Kleenmaid MWG4511 Service Manual

Cover Page

MICROWAVE OVEN

SERVICE MANUAL

CAUTION

BEFORE SERVICING THE UNIT，READ THE SAFETY PRECAUTIONS IN THIS

MANUAL.

REPAIR INSTRUCTION

1 SAFETY·································································2

1.1 Danger ·················································································2

1.2 Caution!················································································2

1.3 Leak test (leak detection measurement) ·······························3

COMPONENTS··················································· 4

High-voltage diode ·····························································4

High-voltage capacitor························································5

High-voltage transformer ····················································6

Magnetron·········································································· 7

Safety switches ··································································8

REPAIR ·······························································9

Removing ························································10

Removing
Removing ···································· 10
Removing ·················································· 10

Removing ······························· 11

Removing Orifice Assembly ··············································· 11

FAULT DIAGNOSTICS······································· 14

Troubleshooting plan - when getting a complaint··············· 14

Troubleshooting plan - ··· 16

Troubleshooting plan - oven does not operate at all···········

Troubleshooting plan - ··········· 1

Troubleshooting plan - output power is low························· 20

··········· 2

Page 1

2

2.1

2.2

2.3

2.4

2.5

3

3.3

3.4

3.5

3.6

3.7

3.8

4

4.1

4.2

4.3

4.4

4.5

4.6

Outer Case

Power Supply Cord ······························· 10

·····

·····

Control Panel Assembly

Door Assembly

High-voltage Transformer

probable defective control circuit

oven does not start cooking

Troubleshooting plan - oven does not cook properly

Removing ··················· 3.9 High-voltage Capacitor and Diode 11

Removing 3.10 Air guide Assembly··········································· 11

Removing ··············································· 12 3.11 Magnetron

···

··

·

··

Removing 3.12 Pcb Assembly··················································· 12

Removing ······························· 13.13 Turntable Motor

·········

·····

··

Removing Trim Assembly 3.1

Removing under Air guide3.2

··················································9

················································9 ·

3

9

1

18

··········· 2 4.7 Troubleshooting plan - grill

···········

······················

····

2

1 SAFETY

1.1 Danger

Repairs may be carried out by an electrician only!

Improper repairs may endanger and injure the user!

To prevent electric shocks, always comply with the following

information:

• Do not touch the housing and frame if the appliance is faulty,

• Do not touch any modules in the appliance, even modules can be
live!

• Before commencing repairs, always disconnect the appliance from
the power supply!

• If tests have to be performed while the appliance is live, always

use a residual-current-operated circuit-breaker!

• The protective conductor connection must not exceed the standard

values! This connection is extremely important for personal safety
and function of the appliance!

• When repairs are complete, conduct a test in accordance with
VDE 0701 or national regulations!

• When repairs are complete, conduct a function test!

• When repairs are complete, conduct a leak rate test!

1.2 Caution!

Always comply with the following instructions to prevent damage to

the appliance or to components:

• Comply with ESD instructions!

• Never attempt repairs by randomly replacing components!

• Always proceed systematically and follow the troubleshooting
instructions!

• Do not test the high-voltage circuit while the appliance is running –
Danger of death!

• Discharge the high-voltage capacitor before testing!

• Discharge the high-voltage capacitor by shorting across the two
terminals with an insulated srewdriver when replacing or checking,

because an electric charge remains in the high-voltage capacitor for
30 seconds after the oven stops.

the housing and frame may be live!

Page 2

1.3 Leak test (leak detection measurement) 1.3 Leak test (leak detection measurement)

The leak rate is the microwave energy which escapes despite the
intact sealing systems.

The leak rate is the microwave energy which escapes despite the
intact sealing systems.

The leak rate is measured as an energy density with suitable
measuring instruments at a distance of 5 cm. The unit of
measurement is mW/cm.

2

The leak rate is measured as an energy density with suitable
measuring instruments at a distance of 5 cm. The unit of
measurement i

The limiting values for the permitted measured values, as well as
the measurement conditions, have been specified in the VDE
regulation 0700/Part 25 and are as follows:

The limiting values for the permitted measured values, as well as
the measurement conditions, have been specified in the VDE
regulation 0700/Part 25 and are as follows:

1.3.1 Normal operation with load 1.3.1 Normal operation with load

Setting: maximum power setting of the appliance Setting: maximum power setting of the appliance

Load: 275 cm3 water Load: 275 cm

Permitted limiting value: 5 mW/cm2 Permitted limiting value: 5 mW/cm

Measurement distance: 5 cm Measurement distance: 5 cm

2

3

water

2

1.3.2 Abnormal operation (no-load operation)

Setting: maximum power setting of the appliance

Load: none (no-load operation)

Permitted limiting value: 10 mW/cm

2

Measurement distance: 5 cm

Page 3

Set to insulation resistance.

2 COMPONENTS

2.1 High-voltage diode

Blocking direction = infinite.

The high-voltage diode can be tested like a standard diode.

Use an EHG tester for this.

• Full continuity in conducting direction.

• Infinite in blocking direction.

Set to insulation resistance.

Conducting direction = full continuity.

Page 4

2.2 High-voltage capacitor

The high-voltage capacitor can be tested by ‘ohmic’ measurement’
(resistance measurement range 20 ΜΩ).

A correctly functioning capacitor indicates transient continuity.

The resistance then increases proportionally with the load.

A defective capacitor (e.g. short-circuit) indicates permanent
continuity.

The measuring instrument must indicate infinitely between the
connection and housing.

Page 5

2.3 High-voltage transformer

This transformer supplies the heater voltage for the magnetron and
the operating voltage for doubling the voltage.

• Input voltage 230 V

• Heater voltage approx. 3.3 V

• Operating voltage approx. 2300 V

The operating voltage cannot be measured!!

Heater voltage of
approx. 3.3V

Primary side 230V
of input voltage

Page 6

2.4 Magnetron

The magnetron can be tested by ‘ohmic’ measurement´ only.

The volume resistance of the terminals F and FA should be less than 1
Ω.

The insulation resistance between the two terminals and the housing
should be infinite.

Measure the resistance with an EHG tester.

Note:

An internal flashover (short-circuit between cathode and anode)
cannot usually be established by taking a measurement.

This is not indicated until the appliance is switched on when high
voltage is applied to the magnetron.

It may also be possible to detect the fault by loud humming noises.

Before installing the magnetron, ensure that the metal seal is ok and is
seated correctly.

Page 7

2.5.1 Switching sequence

2.5 Safety switches

Each door switch independently switches off the power supply for the
microwave oven when the door is opened.

Microwave ovens usually feature at least three safety switches.

The switching sequence is specified by the arrangement and is as
follows.

These switches are supported by the switch brackets.

The basic function of these switches is to interrupt microwave
generation as soon as the door is opened.

One of the three switches is the short-circuit switch. It monitors one of
the two other switches and actuates the appliance safety device if the
monitored switch does not function.

Switching
sequence

Open door Close door

1.) Safety switch on right Short-circuit switch

2.) Safety switch on left Safety switch on left

3.) Short-circuit switch Safety switch on right

In this case the appliance is disconnected from the power supply and
can no longer be switched on.

Page 8

3 REPAIR

3.1 Removing Trim Assembly

1. Open the door, remove the Screw B from the installation hole.

2. Pull the Microwave oven out.

3. Remove the screws holding the Trim Assembly to the Cavity

Caution!:

Discharge the high-voltage capacitor before testing!

Page 9

Installation Hole

Screw B

Assembly.

3.2 Removing Under Air Guide

1. Remove the screws holding the under Air Guide to Cavity Assembly.

under Air Guide

3.3 Removing Outer Case

1. Disconnect the power supply cord from the outlet.

2. Remove the screws from the rear and along side edges of the

3.4 Removing Power Supply Cord

1. Remove the outer case.

2. Disconnect two terminals, and remove one screw of the earth

terminal.

case. The outer case must be moved backward to be lifted off.

3.5 Removing Control Panel Assembly

1. Disconnect the leadwire from the PCB sub assemble

2. Remove the screws for securing the control panel.

3. Lift control panel assemble from the oven by the tab unhooked.

.

3.6 Removing Door Assembly

1. Open the door.

2. Remove two screws holding the Hinge to the cavity Assembly.

CAUTION : Be careful not to damage Door C by screwdriver.

3. Lift up and pull the door.

Remove door Assembly

Remove door Assembly

Page 10

Page 11

3.8 Removing Orifice Assembly

1. Discharge the high voltage capacitor.

2. Disconnect the leadwire from fan motor, noise filter and high voltage

capacitor.

3. Remove the two screws holding the orifice assembly to the oven

cavity and remove the high voltage diode earth screw.

4. Remove the screw of the capacitor bracket.

5. Remove the two screws holding the fan motor assembly to the

.Orifice Assembly

3.7 Removing High Voltage Transformer-

1. Discharge the high voltage capacitor.

2. Disconnect the leadwire from magnetron, high voltage transformer,

and capacitor.

3. Remove the screw holding the high voltage transformer to the

baseplate.

3.9

1. Discharge the high voltage capacitor.

2. Disconnect the leadwire from fan motor, noise filter and high voltage

capacitor.

3. Remove the screw holding the Orifice Assembly to the oven cavity

and remove the high voltage diode earth screw.

4. Remove the screw holding the high voltage capacitor bracket.

3.10 Removing Air Guide Assembly

1. Disconnect the leadwire from lamp, A.C Relay and monitor resistor

2.

and magnetron.

Remove the screw to the cavity.

Removing High-Voltage Capacitor and Diode

3.11 Removing Magnetron

1. Disconnect the leadwire from the high voltage transformer and

high voltage capacitor.

2. Remove the air guide.

3. Carefully remove the mounting screws holding the magnetron

and the waveguide.

4. Remove the magnetron until the tube is clear from the waveguide.

Waveguide

Magnetron
Gasket

Magnetron

Dome

Waveguide
Bracket

Magnetron

3.12 Removing PCB Assembly

1. Remove the control panel assembly from the cavity.

2. Remove the screws which hold the PCB to the

3. Diconnect the flat cable from the PCB and take off the PCB.

control panel.

Page 12

3. 1 Removing Turntable Motor 3

1. Remove the glass tray.

2. Remove the pully shaft VERY CAREFULLY.

3. Lay the unite down on its back.

4. Remove the turntable motor cover.

The turbtable base cover is easily removed by pinching the six parts

with a wire cutting.

5. Disconnect the leadwire from the turntable motor terminals.

6. Remove the screw securing the turntable motor to the oven cavity

assembly.

7. After replacing the motor, rotate the removed turntable motor cover.

8. Fit the turntable motor cover s projecting part to the base plate slit.

NOTE:

’

1. Remove the wire lead from the turntable motor VERY CAREFULLY.

1. Be sure to grasp the connector, not the wires, when removing.

Page 13

Remove Turntable Motor

FAULT DIAGNOSTICS 4

4.1 Troubleshooting plan - when getting a complaint

When you get a complaint from your customer, evaluate the complaint carefully. If the following sysmptoms apply, please instruct the customer

in the proper use of the microwave oven. This can eliminate an unnecessary service call.

1. Check grounding before checking for trouble.

2. Be careful of the high voltage circuit.

3. Discharge the high voltage capacitor. (See page 2)

4. When checking the continuity of the switches or of 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.

5. Do not touch any part of the circuitry on the digital programmer circuit since static electric discharge may
damage this control panel.

Always touch yourself ground while working on this panel to discharge any static charge built up in your

body.

CAUTIONS

Page 14

Microwave oven

does not work.

Inserting many plug into one
plug outlet and using
them at the same time
(causes overloading).

Microwave oven plug is not
inserted tightly.

Output power is too low. Low AC input voltage.

Food temperature is too low.

Using metallic ware and
allowing it to touch the oven
wall.

Sparks occurring.

Inconsistent intensity of
microwave by their
characteristics.

1. Wrap the thinner part with
aluminum foil.

2. Use plastic wrap or lid.

3. Stir once or twice while cooking
soup, cocoa or milk, etc.

Uneven cooking.

Ceramic ware trimmed in
gold or silver powder is used.

Avoid using other electrical
appliances when you use the
microwave oven.

Insert microwave oven plug
securely.

Use the microwave oven at
adequate line voltage.

This may not be a defect.
It is possible that the food
should be cooked for a
longer time period.

Do not use metallic ware for
cooking except where noted
in the cooking guide.

Do not use any type of
cookware with metallic
trimming.

Excessive weight on tray or
improperly balanced.

Distribute food evenly. Cook
smaller portions and,or use
lighter weight cookware.

Turntable drags or makes
noise.

CONDITION

CAUSE REMEDY

4.1 Troubleshooting plan - when getting a complaint

Page 15

4.2 Troubleshooting plan - Probable defective control circuit

1. No input can be
programmed.

Continuity.

No continuity.

Defective PCB
assembly.

Replace PCB
assembly.

Check the conn­ection between
membrane key
assembly and
PCB assembly.

Loose
connection.

Connect them
tightly.

2. Some inputs
cannot be
programmed.

Everything works
as specified.

Still have trouble.

Defective key
membrane
assembly.

Replace key
membrane
assembly.

Replace key
membrane
assembly and
check operation.

3. Display shows a
number or figure
different from one
touched.

4. Random
programming
when touching
other pads.

5. Display is fixed
at some figure
and can not
accept any
input.

Defective PCB
assembly.

Replace PCB
assembly.

CONDITION CHECK RESULT CAUSE REMEDY

The following visual conditions indicate a probable defective control circuit.

Page 16

4.3 Troubleshooting plan - Oven does not operate at all

1. Fuse blows. Continuity.

Malfunction of the
monitor switch.

Check continuity
of monitor
switch (with
door closed).

Check continuity
of primary
switch (with
door opened).

No continuity.

Disconnect one
side of the wire
lead connected
from transformer
to the high
voltage
capacitor and
operate the unit.

No continuity.

Continuity.

Shorted contact at
the primary switch.

Fuse blows again

Normal.

Defective high
voltage capacitor.

Replace high
voltage capacitor.

Defective high volt­age transformer.

Replace high volt­age transformer.

Replace fuse

CONDITION CHECK RESULT CAUSE REMEDY

Replace primary
and monitor
switches.

Replace primary
and monitor
switches.

Oven does not operate at all, display window does not display any figures and no input is accepted.

Page 17

4.3 Troubleshooting plan - Oven does not operate at all

2. Fuse does not
blow.

No continuity.

No continuity.

Replace power
supply cord.

Defective mag­netron thermostat.

Defective power
supply cord.

Replace mag­netron thermostat.

Check continuity
of magnetron
thermostat.

Check continuity
of power supply
cord.

Continuity.

No continuity.

Defective
oven thermostat.

Replace
oven thermostat.

Check continuity
of oven
thermostat.

Continuity.

CONDITION CHECK RESULT CAUSE REMEDY

Page 18

4.4

Troubleshooting plan - Oven does not start cooking

Display shows all figures set, but oven does not start cooking while desired program times are set and START pad is touched.

CONDITION CHECK RESULT CAUSE REMEDY

1.Setting time does
not count down
when touching
START pad.

2. Fan motor or
oven lamp
do not turn
on.

No continuity.

continuity.

No continuity.

Continuity.

Check the con­nection between
connector and
P.C.B assembly.

Defective
secondary switch.

Replace
secondary switch.

Check continuity
of secondary
switch (with
door closed).

Check fan motor.

Check oven lamp.

Abnormal.

Abnormal.

Normal.

Defective fan
motor.

Defective oven
lamp.

Replace fan
motor.

Replace oven
lamp.

Defective P.C.B
assembly.

Replace P.C.B
assembly.

Loose connection.

Connection then
tightly.

Page 19

4.5

Troubleshooting plan - Output power is low

Oven seems to be operation but output is low.

CONDITION CHECK RESULT CAUSE REMEDY

Loose connection. Correct connection.

Output is low.

Lower than 90% of
rating voltage.

Normal.

Normal.

Abnormal.

Abnormal.

Measure the
output power.

Disconnect the
wire leads from

on and off time
with multitester.

Defective P.C.B
assembly.

Replace P.C.B
assembly.

Decrease in power
source voltage
with load.

Suggest customer
contact local
electric power
utility co. or
qualified
electrician.

Check the
power source
voltage.

Defective
magnetron.

Replace
magnetron.

Normal.

Abnormal.

Check connection
between magnetron
filament terminals
and lead wires.

power relay and check

Page 20

4.6 Troubleshooting plan - Oven does not cook properly

Oven does not cook properly when programmed for the set power level (Operates properly in HIGH)

Output is full when
you set lower
power level.

Abnormal.

Defective P.C.B.
assembly.

Replace P.C.B.
assembly.

Disconnect the
wire leads from

(Operate the unit)

CONDITION CHECK RESULT CAUSE REMEDY

power relay and
check continuity

power relay.

Page 21

4. Troubleshooting plan - Grill7

1. Heater is not
operating.

Abnormal.

Malfunction the
heater.

Replace.Heater.

Normal.

Abnormal.

Malfunction the
thermostat.

Replace.

Thermostat and

Normal.

2. Lower tempera­ture the oven.

Abnormal.

Malfunction the
heater.

Replace.Heater.

Normal.

Abnormal.

Malfunction the
thermostat.

Replace.

Thermostat and

No continuity. Open or loosen.

Replace or
connect tightly.

Wire connection.

NOTE: * Make sure the wore leads correct position.

* When removing the wire leads from parts be sure to grasp the connector not the wires.
* When removing the magnetron, be sure to install the magnetron gasket in the correct position and in

good condition.

CONDITION CHECK RESULT CAUSE

REMEDY

Page 22

heater relay(Grill)

heater relay(Grill)