTD. SERVICE MANUAL
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WHIRLPOOL MICROWAVE
PRODUCTS DEVELOPMENT LIMITED
SERVICE INFO MANUAL
MODEL: AVM585/IX
SKU#: 853858558791
DATE: September 02, 2003
REVISON: 0

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CONTENTS
1. SPECIFICATIONS
2. SAFETY PRECAUTIONS
3. INSTALLATION REQUIREMENTS
3.1 GENERAL
3.2 GROUNDING INSTRUCTIONS
4. SCHEMATIC DIAGRAM
5. MICROWAVE AND LEAKAGE TEST
5.1 MICROWAVE TEST
5.2 MICROWAVE LEAKAGE TEST
6. TROUBLE SHOOTING GUIDE
6.1 CAUTION AND IMPORTANT
6.2 MICROWAVE LEAKAGE
6.3 QUICK REFERENCE
7. MAJOR COMPONENT TESTS
7.1 HV TRANSFORMER
7.2 HV CAPACITOR
7.3 HV DIODE
7.4 MAGNETRON
7.5 INTERLOCK SWITCH SYSTEM
8. PART LIST & EXPLODED DIAGRAM

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1. SPECIFICATION
Oven model
AVM585/IX
Items
Technical Data
Outside Dimensions
(H) x (W) x (D)
332mm x 424mm x 548mm
Dimensions of Cavity
(H) x (W) x (D)
225mm x 339.4 x 345mm
Cavity
27L
Net Weight
22kg
Gross Weight
24kg
Power supply
220V/60Hz, Single Phase
Input Power
1380W
Output Power
850W (Microwave)
Microwave frequency
2450MHz
Grill Power
900W
Current consumption
6.7A (Microwave)
Fuse
8A
Control
Electrical touch foil control
99 minute 99 second timer
10-level microwave power level
3-level combi power level
Pure browning cooking function
Cooking Type
Microwave cooking only
Browning cooking only
Microwave/browning combi cooking

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2. SAFETY PRECAUTIONS
This manual is intended for use by personnel with adequate background in
electrical, electronic and mechanical engineering. Any improper attempt to
repair this oven may result in personal injury and property damage. The
manufacturer or seller cannot be hold responsible for the interpretation of this
manual nor can they assume any liability in connection with its use.
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 sources, and make repairs
when 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 the microwave power for any service test or
inspection within the microwave generating compartments, check the
magnetron, waveguide or transmission line, and cavity for proper
alignment, integrity, and connection.
d. Any defective or misadjusted components in the interlock, monitor,
door seal, and microwave generation and transmission system 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.
TO PREVENT ELECTRICAL SHOCK, PAY EXTREME CAUTION
WHEN DIAGNOSING OVEN WITH OUTER CASE REMOVED AND
POWER TURNED “ON”. THE HIGH VOLTAGE SECTION OF THE
POWER SUPPLY, INCLUDING FILAMENT LEADS, ARE AT A HIGH
TENSION OF -4000 VOLTS. ALSO, ENSURE THAT THE HIGH
VOLTAGE CAPACITOR IS DISCHARGED.

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3. INSTALLATION REQUIREMENTS
3.1 GENERAL
1. The oven should be placed on a flat and stable surface
2. Place the oven away from high temperature and steam sources.
3. Clearance of at least 5cm (2”) on each side must be provided to allow
adequate ventilation.
4. The microwave oven must be plugged directly to a 3-prong wall receptacle
which is properly grounded.
5. The power source must be 220V 50Hz 8A single phase.
3.2 GROUNDING INSTRUCTIONS
IMPORTANT:
DISCONNECT POWER BEFORE SERVICING, RECONNECT ALL
GROUNDING DEVICES.
All mechanical parts of this appliance capable of conducting electricity are
grounded. In the event of an electrical short circuit, grounding reduces the
risk of electric shock. This appliance is equipped with a cord having a
grounding wire with a ground plug. The plug must be plugged into an outlet
that is properly installed and grounded.
WARNING:
IMPROPER USE OF THE GROUNDING PLUG MAY RESULT IN
ELECTRICAL SHOCK.
If grounding wires, screws, straps, clips, nuts or washers used to complete a
path to ground are removed for service, they must be returned to their original
positions and properly fastened.
GROUNDING SPECIFICATION:
Leakage current: 0.5mA max.
Ground path resistance: 0.1 ohm max.

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4. SCHEMATIC DIAGRAM

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5. MICROWAVE AND LEAKAGE TESTS
5.1 MICROWAVE TEST
The following is a simple test to check if the appliance is generating
microwave energy. This test is not intended to be an accurate test. An
accurate measurement of output power must be performed under strict control
following the IEC standard. In field service, accurate measurement of output
power is usually not required.
1. Prepare a beaker of water of quantity about 1000cc.
2. Measure the temperature of the water before putting into the oven.
3. Heat the water in the oven with full power (microwave only) for 60
seconds.
4. Again measure the temperature of the water.
5. If the temperature rise by about 10 degree C, then the microwave
generating system is working.
5.2 MICROWAVE LEAKAGE TEST
5.2.1 TESTING EQUIPMENT
600cc beaker
Microwave meter
6.2.2 TESTING PROCEDURE
1. Place 275cc of water into the beaker and place it in the center of the oven.
2. Turn on the microwave oven by setting the timer ON at full power.
3. Hold the probe of the microwave meter perpendicular to the surface of the
oven and scan it at the rate of 1 inch/sec.
4. Test the following areas for microwave leakage:
Door and control panel
All ventilation openings

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All lockseams
Weld at bottom
Bottom plate
Oven foot
5. Pull the door to the position at which the oven is just about to turn off due to
the interlock switch action, scan the door perimeter for microwave leakage.
6. Maximum allowable leakage is 1 mW/cm2.
7. Record all data.
5.2.3 OVEN LEAKAGE REPAIR
If leakage figure is found to be above 5 mW/cm2, owner should be told not to use
the oven until it has been serviced. Service personnel should notify the
manufacturer and CDRH (FDA) immediately.
5.2.4 OPEN DOOR TEST
With the oven in operation state, open the oven door and check if the oven is still
operating. If so, the service personnel should tell the owner not to operate the
oven again and should notify the manufacturer and CDRH (FDA) immediately.

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6. TROUBLE SHOOTING GUIDE
6.1 CAUTION AND IMPORTANT
1. Before disassembling the oven, the oven power must be turned off. Remove the
power plug of the oven from the outlet and wait for at least 3 minutes.
2. When disassembling, service personnel should remove their watches and metal
chains from their hands. Never touch the high voltage components and wire.
3. Before checking or replacing, discharge the high voltage capacitor to oven chassis
grounded with an insulated wire. Make sure that the wire is grounded to chassis
side before short circuiting the capacitor terminal.
4. Do not measure high voltage with a common voltmeter.
6.2 MICROWAVE LEAKAGE
1. Refer to section 5.2 regarding microwave leakage. If the leakage is greater than
1 mW/cm2, it is necessary to repair the oven.
2. If leakage is found worst at control panel, ventilation openings or oven bottom,
check if there is any damaged parts or loose screws in the respective areas. If so,
replace the damaged parts and fasten the screws.
3. If leakage is found worst around the door perimeter, adjust the door hinges and the
interlock support.

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6.3 QUICK SERVICE REFERENCES
PROBLEM
POINTS TO CHECK
Cavity lamp does not light, but other
electrical components (e.g. turntable) are
working.
1. Lamp burnt.
2. Bad contact between lamp and lamp
socket.
Cavity lamp does not light, all other
electrical components also do not work.
1. Power plug not in good connection
with the socket. No power supply.
2. Fuse blown.
3. Bad contact between fuse and fuse
holder/clip.
4. Loose door hinge, door poorly adjusted,
interlock poorly adjusted; causing fuse
to be blown.
5. Short circuit within electrical circuit.
Lamp filament short, HV transformer
short, all causing fuse blown.
6. Bad contact in contacts or terminals of
timer switch, primary and secondary
interlock switch.
7. HV diode break down.
Oven seems working, food does not cook
1. Defective magnetron (filament broken,
filament short to ground etc.).
2. Ground wire of HV transformer broken.
3. Filament wire short to ground.
4. Filament wire broken.
5. Bad contact in magnetron terminals.
6. Defective control boards.
7. HV diode break down, giving a hum
noise.
Oven cooks for a short while and stop.
1. Cooling fan jammed.
2. Cooling fan motor open circuit.
3. Defective cooling fan control relay.
Turntable does not turn.
1. Defective turntable motor.
2. Turntable shaft deformed.
User circuit breaker activates.
1. High leakage in electrical components
(mostly motor).

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7. MAJOR COMPONENT TESTS
7.1 HV TRANSFORMER
1. Remove lead wire.
2. Measure the resistance of the winding using an ohm meter
3. Primary winding 3 ohm (approx.)
4. Secondary winding100 ohm (approx.)
5. Filament winding 0 ohm (approx.)
7.2 HV CAPACITOR
1. Remove lead wire
2. Measure the resistance using an ohm meter set to R*1000
3. Terminal to terminal should momentary indicates several ohms but
gradually increases to infinite.
4. Terminal to case should show infinite.
7.3 HV DIODE
1. Remove lead wire.
2. Measure forward resistance, normal diode show continuity.
3. Measure reverse resistance, normal diode show infinite resistance.
7.4 MAGNETRON
1. Remove lead wire.
2. Install the magnetron gasket in the correct position. Check that the
gasket is in good condition.
3. Measure the resistance of the filament terminals. Normal magnetron
should be less than 1 ohm.
4. Measure the resistance between the filament terminal to chassis. Normal
magnetron should be infinite.
7.5 INTERLOCK SWITCH SYSTEM
Oven door
status
Primary switch
Secondary
switch
Monitor
switch
Open
Open
Open
Close
Close
Close
Close
Open

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1. The interlock and monitor switches positions are not service adjustable.
If the screws on the hinges of the oven door are loosen, the door may not
be in a correct position. In this case, the interlock switches cannot be
operated by the latch pins of the door when the door is shut. To repair the
door, remount the door and fasten the screws on the door hinges.
2. The monitor switch is provided to monitor the operation of the primary
interlock switch. If the primary switch fails to operate when the door is
open, the monitor switch will form a short circuit across the supply and the
fuse in the oven will blow. Electric arc may form across the switch
contacts of the primary interlock switch, the secondary switch and the
monitor switch. The switches may then be damaged. If the fuse is
blown due to the failure of the primary interlock, repair the failed
mechanical parts and replace all the interlock switches.
IMPORTANT
After replacement of any part of the interlock and monitor circuit:
1. Check if the microswitches are turned ON and OFF by the latches as
specified in the table above.
2. Apply sealant to the screws and nuts of the door hinges.
3. Check microwave leakage.
4. Check if the oven will turn off instantly when the door button is pushed to
the position where the door latches leave the interlock switches.

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8. EXPLODED VIEWS & PART LISTS

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Item no.
Description
Service parts no.
A01
Outer cover
4619
64027853
A02
Thermostat
4619
64874951
4619
64874671
A03
Thermostat support
4619
64410071
4619
64410991
A04
Upper hinge assy
4619
64411841
A05
Lower hinge assy
4619
64414051
A06
Air guide chassis
4619
64411021
A07
Upper wave guide cover
4619
65696301
A08
Lower wave guide cover
4619
65696311
A09
Water-proof spacer
4619
64158502
A10
Turntable motor
4619
64781771
A11
Oven foot
4619
64156603
A12
Air guide 3
4619
64156903
A13
Lamp
4619
64862501
A14
Air guide 2
4619
64156803
A15
Support
4619
64411002
A16
Special terminal
4619
64405701
A17
Back spacer
4619
64138501
A18
Wire saddle clip
4619
64153021

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Item no.
Description
Service parts no.
B01
Glass tray
4619
65690701
B02
TT bearing assy
4619
64189271
B03
Interlock support
4619
64157901
B04
Lock spring
4619
67570131
B05
Cam plate
4619
64158203
B06
Micro switch
4619
64832001
B07
Micro switch
4619
64831901
B08
HVR assy
2431
26500001
B09
Grill grid
4619
64409951
B10
Shelf
4619
64150502
B11
HV capacitor
4619
64651102
B12
Capacitor support
4619
64396602
B13
Power cord
4619
64028081

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Item no.
Description
Service parts no.
C01
Thermostat
4619
64874941
C02
Magnetron
4619
64833231
C03
Magnetron terminal cover
4619
64149701
C04
Air guide
4619
64411011
C05
Fan wheel
4231
07752491
C06
Air guide 1
4619
64184521
C07
Fan motor
4619
64781511
C08
Fan support
4619
64396201
C09
HVT assy
4619
64876113
C10
Heater
4619
64875601

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Item no.
Description
Service parts no.
D01
Door body assy
4619
64018975
D02
Plastic door cover
4619
64192861
D03
Lock hook
4619
64183443
D04
Front glass plate
4619
65696111
D05
Door frame
4619
64191191
D06
Back PE plate
4619
64183501
D 01
D 02
D 03
D 04
D 06
D 05

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Item no.
Description
Service parts no.
E01
Display cover
4619
64192341
E02
Display lens
4619
64194221
E03
Membrane switch
4619
64879881
E04
Electronic panel
4619
64192831
E05
PCB assy
4619
64037591
Other information:
Item no.
Description
Service parts no.
IFU
4619
65263301
E 01
E 02
E 03
E 05
E 04

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Revision log
Revision
Description
Revised by
Revision Date
0
Original
Wang, Wei Guo
Sep. 02, 2003