Amana RC520S, RC518SU, RC5MCTP, RC5PHBU, RC5PHB Service Manual

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Page 1

Service

This manual is to be used by qualified appliance technicians only. Maytag does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person.

International Countertop

MENUMASTER

C O M M E R C I A L M I C R O W A V E O V E N

This Base Manual covers general information.

Refer to individual Technical Sheet

for information on specific models.

This manual includes, but is

not limited to the following:

Commercial Microwave Ovens

RC5PHBU2 P1331421M RC5PHB2 P1331422M RC520T2 P1331423M RC5KFT2 P1331424M RC5MCTP2 P1331425M RC5MCTS2 P1331426M RC5MDTS2 P1331427M RC5MDTM2 P1331428M

RC520S P1327601M RC518SU P1327602M RC5MCTP P1327603M RC5PHBU P1327606M RC5PHB P1327607M RC5MCSP P1327608M RC5MCSS P1327609M RC5MCTS P1327610M RC5KFT P1327611M RC5MDTS P1327612M MRC518SU P1327613M MRC520S P1327614M RC5MDTM P1327615M RC518SU2 P1331416M RC520S2 P1331417M RC5MCSP2 P1331418M RC518U2 P1331419M MRC520S2 P1331420M

16022149

May 2005

Page 2

Important Information

Important Notices for Servicers and Consumers

Maytag will not be responsible for personal injury or property damage from improper service procedures. Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service information. IT IS THE TECHNICIANS RESPONSIBILITY TO REVIEW ALL

APPROPRIATE SERVICE INFORMATION BEFORE BEGINNING REPAIRS.

To avoid risk of severe personal injury or death, disconnect power before working/servicing on appliance to avoid electrical shock.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

WARNING

Service Support Center

Contact your local product distributor or vist the Web site at www.amanacommercial.com.

Recognize Safety Symbols, Words, and Labels

DANGER!

DANGER—Immediate hazards which WILL result in severe personal injury or death.

WARNING!

WARNING—Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION!

CAUTION—Hazards or unsafe practices which COULD result in minor personal injury, product or property

damage.

Page 3

Table of Contents

Important Information .................................................... 2

Important Safety Information ......................................... 4

Wiring .....................................................................8

Earthing Instructions............................................... 8

Servicing of Earthing Products ................................ 8

General Information

Unpacking Oven ..................................................... 9

Oven Placement ..................................................... 9

Radio Interference ...................................................9

Earthing Instructions............................................... 9

Microwave Oven Description ................................. 10

Troubleshooting

Power up .............................................................. 11

Standby Condition ................................................ 12

Cook Condition ..................................................... 13

Component Testing Procedures .................................. 14

Power Testing Procedure

Power Test ........................................................... 21

Display Diagnostics

Error Codes .......................................................... 22

Service Test ........................................................... 23-24

Service Information

Proper Handling of Magnetron Tubes .................... 25

Magnetron Failure Modes ..................................... 25

Operating Instructions for the Holaday

HI1501, HI1510, HI1710, and HI1801 .............. 26

Microwave Leakage Test

Equipment ............................................................ 27

Procedure For Measuring Radiation Leakage ....... 27

Measurement With the Outer Panel Removed ...... 27

Measurement With a Fully Assembled Oven ........ 27

Record Keeping and

Notification After Measurement ............................. 27

Disassembly

Door Handle ......................................................... 28

Door ..................................................................... 28

Outer Door ............................................................ 28

Inner Door Ring Assembly .................................... 28

Hinge .................................................................... 28

Outer Case ........................................................... 29

Back Panel .......................................................... 29

Splatter Shield ...................................................... 29

Top Touch Panel Assembly ................................... 29

Side Touch Panel Assembly ................................. 29

High Voltage Circuit Board ................................... 29

Interlock Switch Module ....................................... 30

Adjustment .................................................... 30

Display Module ..................................................... 30

Top Rear Magnetron ............................................. 30

Top Front Magnetron ............................................. 30

Bottom Magnetron ................................................ 30

Magnetron Cutout (TCO) ....................................... 31

Cavity Thermal Cutout (TCO) ................................ 31

Triacs ................................................................... 31

Capacitor .............................................................. 31

Transformer .......................................................... 31

Auto Transformer .................................................. 31

Microwave Blower Wheel and Motor ..................... 31

Fan Blade .............................................................31

Top Antennas ........................................................ 32

Bottom Antenna.................................................... 32

Antenna Motors .................................................... 32

Oven Tray Removal / Installation ...........................32

Fuse ..................................................................... 33

Power Cord .......................................................... 33

Light Socket .........................................................33

Relay .................................................................... 33

Line Filter ............................................................. 33

Replacing Oven Light Bulb ................................... 33

Component Location ........................................ 34-36

Page 4

Important Safety Information

Page 5

Important Safety Information

Page 6

Important Safety Information

Page 7

Important Safety Information

CAUTI ON

Read the following information to avoid possible exposure to microwave radiation:

The basic design of the Amana and Menumaster microwave ovens make it an inherently safe device to both user and servicer. However, there are some precautions which should be followed when servicing the microwave oven to maintain this safety. These are as follows:

1. Always operate the unit from an adequately earthed outlet. Do not operate on a two-wire extension cord.

2. Before servicing the unit (if unit is operable), perform the microwave leakage test.

3. The oven should never be operated if the door does not fit properly against the seal, the hinges or hinge bearings are damaged or broken; the choke is damaged, (pieces missing, etc.); or any other visible damage can be noted. Check the choke area to ensure that this area is clean and free of all foreign matter.

4. If the oven operates with the door open and produces microwave energy, take the following steps.

A. Tell the user not to operate the oven. B. Contact Maytag immediately.

5. Always have the oven disconnected when the outer case is removed except when making the "live" tests called for in this Service Manual. Do not reach into the equipment area while the unit is energized. Make all connections for the test and check them for tightness before plugging the cord into the outlet.

6. Always earth the capacitors on the magnetron filter box and H. V. Capacitor with an insulated-handle screwdriver before working in the high voltage area of the equipment compartment. Some types of failures will leave a charge in these capacitors and the discharge could cause a reflex action which could make you injure yourself.

7. In the area of the transformer, capacitor, diode, and magnetron there is HIGH VOLTAGE. When the unit is operating, keep this area clean and free of anything which could possibly cause an arc or earthing, etc.

8. Do not for any reason defeat the interlock switches. There is no valid reason for this action at any time; nor will it be condoned by Maytag.

9. IMPORTANT: Before returning a microwave to a customer, check for proper switch interlock action. The primary and secondary switches MUST actuate when the door is opened. The monitor switch MUST close at a opened.

10.Before returning a microwave to a customer, verify the door spacing is reasonably uniform along the top, bottom, and sides, and that it measures

/64–inch (0.5 mm) or less.

11. The Amana or Menumaster microwave oven should never be operated with:

• Any components removed and/or bypassed.

• Any of the safety interlocks found to be

defective.

• Any of the seal surfaces defective, missing,

or damaged.

12.To ensure that the unit does not emit excessive microwave leakage and to meet the Department of Health Human Service guidelines, check the oven for microwave leakage using leakage monitor as outlined in the instructions. The maximum leakage level allowed is 4mW/cm2.

13.If servicer encounters an emission reading over 4 mw/cm2 the servicer is to cease repair and contact the Maytag Service Department immediately for further direction. Maytag will contact the proper Government Agency upon verification of the test results.

/64–inch (0.5 mm) when the door is

Page 8

Important Safety Information

WARNING

Precautions to be observed before and during servicing to avoid possible exposure to excessive microwave energy, or electrical shock disconnect power to oven.

(A) Do not operate or allow oven to be operated with

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:

• Interlock operation

• Proper door closing

• Seal and sealing surfaces (arcing, wear, and other damage)

• Damage to or loosening of hinges and latches

• Evidence of dropping or abuse

test or inspection within the microwave generating compartments, check the magnetron, waveguide or transmission line, and cavity for proper alignment, integrity, and connections.

(D) Any failed or misadjusted components in the

interlock, monitor, door seal, microwave generation, and transmission systems shall be repaired, replaced or adjusted by procedures described in this manual before oven is released to the consumer.

(E) Check microwave leakage to verify compliance with

the federal performance standard should be performed on each oven prior to release to the consumer.

Wiring

Good service practice is to never route wiring over terminals and/or sharp edges. This applies to any wiring without regard to the circuit voltage. Wire insulation material and thickness is designed and regulated for electrical spacing purpose only, but cannot always be relied upon because of possible cuts and/or abrasions, which can occur during servicing.

WARNING

To avoid risk of electrical shock, personal injury or death, make sure these earthing instructions are followed.

Earthing Instructions

WARNING

Do not remove earthing prong when installing earthed appliance in a home or business that does not have three wire earthing receptacle, under no condition is earthing prong to be cut off or removed. It is the personal responsibility of the consumer to contact a qualified electrician and have properly earthed three prong wall receptacle installed in accordance with appropriate electrical codes

Should a two prong adapter plug be required temporarily, it is the personal responsibility of the consumer to have it replaced with properly earthed three prong receptacle or the two prong adapter properly earthed by a qualified electrician in accordance with appropriate electrical codes.

Servicing of Earthed Products

The standard accepted color coding for earthing wires is GREEN or GREEN WITH YELLOW STRIPE. These earth leads are NOT to be used as current carrying conductors. It is extremely important that the technician replace any and all earths prior to completion of the service call. Under no condition should earth wire be left off causing a potential hazard to technicians and consumer.

Page 9

General Information

Unpacking Oven

• Inspect oven for damage such as dents in door or inside oven cavity.

• Report any dents or breakage to source of purchase immediately.

• Do not attempt to use oven if damaged.

• Remove all materials from oven interior.

• If oven has been stored in extremely cold area, wait a few hours before connecting power.

Oven Placement

• Do not install oven next to or above source of heat, such as pizza oven or deep fat fryer. This could cause microwave oven to operate improperly and could shorten life of electrical parts.

• Do not block or obstruct oven filter. Allow access for cleaning.

• Install oven on level countertop surface.

• Place warning label in a conspicuous place close to microwave oven.

• Outlet should be located so that plug is accessible when oven is in place.

Radio Interference

Microwave oven operation may cause interference to radio, television, or similar equipment. Reduce or eliminate interference by doing the following:

• Clean the door and sealing surfaces of microwave oven according to instructions in “Care and Cleaning” section.

• Place radio, television, etc. as far as possible from the microwave oven.

• Use a properly installed antenna on radio, television, etc. to obtain stronger signal reception.

Earthing Instructions

This appliance MUST be earthed. If an electrical short circuit occurs, earthing reduces the risk of electric shock by providing an escape wire for the electric current. The cord for this appliance has a earthing wire with a earthing plug. Place the plug into an outlet that is properly installed and earthed. Do not use a two–prong adapter.

WARNING

To avoid risk of electric shock, personal injury or death, do not alter the plug and use earthing plug properly.

A—Allow at least 7 " (17.8 cm) of clearance around

top and sides of oven. Proper air flow around oven cools electrical components. With restricted air flow, oven may not operate properly and life of electrical parts is reduced.

B—Allow at least 2 9/16 " (6.5 cm) between air

discharge on back of oven and back wall.

Consult a qualified electrician if you do not understand the earthing instructions or if you wonder whether the appliance is properly earthed.

Keep the electrical power cord dry and do not pinch or crush it in anyway.

The wires in the power cord are colored in accordance with the following code:

• Green/Yellow: Earth

• Blue: Neutral

• Brown: Live

Page 10

General Information

Receptacle

230 V / 13 AMP

Equipment requires a

230 VAC, 50 Hz, 13 amp power supply

Do not use a extension cord. If the product power cord is too short, have a qualified electrician install a three-prong receptacle. This unit should be plugged into a separate dedicated 230 VAC / 50 Hz power supply. If other equipment is on the same circuit, an increase in cooking times may be required and fuse can be blown.

Plug

Receptacle

230 V / 16 AMP

Equipment requires a

230 VAC, 50 Hz, 16 amp power supply

Plug

Microwave Oven Description

A—Door Handle B—Spatter Shield C—Top Control panel D—Display E—Side Control Panel F—Air Filter

Page 11

Troubleshooting

Power Up

Plug oven into power source with oven door closed.

Error Code Appears.

STG

ITEM POWER

QTY

1 2 3 4

PREHEAT STANDBY

LMT

NOT READY

COOK LEVEL

YES

POWER UP CONDITION NORMAL

YES

Proceed to DISPLAY DIAGNOSTICS.

1. No line voltage.

2. Inoperative power cord.

3. Inoperative fuse.

4. Inoperative display board.

5. Inoperative H.V. board.

6. Broken or loose wire connection.

Page 12

Troubleshooting

Standby Condition

Open oven door.

STG

ITEM POWER

QTY

1 2

3 4

LMT

PREHEAT

Yes

Oven light is on?

Yes

NOT READY

STA NDBY

COOK LEVEL

Inoperative interlock switch assembly (primary).

1. Inoperative H.V. board.

2. Broken or improper wire connections.

Inoperative light bulb.

1. Inoperative light socket.

2. Inoperative auto-transformer.

3. Inoperative H.V. board.

Broken or improper wire connections.

Blower motor operates?

Yes

Antenna motor(s) ope rate?

Yes

"Standby Condition" normal - proceed to

"Cook Condition".

Inoperative blower motor.

1. Inoperative auto-transformer.

Inoperative H.V. board.

Broken or improper wire connections.

Inoperative antenna motor.

Binding gears.

Inoperative auto-transformer.

3. Inoperative H.V. board.

Broken or improper wire connections.

Page 13

Troubleshooting

Cook Condition

Place cup of water in oven and close oven door.

Flashing

STG

ITEM POWER

QTY

3 4

LMT

PREHEAT

NOT READY

STANDBY

Push pad number 1. Pad beeps when pushed?

COOK LEVEL

Beep not programmed into oven.

Pad not programmed. Display indicates 00:00 and beeps rapidly. Inoperative touch panel.

3. Inoperative H.V. board.

Broken or improper wire connections.

Yes

ITEM

STG

QTY

2 3 4

LMT

PREHEAT

NOT READY

STANDBY

POWER

COOK LEVEL

Display starts counting down.

Yes

Display counting down to "0" and beep sounds.

Yes

Open oven door, water is properly heated?

Yes

Oven is operating properly.

Magnetron TCO opened in mid-cycle: "HOT" displays and blower operates. When TCO resets, blower shuts OFF and display goes blank.

If TCO does not reset within 2 minutes, The H.V. board will turn off blower and the display goes blank.

Heats very slowly.

NOTE: Verify by performing power test (page 19).

One inoperative diode.

1. One inoperative capacitor.

2. One inoperative magnetron.

3. Broken or improper wire connection.

No heat.

Inoperative triac.

1. Inoperative diodes.

Inoperative capacitors. Inoperative high voltage transformer.4. Inoperative H.V. board.

5. Inoperative or misadjusted interlock

6. switch assembly (secondary).

Broken or improper wire connections.7.

NOTE: Shut down after cook cycle - door closed - factory preset at 60 seconds, but can be changed with user options.

Shut down, door open - approximately 2 minutes. Blower shuts down and display indicates door.

Page 14

Component Testing Procedures

WARNING

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

Refer to Technical Sheets for specific model information.

Illustration Component Test Results

MT2

MT1 GATE

Triac 1 (center) Triac 2 (left) Triac 3 (right

Thermal cutout

Diode Discharge Capacitor

Triac Resistance Check

Voltage Check

Capacitor

Some units may use more then one type of capacitor. Refer to Parts Manual for correct capacitor quantity.

Snubber assembly Disconnect wires to snubber.

Magnetron Discharge Capacitor

Blower motor Remove all wires from motor.

Disconnect all wires from TCO. Measure resistance across terminals.

Magnetron TCO..................................

Relay TCO..........................................

Cavity TCO .........................................

Remove diode lead from capacitor and connect ohmmeter.

Reverse leads for second test.

Disconnect wires to triac.

Measure resistance from:

MT1 to MT2 .........................................

MT1 to Gate.........................................

MT2 to Gate.........................................

All terminals to ground .........................

Measure voltage from:

MT1 to Gate

Discharge Capacitor

Remove wires from capacitor terminals and connect ohmmeter, set on highest resistance scale to terminals.

Also check between each terminal and capacitor case.

Measure resistance across terminals ........

Remove wires from magnetron and connect ohmmeter to terminals. Also check between each terminal and ground.

Measure resistance across coil .................

Open at 149°C (300°F) and closes at 125°C (257°F) Open at 280°F (138°C) and closed at 180°F (82°C) Open at 300°F (149°C) and closed at 257°F (125°C) Open at 235°F (113°C) and closed at 150°F (66°C) Opens at 128°C (262°F) Opens at 219°F (104°C) Opens at 262°F (128°C) Infinite resistance should be measured in one direction and 50KΩ or more in the opposite direction.

NOTE: Ohmmeter must contain a battery of 6 volts minimum.

Caution - Do not operate oven with wire to terminal MT2 removed.

Infinite Approximately 60 Ω Infinite Infinite

0.8 VAC when energized. If no voltage, check H.V. board and wiring.

Between Terminals: Meter should momentarily deflect towards zero then return to over 5 MΩ. If no deflection occurs, or if continuous deflection occurs, replace capacitor.

Terminal to Case: Infinite resistance

Infinite

Between Terminals: Less than 1 Ω

Each terminal to ground measures Infinite resistance. Note: This test is not conclusive. If oven does not heat and all other components test good replace the magnetron and retest.

Approximately 25 Ω

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Page 15

Component Testing Procedures

WARNING

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

Refer to Technical Sheets for specific model information.

Illustration Component Test Results

Less than 1 Ω Infinite Less than 1 Ω Approximately 65 Ω

Less than 1 Ω Less than 1 Ω Infinite Infinite Less than 1 Ω Approximately 70 Ω

Infinite Infinite Indicates continuity

Indicates continuity Indicates continuity Infinite

and screwed in.

COM

220

230

230 V

Transformer

COM

230 VAC

TCO

COM

220 VAC

230 VAC

Interlock switch

Door Closed

Secondary

Primary

Monitor

Discharge Capacitor

Remove all wires from terminals.

Measure resistance from:

230 to COM.............................................

230 to Ground .........................................

Terminal 5 to 6 ........................................

Terminal 4 to Ground ..............................

Discharge Capacitor

Remove all wires from terminals.

Measure resistance from:

230 to COM.............................................

208 to COM.............................................

230 to Ground .........................................

208 to Ground .........................................

Terminal 5 to 6 ........................................

Terminal 4 to Ground ..............................

Disconnect wires to switch.

With door open measure resistance from:

Terminal 2 to 3 ........................................

Terminal 4 to 5 ........................................

Terminal 7 to 8 ........................................

With door closed measure resistance from:

Terminal 2 to 3 ........................................

Lamp receptacle

Terminal 4 to 5 ........................................

Terminal 7 to 8 ........................................

Test continuity of receptacle terminals. Indicates continuity if bulb is good

(some models)

Black

White

Brown

Blue

Antenna motor Remove all wires from terminals.

Measure resistance from:

Relay

This relay contains a diode in the coil circuit.

Line filter

Terminal to terminal ....................................

Measure resistance from:

Terminal 0 to terminal 1 (coil) ..................

2468

Disconnect wire from terminals. Measure resistance of the following terminals:

White to Blue..........................................

Black to Brown .......................................

Approximately 12K Ω

Approximately 6 to 7 MΩ

NOTE: Analog meter is recommended for measurement.

NOTE: If using a digital meter it must contain a battery of 6 volts minimum.

< 1 Ω < 1 Ω

Terminal block Visual check. Verify fuse holding terminals are not

damaged. Verify terminals are not damaged.

Refer to Parts Manual for proper power cord part number.

Power cord Measure resistance of wires. Continuity should be indicated on

each wire. Verify polarity and grounding.

Page 16

Component Testing Procedures

WARNING

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

Refer to Technical Sheets for specific model information.

Illustration Component Test Results

Side touch panel

Continuity is indicated as 100 Ω and below.

Top touch panel Removal of touch panel is required to

perform test. Continuity is indicated as 100 Ω and below.

Pad

1 2 3 4 5 6 7 8 9 0 Start Stop/Reset

Pad

Time Entry Power Level Stage Program Save Quantity Menu Hidden Pad

Trace

3 & 5 3 & 6 3 & 7 3 & 8 3 & 9 4 & 5 4 & 6 4 & 7 4 & 8 4 & 9 5 & 6 6 & 9

Trace

5 & 7 5 & 8 5 & 9 6 & 7 6 & 8 7 & 9 8 & 9

Measurement

Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity

Measurement

Continuity Continuity Continuity Continuity Continuity Continuity Continuity

Display board

Side Touch Panel Connector

Pin 1

A B

Test Points

Function Test Set-Up Meter

Setting

Input to Display

Board

At Display

Board

Volts Test points A and B 3.0 VAC

Pin 1

H.V. board Connector

Pin 1

Interlock Connector

Probe Placement Results

If voltage is present and no display is indicated, replace display board. If no voltage is present, check wire harness connections and H.V. board.

Top Touch Panel Connector

16022149

Page 17

Component Testing Procedures

WARNING

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

Refer to Technical Sheets for specific model information.

H.V. board

Pin 1

Pin 28

Pin 50

E2E3

Pin 1

Pin 1Pin 1

Function Test Set-Up Meter

Probe Placement Results

Setting

Input to H.V. board At H.V. board Volts J1 pin 1 (Brown wire)

& J1 pin 2 (White wire)

Output to display

board

Disconnect J5 connector,

Volts J5 pin 28 &

J5 pin 50 blower runs continuously

Line voltage

− 24 VDC

Page 18

Component Testing Procedures

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

Refer to Technical Sheets for specific model information.

NOTE: For the following test, place oven in Service Test Mode.

Relay Function Test Set-Up Meter

K1 at 230 VAC line voltage

Blower motor Antenna motor Cavity light

Disconnect J2 connector

WARNING

Probe Placement Results

Setting

Ohms J1 pin 1 (Brown wire)

& J2 pin 4

Test mode 5 off − no continuity Test mode 5 on − < 1 Ω

H.V. Board − Relay Test

Three Magnetron Models

Relay Function Test Set-Up Meter

Setting

Magnetron 1 (Top rear) at 230 VAC

Magnetron 2 (Top front) at 230 VAC

Magnetron 3 (Bottom) at 230 VAC

All wires connected to H.V. board

VAC E2 (Black wire)

VAC E5 (Red wire)

VAC J4 pin 4 (Black wire)

Probe Placement Results

Test mode 1 off – line voltage

& J4 pin 2 (Red wire)

& J3 pin 1 (Gray wire)

& J4 pin 6 (Black wire)

Test mode 1 on – 0 volts

Test mode 2 off – line voltage Test mode 2 on – 0 volts

Test mode 3 off – line voltage Test mode 3 on – 0 volts

Two Magnetron Models

Relay Function Test Set-Up Meter

Setting

16022149

Magnetron 1 (Top rear) at 230 VAC

Magnetron 3 (Bottom) at 230 VAC

All wires connected to H.V. board

VAC E5 (Red wire)

VAC J4 pin 4 (Black wire)

Probe Placement Results

Test mode 1 off – line voltage

& J4 pin 2 (Red wire)

& J4 pin 6 (Black wire)

Test mode 1 on – 0 volts

Test mode 3 off – line voltage Test mode 3 on – 0 volts

Page 19

Component Testing Procedures

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

WARNING

Three Magnetron Models

# 1

# 2

# 1

# 3

# 1

Bottom Magnetron

Right Transformer

Right Capacitor

Diode

Right Triac

# 2

# 1

# 2

# 3

H.V. System # 1 H.V. System # 2 H.V. System # 3

Top Rear Magnetron

Center Transformer

Bottom Center Capacitor

Diode

Center Triac

Top Front Magnetron

Left Transformer

Top Left Capacitor

Diode

Left Triac

Page 20

Component Testing Procedures

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

WARNING

Two Magnetron Models

# 1

# 3

# 1

H.V. System # 1 H.V. System # 3

Top Rear Magnetron

Left Transformer

Top Capacitor

Diode

Left Triac

# 3

Bottom Magnetron

Right Transformer

Bottom Capacitor

Diode

Right Triac

# 3

16022149

Page 21

Power Testing Procedure

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

All Amana and Menumaster microwave oven power outputs are rated using the IEC705 standards. Using the IEC705 test method requires precision measurements and equipment that is not practical to be performed in the field. Using the test shown below will indicate if the oven performance is satisfactory.

WARNING

Test equipment required:

• 1000 ml test container and thermometer (Amana power test kit R0157397 Fahrenheit / Menumaster power test kit M95D5 Celsius).

• Digital watch / watch with a second hand for use on ovens with electromechanical timers.

Important Notes:

• Low line voltage will cause low temperature rise / power output.

• Ovens must be on a dedicated circuit, properly grounded, and polarized. Other equipment on the same

circuit may cause a low temperature rise / power output.

• This test and results are not a true IEC705 test procedures and are only intended to provide servicers with an easy means of determining if the microwave oven cooking output is correct.

Procedure

1. Fill the test container to the 1000 ml line with cool tap water.

NOTE: Water temperature should be approximately 60°F / 16°C

2. Using the thermometer, stir water for five to ten seconds; measure, and record the temperature (T1).

3. Place test container of water in the center of oven cavity and close door.

4. Heat the water for a 33-second full power cycle.

NOTE: Use a digital watch or a watch with a second hand for ovens with electromechanical timers.

5. At end of the cycle, remove test container. Using the thermometer, stir water for five to ten seconds and record temperature (T2).

6. Subtract the starting water temperature (T1), from the ending water temperature (T2) to obtain the temperature rise (

∆

T).

7. If the temperature rise ( fails to meet the minimum temperature rise, test the line voltage to verify it is correct. Then repeat steps 1 - 6 making sure to change the water. If the temperature rise ( the oven will require service.

∆

T) meets or exceeds the minimum, the test is complete. If the temperature rise (∆T)

∆

T) fails to meet the minimum temperature rise again

Minimum Temperature Rise at Thirty -Three (33) Seconds Run Time

∆

T Cooking

(°F) Power Output (°F) Power Output (°C) Power Output (°C) Power Output

10 .................1000 20 ................. 2000 5 ...............1000 11 ............ 2000

11 .................1100 21 ................. 2100 5.5............. 1100 11.5 ......... 2100

12 .................1200 22 ................. 2200 6.5............. 1200 12 ............ 2200

14 .................1400 24 ................. 2400 7.5............. 1400 13 ............ 2400

17 .................1700 25 ................. 2500 9.5............. 1700 13.5 ......... 2500

18 .................1800 27 ................. 2700 10.............. 1800 15 ............ 2700

19 .................1900 30 ................. 3000 10.5........... 1900 16.5 ......... 3000

∆

T Cooking ∆T Cooking

∆

T Cooking

Page 22

Display Diagnostics

WARNING

To avoid risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

CAUTION

1. All repairs as described in this troubleshooting section are to be performed only after the caution procedures one through eight listed below have been followed.

2. Check grounding before checking for possible causes.

3. Be careful of the high voltage circuit.

4. Discharge high voltage capacitor.

5. When checking the continuity of the switches or the high voltage transformer, disconnect one lead wire from these parts and then check continuity with the AC plug removed. To do otherwise may result in a false reading or damage to your meter.

6. Do not touch any parts of the circuitry on the P.C. Board circuit since static electric discharge may damage this control panel. Always touch yourself to ground while working on this panel to discharge any static charge in your body.

7. 240/230 VAC is present in the high voltage circuit board, power relay and primary circuit of low voltage transformer.

8. When troubleshooting, be cautious of possible electrical hazard.

9. When testing convection operation, convection fan may start at any time or if oven is hot.

Error Codes

During operation, the display may show the following service codes:

NOTE: Before scheduling service for any error codes, instruct customer to unplug oven for 1 minute,

reconnect power, and retest. If unit operates properly, no service call is required.

Display Description Corrective Action

Err1 Failed H.V. Board Replace H.V. board. Err2 Shorted Touch Panel

Failed H.V. Board Shorted Display Board

Shorted Cable HV to Display Board Err3 Failed H.V. Board Replace H.V. board. Err4 Failed H.V. Board Replace H.V. board. Err5 Shorted Touch Panel

Err6 Failed H.V. Board Replace H.V. board. HOT

Door Door Interlock Primary Switch

Replace Touch Panel. Replace H.V. board. Replace Display Board. Replace Cable.

NOTE: If Touch Panel is pressed for more than 30 seconds, this error

code will appear.

1. Disconnect oven from power supply.

2. Disconnect side touch panel connector from display board (J5).

3. Reconnect oven to power supply.

4. If “Err5” reappears after 30 seconds, replace top touch panel.

5. If “Err5” does not reappear after 30 seconds, replace side touch panel.

• Open TCO (magnetron).

• Blower motor inoperative.

• Restricted air filter.

• High ambient temperature.

• Oven operated empty or with light loads.

• Broken or loose wire.

• H.V. board inoperative.

• Verify latch mechanism moves freely on door.

• Verify J1 connector on display board is properly seated.

• Test interlock switch assembly and perform door adjustment if

necessary.

• Replace interlock switch assembly.

16022149

Page 23

Service Test

NOTE: Unit must be in OFF condition or INITIAL power up mode.

To Enter Service Test Mode, oven door must be closed.

NOTE: Pads will not beep when accessing Service Test Mode.

To EXIT Service Test Mode press STOP/RESET pad.

MC units

REG MENU

MISC

Press Hidden Pad as indicated above on touch panels.

0 = Deactivated 1 = Activated

High Voltage System # 1

Tog gles Magn etron 1 (Top Rear) ON/OFF.

High Voltage System # 2

Toggles Magnetron 2 (Top Front) ON/OFF.

1 3 5 7 9

Timer counts up to 62 seconds and unit shuts off.

PREHEAT STANDBY

READY

LEVEL

Displays actual Amperage, will vary by model

PREH EAT STANDBY

READY

Displays actual Amperage, will vary by model

PREH EAT STANDBY

READY

LEVEL

STGITEM POWERQTY

LMT

Component Evaluation

Indicates Service Mode

If no Amperage, check for line voltage at H.V. transformer primary winding. If no voltage, check: Interlock switch (secondary) Tri ac 1 H.V. board (relay K8 if 230 VAC, and triac 1 drive voltage T1 - G) Wiring

If voltage is present, check:

H.V. components and wiring.

If no Amperage, check for line voltage at H.V. transformer primary winding. If no voltage, check:

Interlock switch (secondary)

Tri ac 2

H.V. board (relay K4 if 230 VAC, and triac 2 drive voltage T1 - G) Wiring

High Voltage System # 3

Toggles Magnetron 3 (Bottom) ON/OFF.

Timer counts up to 62 seconds and unit shuts off.

If voltage is present, check:

H.V. components and wiring.

Displays actual Amperage, will vary by model

If no Amperage, check for line voltage at H.V. transformer primary winding. If no voltage, check:

Interlock switch (secondary)

Triac 3

PREHE AT STANDBY

READY

LEVEL

H.V. board (relay K6 if 230 VAC, and triac 3 drive voltage T1 - G)

Wiring

If voltage is present, check:

H.V. components and wiring.

Page 24

Service Test

Pres

NOT ACTIVE

ITEM

Dis pla

STG

QTY

1 2 3 4

LMT

POWER

Component Ev alua tion

This mode is NOT active with these models.

To ggles Blow er Motor An tenna M otor(s ) Cavity Light (if applicable) ON/OFF.

NOT ACTIVE

Displays # of Magn etron Hours.

Displays # of Door Cycles with a 1 to 1 ratio round ed to the nearest ten

ITEM

STG

QTY

1 2 3 4

LMT

POWE R

If no fan operation, check: B lower motor an d w heel An tenna motor Cavity light (if applicable) H.V. board relay K1 - 230 V

Wiring

STG

QTY

1 2 3 4

STG

1 2 3 4

STG

1 2 3 4

LMT

QTY

LMT

QTY

LMT

POWER

This mode is NOT active with these models.

Clears Hours and Cycles (press START to activ at e)

ITEM

(Resets to 0).

Pressing 0 will clear CALL SERVICE display.

STG

QTY

1 2 3 4

LMT

POWER

CALL is displayed for 1 second SErv is displayed for 1 second. Then the display will be OFF for 5 seconds.

This will continue until Ca ll S er v ic e i s c le ar e d from the display.

Page 25

Service Information

To avoid risk of electrical shock, personal injury, or death, disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

Proper Handling of Magnetron Tubes

CAUTION

A magnetron tube, like a radio or television tube must be handled with a reasonable amount of care. When handling a tube, always handle by the housing only. Use caution not to touch or strike the ceramic portion at the top. The carton used to ship service replacement tubes is reusable.

Magnetron Failure Modes

Magnetron failures that have been identified are generally grouped into categories shown below.

1. Shorted Air - This is a case where the tube has had the vacuum

envelope destroyed and air has entered the tube. This will cause internal arcing and high secondary current if high voltage is applied.

R.F. Capacitors - May short to chassis. This condition

will also cause loss of high voltage.

WARNING

2. Open Heater (Filament) - Can be determined by a ohmmeter when transformer leads are disconnected. Resistance is normally less than one ohm; filament does not short internally. Any tube removed should be checked since usage tends to make the filament more fragile. Later handling and shipping may open the filament and thereby mask the true failure mode when checked at the factory.

3. Low Power - Caused by “wearout” of the emission characteristics of the directly heated cathode. Symptoms are: (1) tube current will take longer to get to operating point then a new tube (normally about 2 - 3 seconds), (2) tube current does not get high enough to cause the tube to oscillate with normal line voltage, (3) oven produces low power into a load, two-thirds or less than normal.

4. Physical Damage - Caused by mishandling of magnetron tube.

Fins

Magnet

Output Antenna

Ceramic

Terminals/R.F. Capacitors

Not Replaceable

Serial Number

Anode Block

Page 26

Service Information

To avoid risk of electrical shock, personal injury, or death, disconnect power to oven and discharge capacitor before servicing, unless testing requires it.

Operating Instructions for the Holaday HI1501, HI1510, HI1710, and HI1801

Purpose of these monitors is to check radiation leakage around microwave oven door or other places where radiation could possibly occur.

Instrument measures radiation leakage in milliwatts per square centimeters (mW/cm used with the 2" (5 cm) cone spacer. Water load of 275 cc. (approximately 1 the oven and used as a load during leakage tests.

Operate the instrument on its internal 9 Volt battery power supply. “Range” switch is used on low and high while using test probe. On an oven with an unknown leakage, use high scale then switch to low scale and test for low leakage. “Bat Test” switch is used to check the battery and probe on the Holaday Instruments. If either is faulty, meter needle will not read above “Test Minimum” or battery mark on meter. Holaday Instrument has a probe test switch position. Meter needle must indicate in the “OK probe test” portion of the scale when in this position. Zero control is used to zero the needle. “ON-OFF” switch provides a means of turning the operating voltage on or off. “Range Multiplier” switch provides a means of selection either 0-2 or 0-10 and 0-100 on the Holaday Instruments sensitivity ranges.

). Probe should be

/3 cup), is to be placed in

WARNING

Hold probe perpendicular to cabinet door. Place cone of probe on the door and/or cabinet door seam and move along the seam. If leakage of the oven is unknown, move probe slowly. Proceed with care in order not to exceed a full scale reading of meter. When testing near a corner or access area of door, keep probe perpendicular to the areas making sure probe end at the base of the cone does not get closer than 2” (5cm) to any metal. If it does, an erroneous reading may result.

Always use the 2” (5cm) spacer with probe. Also, always proceed carefully in areas of high leakage or probe can be accidentally burned-out. Rotating antenna causes high peaks of energy. Although meter has averaging capabilities, probe will react instantaneously to peak power changes which will cause burn-out.

Test probe must be held by the grip portion of the handle, otherwise a false reading may result if operators hand is between the handle and probe.

If oven is likely to have a large amount of leakage, approach oven slowly with the probe, while observing meter. This is achieved by holding the probe two or three feet from oven surface or gap between door and oven body while observing meter. When high leakage is expected, do not move probe horizontally along the oven surface. This could cause possible probe burn-out. Greatest leakage is generally found at the corners. After maximum leakage is established to be within the meter scale range, then the probe may be moved horizontally around the door surface.

16022149

Page 27

Microwave Leakage Testing

To avoid risk of electrical shock, personal injury, or death, disconnect power to oven and discharge capacitor before servicing, unless testing requires power.

WARNING

Measurement with the Outer Panel

WARNING

Check for radiation leakage after servicing. Should the leakage be more than 4 mW/cm Maytag immediately. After repairing or replacing any radiation safety device, keep a written record for future reference, as required by D.H.H.S. and HEW regulations. This requirement must be strictly observed. In addition, the leakage reading must be recorded on the service repair ticket while in the customer’s home.

Equipment

• Electromagnetic radiation monitor

• 600 cc glass beaker or plastic power bowl

inform

Removed

WARNING

Avoid contacting any high voltage components.

Whenever you replace the magnetron, measure for radiation leakage before the outer panel is installed and after all necessary components are replaced or adjusted. Special care should be taken in measuring around the magnetron.

Measurement with a Fully Assembled Oven

Procedure for Measuring Radiation Leakage

Note before measuring:

• Do not exceed meter full scale deflection. Leak monitor should initially be set to the highest scale.

• To prevent false readings the test probe should be held by the grip portion of the handle only.

• The scan speed is equal to one inch per antenna revolution or one inch per second if antenna speed is unknown.

• Areas to be checked are all door seal areas and any venting parts.

• Leakage with the outer panel removed ...4mW/cm or less.

• Leakage for fully assembled oven with door normally closed ...4 mW/cm

• Leakage for a fully assembled oven (before the latch switch (primary) is interrupted) while pulling the door ... 4 mW/cm

1. Pour 275 cc ±15 cc (9 oz ±1/2 oz) of 20°C ± 5°C (68°F ± 9°F) water in a beaker which is graduated to 600 cc and place the beaker in the center of oven.

2. Set the radiation monitor to 2450 MHz and use it following the manufacturer’s recommended test procedure to assure correct results.

3. While measuring the leakage, always use the two inch (5 cm) spacer supplied with the probe.

4. Press the start pad or turn on the timer and with the magnetron oscillating, measure the leakage by holding the probe perpendicular to the surface being measured.

or less.

After all components including the outer panel are fully assembled, measure for radiation leakage around the door periphery, the door viewing window, the exhaust opening, and air inlet openings.

Record Keeping and Notification After Measurement

1. After any adjustment or repair to a microwave oven, a leakage reading must be taken. Record this leakage reading on the repair ticket even if it is zero.

2. A copy of the repair ticket and the microwave leakage reading should be kept by the repair facility.

Page 28

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Door Handle

Remove door handle by removing plactic plugs to gain access to set screws. Loosen set screws (3/32 inch allen screws), one located to the left of the door handle and one located on the bottom of the door handle.

Tighten first

Plastic plugs

NOTE: When replacing door handle, tighten side set

screw first and apply Loctite®.

NOTE: If set screws are removed, the set screw with

the flat end must be used in the bottom of the door handle.

Door

1. Remove latch handle.

2. Remove outer door ring assembly from inner door ring by removing 10 y-drive screws.

NOTE: When reinstalling outer door, tighten screws in

pattern as shown above.

Pointed tip

Flat tip

WARNING

Inner Door Ring Assembly

1. Remove latch handle.

2. Remove outer door assembly.

3. Remove 5 hinge screws securing inner door ring assembly.

Door Weldment

The door ring assembly consists of the inner door ring, the inner door panel, and latch assembly. These components are available only as a complete assembly.

Hinge

1. Remove outer case.

2. Remove door latch handle.

3. Remove outer door assembly.

4. Remove nine hinge mounting screws from hinge (5 on the front, 4 on the side).

NOTE: Reinstall foam gasket on side of hinge when

reinstalling.

5. When reinstalling hinge mounting screws, keep the side screws loose and the front screws tight, close door, press door against oven on the hinge side and tighten side hinge mounting screws in the sequence shown below.

Inner Door / Window Assembly

Spring

Inner Door Ring Assembly

Latch Assembly

Outer Door

The outer door assembly consists of the outer door, outer window, and lens retainer. These components are available only as a complete assembly.

Page 29

Disassembly

WARNING

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Outer Case

1. Remove screws securing outer case to chassis, see illustration below.

2. Slide outer case back and lift off.

3. Reassemble outer case in reverse order.

Top Touch Panel Assembly

1. See “Component Location” Figure 1, for location.

2. Remove outer case.

3. Disconnect wire connectors at display board.

4. Remove screws securing top touch panel to unit.

5. Remove screws securing display board to top touch

Back Panel

1. Remove outer case.

2. Remove screws securing back panel.

3. Reassemble back panel in reverse order.

panel assembly.

6. Disconnect touch panel connector from display board.

7. Reassemble touch panel in reverse order.

Side Touch Panel Assembly

1. See “Component Location” Figure 1, for location.

2. Remove outer case.

3. Disconnect ribbon cable from display board.

4. Remove mounting screws securing side touch panel to unit.

5. Reassemble touch panel in reverse order.

Back Panel

Outer

Case

Mounting

Screw

Splatter Shield

1. See “Component Location” Figure 2, for location.

2. Place fingers on front of shield, push forward, and down.

• When removing and replacing splatter shield, be

careful not to bend antenna.

High Voltage Circuit Board

1. See “Component Location“ Figure 3, for location.

2. Remove outer case.

3. Unplug connectors.

4. Disconnect wires from terminal locations on H.V. board.

5. Release mounting clips and remove board from plastic supports.

6. Reassemble high voltage board in reverse order.

Clip

Pin 1

Clip

3. Reinstall splatter shield by fitting tabs into slots at top of oven cavity back. Lift and press front of shield until shield snaps into place.

Pin 1

Clip

Pin 1

Clip

Pin 1

Pin 28

Pin 50

Pin 1

Clip

Pin 1

Clip

Pin 1

Clip

NOTE: When reassembling, verify cable connection

with illustration of cable locations.

Page 30

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Interlock Switch Module

1. See “Component Location” Figure 1, for location.

2. Remove outer case.

3. Disconnect wiring from interlock switch assembly.

4. Remove mounting screws securing interlock switch.

5. When replacing assembly, all wires must be connected before operating oven.

NOTE: When the line fuse is blown interlock switch

module must be replaced.

WARNING

Top Rear Magnetron

1. See “Component Location” Figure 2, for location.

2. Remove outer case and back panel.

3. Remove wires from TCO and magnetron.

4. Remove screws securing top rear exhaust duct to cavity top. Do not attempt to remove exhaust duct at this time.

5. Remove magnetron mounting nuts.

6. Remove magnetron and exhaust duct.

7. Remove allen screws securing magnetron thermal cutout bracket to magnetron.

8. When replacing magnetron, verify wire mesh gasket is reinstalled properly.

NOTE: Slide exhaust duct on magnetron before

reinstalling magnetron.

Top Front Magnetron

Adjustment

1. To adjust interlock switch assembly, close door.

2. Loosen bottom and top screw on the interlock switch assembly, allowing switch assembly to move in or out.

3. With door closed, push forward on interlock assembly to engage door latch. Then pull back on interlock assembly until door is "snug" against front oven cavity and tighten bottom screw first, then top screw.

4. Door will remain latched when proper adjustment is made.

NOTE: If door is not properly adjusted display will

indicate

Display Module

1. See “Component Location” Figure 1, for location.

2. Remove outer case.

3. Remove top touch panel, see “Top Touch Panel” Assembly procedure.

4. Remove screws securing display module to top touch panel.

5. Reassemble display module in reverse order.

door

when the door is closed.

1. See “Component Location” Figure 2, for location.

2. Remove outer case and back panel.

3. Remove wires from TCO and magnetron.

4. Release center flow divider tabs from bottom flow divider and tilt center divider upward.

5. Remove screws securing top front exhaust duct to cavity top. Do not attempt to remove exhaust duct at this time.

6. Remove magnetron mounting nuts.

7. Remove magnetron, exhaust duct, and center flow divider.

8. Remove allen screws securing magnetron thermal cutout bracket to magnetron.

9. When replacing magnetron, verify wire mesh gasket is reinstalled properly.

NOTE: Slide exhaust duct and center flow divider on

magnetron before reinstalling magnetron.

Bottom Magnetron

1. See “Component Location” Figure 2, for location.

2. Remove outer case and back panel.

3. Remove wires from TCO and magnetron.

4. Remove screws securing bottom exhaust duct to cavity bottom.

5. Lay oven on it’s left side.

6. Remove bottom access panel.

7. Remove magnetron mounting nuts.

8. Remove magnetron and exhaust duct.

9. When replacing magnetron, verify wire mesh gasket is reinstalled properly.

NOTE: Slide exhaust duct on magnetron before

reinstalling magnetron.

Page 31

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Magnetron Cutout (TCO)

1. See “Component Location” Figure 2, for location.

2. Remove outer case.

3. Remove wiring from selected thermal cutout.

4. Remove screws securing thermal cutout.

5. Reassemble thermal cutout in reverse order.

Cavity Thermal Cutout (TCO)

1. Remove outer case.

2. Remove left side air exhaust panel.

3. Remove wires from TCO.

4. Remove TCO.

5. Reassemble thermal cutout in reverse order.

Triacs

1. See “Component Location” Figure 3, for location.

2. Remove outer case and back panel.

3. Remove wires from terminals of selected triac.

4. Remove screws securing triac to chassis.

5. Reassemble triac in reverse order.

WARNING

Microwave Blower Wheel and Motor

1. Remove outer case and back panel.

2. Remove wiring from blower motor terminals.

3. Remove screws securing blower assembly to bracket.

4. Remove assembly from oven.

5. Loosen allen set screw securing blower wheel to motor shaft.

6. Remove blower wheel.

7. Remove screws securing motor to scroll.

8. Reassemble blower wheel and motor in reverse order.

NOTE: When reinstalling blower wheel, push blower

wheel on shaft, tighten, and rotate to insure clearance between blower wheel, and blower housing.

Fan Blade

Motor

Capacitor

1. See “Component Location” Figure 3, for location.

2. Remove outer case and back panel.

3. Discharge capacitor and remove wires from terminals.

4. Remove capacitor bracket mounting screw.

5. Reassemble capacitor in reverse order.

NOTE: Capacitor bracket must be installed into

indented slot located on cavity wall.

Transformer

1. See “Component Location” Figure 3, for location.

2. Remove outer case and back panel.

3. Remove screws securing transformer to chassis.

4. Pry upward and back to release transformer from chassis.

5. Remove wire connections from transformer.

NOTE: When placing transformer back into chassis.

Front portion of transformer must slide into base pan tabs.

6. Reassemble transformer in reverse order.

Housing

Wheel

Blower Assembly

Fan Blade

1. Pull blade off shaft.

2. When reinstalling blade, push blade on shaft and rotate to insure clearance between fan blade and motor mounting bolt.

Auto Transformer

1. See “Component Location” Figure 2, for location.

2. Remove outer case and back panel.

3. Remove screw securing auto transformer mounting bracket.

4. Reassemble auto transformer in reverse order.

Page 32

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Top Antennas

1. See “Component Location” Figure 1, for location.

2. Remove outer case and grease shield.

3. Remove gear retainer from plastic gear.

4. While supporting antenna, carefully pry gear from antenna shaft.

5. Remove nylon washer from antenna shaft.

6. Remove antenna from oven cavity.

NOTE: Important items when re-installing antenna:

• Place nylon washer between gear and cavity.

• On 3-tube ovens, top gears must be aligned as

shown below.

WARNING

Bottom Antenna

1. Remove oven tray, see “Oven Tray Removal” procedure.

2. Lay oven on it’s left side and open oven door.

3. Remove bottom access cover.

4. Remove gear retainer from plastic gear.

5. While supporting antenna, carefully pry gear from antenna shaft.

6. Remove nylon washer from antenna shaft.

7. Remove antenna from oven cavity.

NOTE: Important items when re-installing antenna:

• Place nylon washer between gear and cavity.

Antenna Motors

Retainer, gear

Front Gear (Gray)

1. Remove outer case from oven.

2. Remove wires connected to antenna motor.

3. Remove screws securing motor assembly to cavity.

4. Remove motor from unit.

5. Reassemble in reverse order.

NOTE: On 3-tube models, top antenna gears must be

aligned as illustrated in “Top Antennas” procedure.

Oven Tray Removal / Installation

Nylon washer

Blue tips Top Front ONLY

Three Tube Ovens

Retainer, gear

1. Using a utility knife, cut RTV seal around perimeter of tray.

2. Using a heat gun, apply heat to front lip of tray to release hot melt glue.

3. Pry upward on front lip of tray to remove.

4. Thoroughly remove all traces of old RTV and degrease the tray, cavity bottom, walls, and front flange.

5. Place tray in center of cavity. Do not allow tray to touch side walls.

6. Apply a generous bead of RTV sealent around perimeter of tray.

7. Apply a light water spray to the fresh RTV sealant.

8. Using RTV scrapper, Amana part # R0000039, remove excess RTV.

NOTE: Allow RTV to set for 1 hour before using.

Front Gear (Gray)

Nylon washer

Two Tube Ovens

Page 33

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Fuse

1. See “Component Location” Figure 3, for location.

2. Remove outer case.

3. Replace fuse and reassemble in reverse order.

NOTE: If fuse needs replaced, interlock assembly must

be replaced.

WARNING

Replacing Oven Light Bulb

To avoid electrical shock which can cause severe personal injury or death, unplug power cord or open circuit breaker to oven before replacing light bulb. After replacing light bulb, restore power.

WARNI NG

Power Cord

1. Remove outer case and back panel.

2. Disconnect wiring.

3. Remove strain relief by compressing with pliers.

4. Remove power cord.

5. Reassemble power cord in reverse order.

Light Socket

1. Remove outer case.

2. Remove screws securing lamp cover bracket.

3. Unscrew light bulb from socket.

4. Disconnect wire terminals to light socket.

5. Remove screw securing light socket to light retainer.

6. Reassemble light socket in reverse order.

To avoid personal injury or property damage, observe the following:

• Allow oven and light bulb to cool.

• Wear gloves when replacing light bulb.

Tools Needed

• Protective gloves

• Phillips screwdriver

• 40-watt, 120-volt appliance bulb (available from authorized distributor or servicer)

CAUTION

Relay

1. Remove outer case from oven.

2. Disconnect and label wire terminals to relay.

3. Remove screws securing relay to back of oven cavity.

4. Reassemble in reverse order.

Line Filter

1. Remove outer case from oven.

2. Disconnect and label wire terminals to line filter.

3. Remove screws securing line filter to back of oven cavity.

4. Reassemble in reverse order.

To remove bulb, turn in direction shown.

1. Remove screw from access cover on top left wall of oven exterior. Remove access cover.

2. Remove old bulb and replace with new bulb.

3. Replace access cover and screw by reversing

procedure in step 1.

Page 34

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

WARNING

Component Location

Display Module

Touch Panel (Top)

Antennas

Top front antenna on 3 tube ovens are blue tipped. All other antennas are plain tipped.

Touch Panel (Side)

Interlock Switch Assembly

Figure 1

Page 35

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Splatter Shield

Oven Tray

WARNING

Top Exhaust Duct

Bottom Exhaust Duct

Filter

Rear Flow Divider

Top Flow Divider

Magnetrons

Bottom Flow Divider

Magnetron TCO's

Figure 2

Page 36

Disassembly

To avoid the risk of electrical shock, personal injury or death; disconnect power to oven and discharge capacitors before following any disassembly procedure.

Oven Light

Socket

WARNING

Auto

Transformer

Relay

Fan Blade

Fan Motor

High Voltage

Board

Tria c

Term inal

Block

Fuse Block

and Fuse

Capacitor

Back Panel

Transformer

Figure 3

Amana RC520S, RC518SU, RC5MCTP, RC5PHBU, RC5PHB Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual