Daewoo KOR-633R0S, KOR-633, KOR-863R0S Service Manual

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Page 1

S/M No.:R633R0S001

Service Manual

Microwave Oven

MODEL :

KOR-633R0S KOR-863R0S

D AEW OO ELECTR ONICS CO., LTD

http : //svc.dwe .co.kr

MAR. 2000

Page 2

PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY

(a) Do not operate or allow the oven to be operated with the door open. (b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave

source, and make repairs as necessary: (1) Interlock operation, (2) Proper door closing, (3) Seal and sealing surfaces (arcing, wear, and other damage), (4) Damage to or loosening of hinges and latches, (5) Evidence of dropping or abuse.

generating compartments, check the magnetron, wave guide or transmission line, and cavity for proper alignment, integrity, and connections.

(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave generation and

transmission systems shall be repaired, replaced, or adjusted by procedures described in this manual before the oven is released to the owner.

(e) A microwave leakage check to verify compliance with the Federal performance standard should be performed on

each oven prior to release to the owner.

TABLE OF CONTENTS

SAFETY AND PRECAUTIONS ........................................................................................................ 2

1. FOR SAFE OPERATION ............................................................................................................. 2

2. FOR SAFE SERVICE PROCEDURES ........................................................................................ 2

SPECIFICATIONS ............................................................................................................................ 3

EXTERNAL VIEW ............................................................................................................................ 4

1. OUTER DIMENSION .................................................................................................................... 4

2. FEATURE DIAGRAM ................................................................................................................... 5

3. CONTROL PANEL ....................................................................................................................... 6

INSTALLATION ................................................................................................................................ 7

OPERATIONS AND FUNCTIONS ................................................................................................... 8

DISASSEMBLY AND ASSEMBLY .................................................................................................. 9

INTERLOCK MECHANISM AND ADJUSTMENT ........................................................................... 16

TROUBLE SHOOTING GUIDE ........................................................................................................ 17

MEASUREMENT AND TEST ........................................................................................................... 21

1. MEASUREMENT OF THE MICROWAVE POWER OUTPUT ..................................................... 21

2. MICROWAVE RADIATION TEST ................................................................................................ 22

3. COMPONENT TEST PROCEDURE ............................................................................................ 23

WIRING DIAGRAM .......................................................................................................................... 24

PRINTED CIRCUIT BOARD ............................................................................................................ 25

1. CIRCUIT CHECK PROCEDURE ................................................................................................. 25

2. P.C.B CIRCUIT DIAGRAM ........................................................................................................... 29

3. P.C.B LOCATION NO .................................................................................................................. 30

EXPLODED VIEW AND PARTS LIST ............................................................................................. 32

1. DOOR ASSEMBLY ...................................................................................................................... 32

2. CONTROL PANEL ASSEMBLY ................................................................................................... 32

3. TOTAL ASSEMBLY ...................................................................................................................... 32

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SAFETY AND PRECAUTIONS

1. FOR SAFE OPERATION

Damage that allows the microwave energy (that cooks or heats the food) to escape will result in poor cooking and may cause serious bodily injury to the operator. IF ANY OF THE FOLLOWING CONDITIONS EXIST, OPERATOR MUST NOT USE THE APPLIANCE. (Only a trained service personnel should make repairs.) (1) A broken door hinge. (2) A broken door viewing screen. (3) A broken front panel, oven cavity. (4) A loosened door lock. (5)A broken door lock. The door gasket plate and oven surface should be kept clean. No greas,soil or spatter should be allowed to build up on these surfaces or inside the oven. DO NOT ATTEMPT TO OPERATE THIS APPLIANCE WITH THE DOOR OPEN. The micrwave oven has concealead switches to make sure the power is turned off when the door is opened. Do not attempt to defeat them. DO NOT ATTEMPT TO SERVICE THIS APPLIANCE UNTIL YOU HAVE READ THIS SERVICE MANUAL.

2. FOR SAFE SERVICE PROCEDURES

1) If the oven is operative prior to servicing, a microwave emission check should be performed prior to servicing the oven.

2) If any certified oven unit is found to servicing, a microwave emission check should be performed prior to servicing the oven. (a) inform the manufacturer, importer or assembler, (b) repair the unit at no cost to the owner, (c) attempt to ascertain the cause of the excessive leakage, (d) tell the owner of the unit not to use the unit until the oven has been brought into compliance.

3) If the oven operates with the door open, the service person should tell the user not to operate the oven and contact the manafacterer immediately.

IMPORTANT

The wire in this mains lead coloured in accordance with the following code. Green-and-yellow : Earth Blue : Neartral Brown. : live As the colours of the wires in the manins lead of this appliance may not correspond with the coloured makings

identifying the terminals in your plug, proceed as follows. The wire which is coloured green-and-yellow must be connected to the terminal in the plug which is marked with the letter ‘E’, earth symbol or coloured green-and-yellow. The wire which is coloured blue must be connected to the terminals which is marked with the letter ‘N’ or coloured black. The wire which is coloured brown must be connected to the terminal which is marked with the letter ‘L’ or coloured red.

NOTE

The oven is desigend for counter-top use only.

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SPECIFICATIONS

MODEL

POWER SUPPLY 230V ~ 50Hz, SINGLE PHASE WITH EARTHING POWER

CONSUMPTION

MICROWAVE ENERGY OUTPUT 800W 900W MICROWAVE FREQUENCY 2450MHz OUTSIDE DIMENSIONS(W X H X D) 465 x 279 x 365 mm

CAVITY DIMENSIONS (W X H X D) 290 x 220 x 306 mm

NET WEIGHT APPROX. 13Kg(28.7 lbs.) APPROX. 15Kg(33.1 lbs.) TIMER 59min. 00 sec. FUNCTION SELECTIONS MICROWAVE POWER SELECTIONS 5 LEVELS CAVITY VOLUME 0.7 Cu.Ft. 0.9 Cu.Ft.

MICROWAVE 1200W 1350W GRILL COMBINATION

KOR-633R KOR-863R

495 x 294 x 392 mm

(18.3 x 11.0 x 14.4 in.)

(11.4 x 8.7 x 12.0 in)

(19.5 x 11.6 x 15.4 in.)

320 x 244 x 338 mm (12.6 x 9.6 x 13.3 in)

* SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

Page 5

EXTERNAL VIEW

279/294

1. OUTER DIMENSION(KOR-633R/KOR-863R)

465/495

365/392

Page 6

2. FEATURE DIAGRAM

EXTERNAL VIEW

15 4

1. Safety interlock system

2. Door screen - Allows viewing of food. The screen is transparent to light, but prevents microwaves escaping.

3. Door hook - When the door is closed, it will automatically shut off. If the door is opened while the oven operating,

the magnetron tube will immediately stop operating.

4. Oven cavity

5. Door seal - Door seal surfaces prevent microwave escaping from the oven cavity.

6. Glass cooking tray - Made of special heat resistant glass. The tray can be easily removed for cleaning. Make sure it is

correctly positioned(indentation) before operating. Place food in a suitable container(dish) on the tray.

7. Roller guide - Supports the glass cooking tray.

8. Coupler - This fits over the shaft in the center of the ovens cavity floor. This is to remain in the oven for all cooking.

9. Control panel

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EXTERNAL VIEW

3. Control panel

1 2

3 4

5 6

1. Auto cook - Used to cook using a program or to reheat.

2. Defrost - Used to defrost foods by weight or time.

3. Power - Used to set power level.

4. Clock - Used to set clock.

5. Display - Cooking time, power level, indicators and present time are displayed.

6. Stop/Clear - Used to stop the oven operation or to erase all entries.

7. Strat/Easy cook - Used to start the oven operation and also increase the reheat time by 30 seconds.

8. Dial Knob - Used to set the time and weight.

Page 8

INSTALLATION

1. Steady, flat location

This microwave oven should be set on a steady, flat surface. This microwave oven is designed for counter top use only.

2. Leave space behind and side

All air vents should be kept a clearance. If all vents are covered during operation, the oven may overheat and, eventually, cause oven failure.

3. Away from Radio and TV sets

Poor television reception and radio interference may result if the oven is located close to a TV, Radio, antenna or feeder and so on. Position the oven as far from them as possible.

4. Away from heating appliances and water taps

Keep the oven away from hot air, steam or splash when choosing a place to position it, or the insulation might be adversely affected and breakdowns occur.

5. Power supply

Check your local power source. This microwave oven requires a current of approximately 6 amperes, 230Volts, 50Hz. Power supply cord is about 0.8 meters long. The voltage used must be the same as specified on this oven. Using a higher voltage may result in a fire or other accident causing oven damage. Using low voltage will cause slow cooking, We are not responsible for damage resulting from use of this oven with a voltage of amprer fuse other than those specified. This appliance is supplied with cable of special type, which, if samaged, must be repaired with cable of same type. Such a cable can be purchased from DAEWOO and must be installed by a Qualified Person.

6. Examine the oven after unpacking for any damage such as:

A misaligned door, broken door or a dent in cavity. If any of the above are visible, DO NOT INSTALL, and notify dealer immediately.

7. Do not operate the oven if it is colder than room temperature

(This may occur during delivery in cold weather.) Allow oven to become room temperature before operating.

EARTHING INSTRUCTIONS

This appliance must be earthed. In the event of an electrical short circuit , earthing reduces the risk of the electric shock by providing an escape wire for the electric current. This applicance is equipped with a cord having a earthing wire with a earthing plug. The plug must be plugged into an outlet that is properly installed and earthed.

WARNING

Improper use of the earthing plug can result in a risk of electric shock. Consult a qualified electrician or serviceman if the earthing instructions are not completely understood, or if doubt exists as to whether the appliance is properly earthed, and either: If it is necessary to use an extension cord, use only a 3-wire extension cord that has a 3-blade earthing plug, and a 3-slot receptacle that will accpt the plug on the appliance. The marked rating of the extension cord should be equal to or greater than the electrical rating of the appliance, or Do not use an extension cord.

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OPERATIONS AND FUNCTIONS

1. Connect the main lead to an electrical outlet.

2. After placing the food in a suitable container, open the oven door and put it on the glass tray. The glass tray must always be in place during cooking.

3. Close the door securely.

4. When the oven door is opened, the light turns off.

5. The oven door can be opened at any time during operation by touching the door release button on the control panel. The oven will automatically shut off. To restart the oven, close the door and then touch Start button.

6. Each time a button is touched, a BEEP will sound to acknowledge the touch.

7. The oven automatically cook on full power unless set to a lower power level.

8. The display will show “:0” when the oven is plugged in.

9. Time clock returns to the present time when the cooking time ends.

10. When the Stop/Clear button is touched during the oven operation, the oven stops cooking and all information retained. To erase all information (except the present time), touch the Stop/Clear button once more. If the oven door is opened during the oven operation, all information is retained.

11. If the Start button is touched and the oven does not operate, check the area between the door and door seal for obstructions and make sure the door is closed securely. The oven will not start cooking until the door is completely closed or the program has been reset.

Make sure the oven is properly installed and plugged into the electrical outlet.

Wattage output chart

The power level is set by pressing the Power button. The chart shows the display, the power level and the percentage of power.

Touch Power button Power level (Display) Approximate Percentage of power

Once P-HI 100 %

Twice P-80 80 % 3 times P-60 60 % 4 times P-40 40 % 5 times P-20 20 %

Page 10

DISASSEMBLY AND ASSEMBLY

Cautions to be observed when trouble shooting.

Unlike many other appliances, the microwave oven is high-voltage, high-current equipment. It is completely safety during normal operation. However, carelessness in servicing the oven can result in an electric shock

or possible danger from a short circuit. You are asked to observe the following precautions carefully.

1. Always remove the power plug from the outlet before servicing.

2. Use an insulated scredriver and ware rubber gloves when servicing the high voltage side.

3. Discahrge the high voltage capacitor before touching any oven components or wiring.

(1) Check the earthed.

Do not operate on a two-wire extension cord.

The microwave oven is designed to be used with earthed. It is imperative, therefore, to make sure it is grounded properly

before beginning repair work.

(2) Warning about the electric charge in the high voltage capacitor. For about 30 seconds after the operation stopped and electric charge remains in the high voltage capacitor. When replacing or checking parts, short between oven chassis and the negative high terminal of the high voltage capacitor, by using a properly insulated screwdriver to discharge.

4. When the 12A fuse is blown out due to the operation of the monitor switch; replace primary interlock switch, secondary interlock switch and interlock monitor switch.

5. After repair or replacement of parts, make sure that the screws are properly tightened, and all electrical connections are tightened.

6. Do not operate without cabinet.

CAUTION

Service personnel should remove their watches whenever working close to or replacing the magnetron.

WARNING

When servicing th appliance, need a care of touching or replacing high potential parts because of electrical shock or exposing microwave. These parts are as follows - HV Transformer, Magnetron, HV Capacitor, HV Diode, HVFuse.

SHORT

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DISASSEMBLY AND ASSEMBLY

1. To remove cabinet

1) Remove three screws on cabinet back.

2) Push the cabinet backward.

2. To remove door assembly

1) Remove screws which secure the stopper hinge top.

2) Remove the door assembly from top plate of cavity.

3) Reverse the above for reassembly.

NOTE

After replacing the door assembly, perform a check of correct alignment with the hinge and cavity front plate.

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3. To remove door parts.

DISASSEMBLY AND ASSEMBLY

A06

A05

A04

A03

A02

A01

A07

A08

(1) KOR-633R0S

REF NO.

A01 A02 A03 A04 A05 A06 A07 A08

PART CODE

3512203860 3517005630 3515204100 3511705500 3517002800 3512300200 3513100700 3515101300

PART NAME DESCRIPTION Q’TY REMARK

FRAME DOOR ABS SG-175 1 BARRIER-SCREEN*O SAN 1 STOPPER HINGE*T AS KOR-63150S 1 DOOR WELD AS KOR-61150S 1 BARRIER-SCREEN*I POLYESTER T0.1 1 GASKET DOOR PP 1 HOOK POM 1 SPRING HOOK PW1 1

(2) KOR-863R0S

REF NO. PART CODE PART NAME DESCRIPTION Q'TY REMARK

A01 3512204170 FRAME DOOR ABS SG-175 1 A02 3517005740 BARRIER-SCREEN *O ACRYL 1 A03 3515204100 STOPPER HINGE *T AS KOR-63150S 1 A04 3511705620 DOOR WELD AS KOR-81250S 1 A05 3517002900 BARRIER-SCREEN *I POLYESTER T0.1 1 A06 3512300400 GASKET DOOR PP 1 A07 3513100700 HOOK POM 1 A08 3515101300 SPRING HOOK PW1 1

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DISASSEMBLY AND ASSEMBLY

(1) Remove the gasket door from door plate.

(2) Remove the barrier screen inner from door plate.

(3) Remove the door frame from door plate.

(4) Remove the stopper hinge top from door plate.

(5) Remove the spring and the hook.

(6) Remove the supporter barrier screen outer from door frame. (7) Remove the barrier screen outer from door frame. (8) Reverse the above steps for reassembly.

4. Method to reduce the gap between the door seal and the oven front surface.

(1) To reduce gap located on part ‘A’

Loosen two screws on stopper hinge top, and then push the door to contact the door seal to oven front surface. Tighten a screw.

(2) To reduce gap located on part ‘B’ Loosen two screws on stopper hinge under, and then push the door to contact the door seal to oven front surface. Tighten a screw.

NOTE

A small gap may be acceptable if the microwave leakage does not exceed 4mW/cm

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5. To remove control panel parts.

DISASSEMBLY AND ASSEMBLY

B09B08B07B06B05B04B03B02B01

(1) KOR-633R0S

REF NO. PART CODE PART NAME DESCRIPTION Q'TY REMARK

B01 3515501540 WINDOW DISPLAY PMMA 1 B02 3516723730 CONTROL PANEL ABS SG-175 1 B03 3516907530 BUTTON FUNCTION * A ABS SG-175 1 B04 3516907540 BUTTON FUNCTION * B ABS SG-175 1 B05 3513405240 KNOB VOLUME ABS 1 B06 3514321430 PCB SUB AS KOR-633R0S 1 B07 7621301011 SCREW TAPPING T2 PAN 3X10 PW MFZN 4 B08 3514321350 PCB MAIN AS KOR-633R0S 1 B09 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 3

(2) KOR-863R0S

REF NO. PART CODE PART NAME DESCRIPTION Q'TY REMARK

B01 3515501540 WINDOW DISPLAY PMMA 1 B02 3516723730 CONTROL PANEL ABS SG-175 1 B03 3516907530 BUTTON FUNCTION * A ABS SG-175 1 B04 3516907540 BUTTON FUNCTION * B ABS SG-175 1 B05 3513405240 KNOB VOLUME ABS SG-175 1 B06 3514321430 PCB SUB AS KOR-633R0S 1 B07 7621301011 SCREW TAPPING T2 PAN 3X10 PW MFZN 4 B08 3514321570 PCB MAIN AS KOR-863R0S 1 B09 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 3

Page 15

DISASSEMBLY AND ASSEMBLY

1) Remove the screw which secure the control panel, push up two snap fits and draw forward the control panel assembly.

2) Remove the door open lever from thee control panel.

3) Remove four screws which secure the PCB assembly.

4) Disconnect membrane tail from theconnector of the PCB assembly.

5) Detach membrane from the control panel.

6) Remove door open button and button spring from the control panel.

7) Reverse the above steps for reassembly.

6. To remove high voltage capacitor.

1) Remove a screw which secure the grounding ring terminal of the H.V. diode and the capacitor holder.

2) Remove the H.V.diode from the capacitor holder.

3) Reverse the above steps for reassembly.

High voltage circuit wiring

7. To remove magnetron.

1) Remove a screw which secure the magnetron.

2) Remove the magnetron.

3) Reverse the above steps for reassembly.

NOTE

Never install the magnetron without the metallic gasket plate which is packed with each magnetron to prevent microwave leakage. Whenever repair work is carried out on magnetron, check the microwave leakage. It shall not exceed 4mW/ for a fully assembled oven with door normally closed.

Page 16

8. To remove wind guide assembly.

1) Remove a screw for earthing.

2) Remove the noise filter from the wind guide.

3) Remove a screw which secure the wind guide assembly.

4) Draw forward the wind guide assembly.

5) Pull the fan from the motor shaft.

6) Remove two screws which secure the motor shaded pole.

7) Remove the motor shaded pole.

8) Reverse the above steps for reasembly.

DISASSEMBLY AND ASSEMBLY

9. To remove H.V. transformert.

1) Remove four screws holding the H.V.transformer.

2) Remove the H.V.transformer.

3) Reverse the above steps for reassembly.

Page 17

INTERLOCK MECHANISM AND ADJUSTMENT

The door lock mechanism is a device which has been specially designed to completely eliminate microwave radiation when the door is opened during operation, and thus to perfectly prevent the danger resulting from the leakage of microwave.

Hook

Primary interlock switch

Interlock monitor switch

Button

Lock lever

Condition : DOOR CLOSE

Door open monitor switch(rear)

Secondary interlock switch(front)

Mounting screw

Condition : DOOR OPEN

(1) Primary interlock switch

When the door is closed, the hook locks the oven door. If the door is not closed properly, the oven will not operate. When the door is closed, the hook pushes the button of the microswitch. Then the button of the primary interlock switch bring it under ON condition.

(2) Secondary interlock switch and interlock monitor switch

When the door is closed, the hook pushes the lock lever downward. The lock lever presses the button of the interlock monitor switch to bring it under NO condition and presses the button of the secondary interlock switch to bring it under ON condition.

ADJUSTMENT

Interlock monitor switch When the door is closed, the interlock monitor switch should be changed (NO condition) before other switches are closed. When the door is opened, the interlock monitor switch should be changed (NC condition) after other switches are opened.

3. Adjustment steps

a) Loosen the one mounting screw. b) Adjust interlock switch assembly position. c) Make sure that lock lever moves smothly after adjustment is completed. d) Tighten completely one mounting screw.

NOTE

Microwave emission test should be performed after adjusting interlock mechanism. If the microwave emission exceed 4mW/cm , readjust interlock mechanism.

Page 18

TROUBLE SHOOTING GUIDE

Following the procedure below to check if the oven is defective or not.

1. Check grounding before trouble checking.

2. Be careful of the high voltage circuit.

3. Discharge the high voltage capacitor.

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

NOTE

When electric parts are checked, be sure the power cord is not inserted the wall outlet. Check wire harness, wiring and connected of the terminals and power cord before check the parts listed below.

(TROUBLE 1) Door shut, timer set, but no cooking takes place.

CONDITION

Fuse blows.

CHECK RESULT CAUSE REMEDY

Check continuity of interlock monitor switch with door closed (COM C)

Check continuity of both primary and secondary interlock switch with door closed

Check continuity of primary interlock switch contact with door partially open until interlock monitor switch contact close (COM NO)

Check continuity of

primary winding of low

voltage transformer

Continuity

No Continuity

Continuity

0 Or

Approx.

150~310

(normal)

Malfunction of interlock

monitor

switch

Malfunction of interlock switch

Shorted contacts of primary interlock switch.

Defective low

voltage

transformer

Replace NOTE 1

Replace

Disconnect high voltage fuse and operate the unit

Fuse again

blows

Defective high

voltage transformer

Replace

Page 19

TROUBLE SHOOTING GUIDE

CONDITION

Outlet has proper voltage Fuse does not

blow.

CHECK RESULT CAUSE REMEDY

Check continuity of

magnetron

Check continuity of

noise filter board

Check continuity of power supply cord

Continuity

Normal

Defective

magnetron

Defective line

filter board

Open power

supply cord

Defective touch

control circuit

Replace

Adjust

NOTE

All these switches must be replaced at the same time, please refer to “Interlock Mechanism And Adjustment”.

(TROUBLE 2) Display shows all figures selected, but oven does not start cooking, even thouh desired program and time are set and start pad is tapped.

CONDITION

Turn table

motor and

oven lamp do

not turn on

CHECK RESULT CAUSE REMEDY

Check continuity of

primary interlock switch

Check continuity of

secondary interlock and

D.O.M. switches

Check D.C. voltage

being supplied to

RELAY (RY2) coil

Continuity

0 V

Approx. 15 VDC

Malfunction

of primary

interlock

switch

Malfunction of secondary interlock and

D.O.M. switch

Defective

touch control

circuit

Faulty

contacts of

RELAY

(RY2) or open

relay coil

Adjust or

replace

Adjust or

replace

Replace

Page 20

(TROUBLE 3) No microwave oscillation even though fan motor rotates.

TROUBLE SHOOTING GUIDE

CONDITION

No microwave

oscillation

CHECK RESULT

Check continuity of high

voltage fuse

Replace high voltage fuse

Check continuity of high

voltage capacitor

terminals with wires

removed

Check continuity of high

voltage rectifier in

forward and backward

direction with DC

megger

Connect megger leads to

magnetron terminal and

magnetron body

Check resistance of

primary and secondary

coil of high voltage

transformer

No Continuity

Continuity

Continuity in

backward

direction

Continuity

or o o

0 Ω

CAUSE

Defective

high voltage

transformer

Defective

high voltage

rectifier

Defective

magnetron

Defective

high voltage

transformer

REMEDY

Replace

Check continuity of

magnetron with wires

removed

Check continuity of

filament terminal of high

voltage transformer

Check D.C. voltage

being supplied to

RELAY (RY1) coil

Continuity

0 V

Approx

15 VDC

Defective

magnetron

Defective

high voltage

transformer

Defective

touch control

circuit

Faulty

contacts or

RELAY

(RY1) or open

relay coil

Replace

Page 21

TROUBLE SHOOTING GUIDE

(TROUBLE 4) The following visual conditions indicate a profective touch control circuit or membrane switch assembly.

1. Incomplete segments,

1) Segments missing.

2) Partical segments missing.

3) Digit flickering other than normal display slight flickering.

4) “:0” does not display when power is on.

2. A distinct change in the display are not on when they numbers is the display.

3. One or more digits in the display are not on when they should be.

M/W DEF. Lock

4. Display indicates a number different from one touched.

5. Specific numbers (for example 2 or 3) will not display when the panel is touched.

6. Display does not count down or up with time cooking or clock operation.

7. Oven is programmable and cooks normally but no display shows.

8. Display obviously jumps in time while counting down.

9. Display counts down noticeably too fast while cooking.

10. Display does not show the time of day when clear pad is touched.

11. Oven lamp and turntable motor do not stop although cooking is finished. Check if the RELAY 2 contacts close if they are close, replace touch control circuit.

CONDITION

CHECK RESULT CAUSE REMEDY

Display does

not show programming at all, even if

keyboard is

Check each pad for

continuity of the

membrane keyboard

for the following keyboard check

procedure

Normal

Malfunction

of touch control circuit of control box

sub-assembly

Replace

control box

sub-assembly

touched.

Abnormal

Malfunction of

the membrane

keyboard

Replace the

membrane

keyborad

NOTE

Before following the particular steps listed above in the trouble shooting guide for the membrane keyboard’s, failure, please check for the continuity of each wire-harness between the membrane keyboard and P.C.B. assembly.

Page 22

MEASUREMENT AND TEST

1. MEASUREMENT OF THE MICROWAVE POWER OUTPUT

Microwave output power can be checked by indirectly measuring the temperature rise of a certain amount of water exposed to the microwave as directed below.

PROCEDURE

1. Microwave power output measurement is made with the microwave oven supplied at rated voltage and operated at its

maximum microwave power setting with a load of 1000 5cc of potable water.

2. The water is contained in a cylindrical borosilicate glass vessel having a maximum material thickness of 3 mm and an outside diameter of approximately 190mm.

3. The oven and the empty vessel are at ambient temperature prior to the start of the test. The initial temperature of the water is

10 2 (50 3.6 ). It is measured immediately before the water is added to the vessel. After addition of the water to the vessel, the load is immediately placed on the center of the shelf, which is in the lowest normal position.

4. Microwave power is switched on.

5. Heating time should be exactly A seconds. (Refer to table as following) Heating time is measured while the microwave generator is operating at full power. The filament heat-up time for magnetron is not included.

6. The initial and final temperature of water is selected so that the maximum difference between the ambient and final water temperature is 5K.

7. The microwave power output P in watts is calculated from the following formula :

P = 4187 X T/t

T is difference between initial and ending temperature. t is the heating time.

The power measured should be B (Refer to SPECIFICATIONS) W 10.0%.

CAUTION

1. Water load should be measured exactly to 1 liters.

2. Input power voltage should be exactly specified voltage (Refer to SPECIFICATIONS)

3. Ambient temperature should be 20 2 (68 3.6 )

* Heating time for power output :

A(second) 70 64 60 56 52 49 47 44 42 40 38

B(W) 600 650 700 750 800 850 900 950 1000 1050 1100

Page 23

MEASUREMENT AND TEST

2. MICROWAVE RADIATION TEST

WARNING

1. Make sure to check the microwave leakage before and after repair of adjustment.

2. Always start measuring of an unknown field to assure safety for operating personnel from microwave energy.

3. Do not place your hands into any suspected microwave radiation field unless the safe density level is known.

4. Care should be taken not to place the eyes in direct line with the source of microwave energy.

5. Slowly approch the unit under test until the radiometer readds an appreciable microwave leakage from the unit

under the test.

PROCEDURES

1. Prepare Microwave Energy Survey, 600cc glass

beaker, and glass thermometer 100 (212 ).

2. Pour 275cc 15cc of tap water initially at 20 5 (68 9 ) in

the 600cc glass breaker with an inside diameter of approx. 95mm(3.5in.).

3. Place it at the center of the tray and set in a cavity.

4. Close the door and operate the oven.

5. Measure the leakage by using Microwave Energy Survey

Meter with dual ranes, set to 2450MHz.

1) Measured radiation leakage must not exceed the value

prescribed below. Leakage for a fully assembled oven with door normally closed must be less than 4mW/cm .

2) When measuring the leakage, always use the 5cm(2 in.)

space cone with probe. Hold the probe perpendicular to the cabinet and door. Place the space cone of the prove on the door, cabinet, door seem, door viewing screen, the exhaust air vents and the suction air vents.

3) Measuring should be in a counter-clockwise direction at a

rate of 1 in./sec. If the leakage of the cabinet door seem is unknown, move the probe more slowly.

4) When measuring near a corner of the door, keep the probe perpendicular to the areas making sure the probe end at

the base of the cone does not get closer than 2 in. from any metal. If it does not, erroneous reading may result.

Page 24

MEASUREMENT AND TEST

3. COMPONENT TEST PROCEDURE

High voltage is present at the high voltage terminal of the high voltage transformer during any cooking cycle. It is neither necessary nor advisable to attempt measurement of the high voltage. Before touching any oven components or wiring, always unplug the oven from its power source and discharge the capacitor.

1. High voltage transformer

(1) Remove connections from the transformer terminals and check continuity. (2) Normal readings should be as follows:

Secondary winding ........................ Approx. 110 10%

Filament winding ............................................... Approx. 0

Primary winding ................................................ Approx. 0

2. High voltage capacitor

(1) Check continuity of capacitor with meter on the hightest OHM scale. (2) A normal capacitor will show continuity for a short time, and then indicate 10M once the capacitor is charged.

(3) A shorted capacitor will show continuous continuity. (4) An open capacitor will show constant 10M .

(5) Resistance between each terminal and chassis should be infinite.

3. High voltage diode

(1) Isolate the diode from the circuit by disconnecting the leads. (2) With the ohmmeter set on the highest resistance scale measure the resistance across the diode terminals. Reverse the meter leads and again observe the resistance reading. Meter with 6V, 9V or higher voltage batteries should be used to check the front-back resistance of the diode, otherwise an infinite resistance amy be read in both directions.

A normal diode’s resistance will be infinite in one direction and several hundred K in the other direction.

4. Magnetron

For complete magnetron diagnosis, refer to “ Measurement of the Microwave Power Output ". Continuity checks can only indicate and open filament or a shorted magnetron. To diagnose for an open filament or a shorted magnetron. (1) Isolate magnetron from the circuit by disconnecting the leads.

(2) A continuity check across magnetron filament terminals should indicate 0.1 or less. (3) A continuity check between each filament terminal and magnetron case should read open.

5. Fuse

If the fuse in the primary and monitor switch circuit is blown when the door is opened, check the primary and monitor switch before replacing the blown fuse. In case the fuse is blown by an improper switch operation, replace the defective switch and fuse at the same time. Replace just the fuse if the switches operate normally.

Page 25

WIRING DIAGRAM

Page 26

PRINTED CIRCUIT BOARD

1. CIRCUIT CHECK PROCEDURE

1. Low voltage transformer check

The low voltage transformer is located on the P.C.B. Measuring condition : Input voltage : 230V / Frequency : 50Hz

Terminal Voltage LOAD NO LOAD 4 - 7 AC 12.6 AC 14.7V

NOTE

1. Refer to Circuit Diagram (point 4).

2. Secondary side voltage of the low voltage transformer changes in proportion to fluctuation of power source voltage.

3. The allowable tolerance of the secondary voltage is within 5% of normal voltage.

2. Voltage Check

- Key check point

NO CHECK POINT REMARK

1 IC 1 PIN 2, 21, 30, 34 -5VDC 2 IC 1 PIN 35

T : 20ms(50Hz)

3 IC 1 PIN 31 OR 32

T : 250 ns(4MHz)

- Check method

NO MEASURE POINT WAVE FORM REMEDY REMARK

1 MP1 DC - 5V 0.25V Replace VL1, EC1 NO LOAD 2 MP2 DC - 12V 2.0V Replace EC2, D10,11,12 NO LOAD

NOTE

Each measure point must be measured with GND points.

Page 27

PRINTED CIRCUIT BOARD

Page 28

PRINTED CIRCUIT BOARD

Page 29

PRINTED CIRCUIT BOARD

3. When there is no microwave oscillation

1) When touching START pad, oven lamp does not turn on.

Fan motor do not rotate, but cook indicator in display comes on. * Cause : RELAY 2 does not operate. refer to Circuit Diagram (Point 3)

- Check method

POINT STATE

RELAY 2 ON - 5V DC GND RELAY 2 OFF GND - 12VDC

2) When touching START pad, oven lamp turns on.

Fan motor and turntable rotate and cook indicator in display comes on. * Cause : RELAY 1 does not operate. refer to Circuit Diagram (Point 2)

- Check method

POINT STATE

RELAY 2 ON - 5V DC GND RELAY 2 OFF GND - 12VDC

4. When the door is opened during operation, the count down timer does not stop.

refer to Circuit Diagram (Point 1)

- Check method

POINT STATE

A B

1) DOOR OPEN OPEN -5VDC

2) DOOR CLOSED CLOSE GND

CHECK NO METHOD REMEDY

1 Check the stage(ON, OFF) of the door open monitor switch

by resistance measurement.

5. When the digital clock does not operate properly.

refer to Circuit Diagram (Point 5)

Replace door open monitor switch.

POINT WAVE FORM

T : 20 ms (50Hz)

* If clock does not keep exact time, you must check resistor R5, 6 zener diodeZD2.

Page 30

2. P.C.B. CIRCUIT DIAGRAM

PRINTED CIRCUIT BOARD

161718

4 3

1 2

Page 31

PRINTED CIRCUIT BOARD

3. P.C.B. LOCATION NO

(1) KOR-633R0S

NO. NAME SYMBOL SPECIFICATION PART CODE Q’TY

1 BUZZER BZ1 BM-20K 3515600100 1 2 C ARRAY CA1 5P(4) 102M 50V CN4XB-102M 1 3 C ELECTRO EC1 16V RSS 100uF CEXF1C101V 1 4 C ELECTRO EC2 25V RSS 1000uF CEXF1E102V 1 5 CONNECTOR WAFER CN2 YW396-02AV 3519150520 1 6 CONNECTOR WAFER CN3 YW396-05AV 3519150510 1 7 CONNECTOR WAFER CN1 HLEM15S-1 4CW215SBD0 1 8 CONNECTOR WAFER CN101 HLEM15R-1 4CW215RBD0 1

9 DIODE D1~5, 7~10 1N4148 DZN4148--- 9 10 DIODE D11, 12 1N4004A DZN4004A-- 2 11 DIODE ZENER ZD2 UZ-5.1BSB DZUZ5R1BSB 1 12 DIODE ZENER ZD1 UZ-3.9BSB DZUZ3R9BSB 1 13 LED DISPLAY DP1 DDG-631H DDDG631H-- 1 14 PCB MAIN 169 90X197 3514321150 1 14 PCB SUB 170 70X197 3514321230 1 15 R ARRAY RA1 5P(4) 1/8 100K J RA-85X104J 1 16 R CARBON FILM R7~R9, R16~R19 1/6W 330 5% RD-AZ331J- 7 17 R CARBON FILM R1,10,15,13,21,101,102 1/6W 1K 5% RD-AZ102J- 7 18 R CARBON FILM R12 1/6W 100K 5% RD-AZ104J- 1 19 R CARBON FILM R2 1/6W 100 5% RD-AZ101J- 1 20 R CARBON FILM R3,5,6 1/6W 10K 5% RD-AZ103J- 3 21 R CARBON FILM R4 1/6W 1M 5% RD-AZ105J- 1 22 R CARBON FILM R20 1/4W 27 5% RD-4Z270J- 1 23 R CARBON FILM R14 1/6W 4.7K 5% RD-AZ472J- 1 24 IC REGULATOR VL1 MC7905C 1MC7905C-- 1 25 TRANSISTOR Q2~6, 8~10 KRA-106M TZRA106M-- 8 26 TRANSISTOR Q1 KTA-1266Y TZTA1266Y- 1 27 TRANS POWER LVT1 DMR-631FS 5EPV035303 1 28 WIRE COPPER J1-J8, J101 1/0.52 TIN COATING 85801052GY 9 29 WIRE FLAT WF1 1.25X15X90XCWH WSJ-159007 1 30 SW TACT SW101~106 KPT-1115AM 5S50101Z93 1 31 SW ROTARY SW107 SDB161PVB17F123636 5S10109002 1 32 IC MICOM IC1 TMP47C440BN-NG04 13GS631R00 1 33 RESONATOR CERA CR1 KBR-4.0MSTF 5PKBR40MKS 1 34 SW RELAY RY1 G5G-1A DC12V 5SC0101121 1 35 SW RELAY RY2 DJ-SS-112M-DC12V 5SC0101404 1 36 C CERA C4 102 50V Z AXIAL CCZB1H102K 1 37 C CERA C1~3, C5~C7 104 50V Z AXIAL CCZF1H104Z 6

Page 32

PRINTED CIRCUIT BOARD

(2) KOR-863R0S

NO. NAME SYMBOL SPECIFICATION PART CODE Q’TY

1 BUZZER BZ1 BM-20K 3515600100 1

2 C ARRAY CA1 5P(4) 102M 50V CN4XB-102M 1

3 C ELECTRO EC1 16V RSS 100uF CEXF1C101V 1

4 C ELECTRO EC2 25V RSS 1000uF CEXF1E102V 1

5 CONNECTOR WAFER CN2 YW396-02AV 3519150520 1

6 CONNECTOR WAFER CN3 YW396-05AV 3519150510 1

7 CONNECTOR WAFER CN1 HLEM15S-1 4CW215SBD0 1

8 CONNECTOR WAFER CN101 HLEM15R-1 4CW215RBD0 1

9 DIODE D1~5, 7~10 1N4148 DZN4148-- 9 10 DIODE D11, 12 1N4004A DZN4004A-- 2 11 DIODE ZENER ZD2 UZ-5.1BSB DZUZ5R1BSB 1 12 DIODE ZENER ZD1 UZ-3.9BSB DZUZ3R9BSB 1 13 LED DISPLAY DP1 DDG-631H DDDG631H-- 1 14 PCB MAIN 169 90X197 3514321150 1 14 PCB SUB 170 70X197 3514321230 1 15 R ARRAY RA1 5P(4) 1/8 100K J RA-85X104J 1 16 R CARBON FILM R7~R9, R16~R19 1/6W 330 5% RD-AZ331J- 7 17 R CARBON FILM R1,10,15,13,21,101,102 1/6W 1K 5% RD-AZ102J- 7 18 R CARBON FILM R12 1/6W 100K 5% RD-AZ104J- 1 19 R CARBON FILM R2 1/6W 100 5% RD-AZ101J- 1 20 R CARBON FILM R3,5,6 1/6W 10K 5% RD-AZ103J- 3 21 R CARBON FILM R4 1/6W 1M 5% RD-AZ105J- 1 22 R CARBON FILM R20 1/4W 27 5% RD-4Z270J- 1 23 R CARBON FILM R14 1/6W 4.7K 5% RD-AZ472J- 1 24 IC REGULATOR VL1 MC7905C 1MC7905C-- 1 25 TRANSISTOR Q2~6, 8~10 KRA-106M TZRA106M-- 8 26 TRANSISTOR Q1 KTA-1270Y TZTA1266Y- 1 27 TRANS POWER LVT1 DMR-631FS 5EPV035303 1 28 WIRE COPPER J1-J8, J101,SJ1 1/0.52 TIN COATING 85801052GY 10 29 WIRE FLAT WF1 1.25X15X90XCWH WSJ-159007 1 30 SW TACT SW101~106 KPT-1115AM 5S50101Z93 1 31 SW ROTARY SW107 SDB161PVB17F123636 5S10109002 1 32 IC MICOM IC1 TMP47C440BN-NG04 13GS631R00 1 33 RESONATOR CERA CR1 KBR-4.0MSTF 5PKBR40MKS 1 34 SW RELAY RY1 G5G-1A DC12V 5SC0101121 1 35 SW RELAY RY2 DJ-SS-114LM DC12V 5SC0101404 1 36 C CERA C4 102 50V Z AXIAL CCZB1H102K 1 37 C CERA C1~3, C5~C7 104 50V Z AXIAL CCZF1H104Z 6

Page 33

EXPLODED VIEW AND PARTS LIST

1. DOOR ASSEMBLY

Refer to Disassembly and assembly.

2. CONTROL PANEL ASSEMBLY

Refer to Disassembly and assembly.

3. TOTAL ASSEMBLY

F05

F04F02 F03 F07 F09 F10

F06

F08F01

F46

F45

F44

F43

F42

F41

A00

B00

F40 F39 F38 F37 F36 F35 F34 F33 F32

F31

F27 F26F28F29F30

F11

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

F22

F23

F24

F25

Page 34

EXPLODED VIEW AND PARTS LIST

(1) KOR-633R0S

NO PART CODE PART NAME DESCRIPTION Q’TY

A00 3511712170 DOOR AS KOR-63350S 1 B00 3516720990 CONTROL-PANEL AS KOR-633R0S 1 F01 3510801310 CABINET PCM T0.36 GE 1 F02 7112401011 SCREW TAPPING T1 TRS 4X10 MFZN 3

F03 F04 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 1

F05 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 1 F06 7112401011 SCREW TAPPING T1 TRS 4X10 MFZN 2 F07 35113AEQ0D CORD POWER AS 3X0.75 70X70 100-RTML 1 F08 4413A90012 CLAMP POWER CORD NYLON 66 1 F09 7112401011 SCREW TAPPING T1 TRA 4X10 MFZN 1 F10 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 1

F11 F12 3518606200 NOISE-FILTER DWLF-M12 1

F13 7121403011 SCREW TAPPING T2S PAN 4X30 MFZN 2 F14 F15 3512517000 GUIDE WIND PP 1

F16 3511800300 FAN PP+30% GLASS 1 F17 3518002200 MAGNETRON 2M218HF 1 F18 3516004000 SPECIAL SCREW T2 BOLT FLANGE 5X12 DACRO 1 F19 7S422X4081 SPECIAL SCREW TT2 TRS 4X8 SE MFZN 1 F20 3513003200 HOLDER HV CAPACITOR SECC T0.6 1 F21 3518302200 CAPACITOR HV 2100VAC 0.98uF #187 1 F22 3518400400 DIODE HV HVR-1X-3AB 12KV #187 1 F23 3518701100 FUSE HV 5KV 0.55A HV-41A55-02 1 F24 3518113700 TRANS HV DY-N80S0-63T 1 F25 3516003700 SPECIAL SCREW TT3 HEX 4X8 FLG MFZN 4 F26 3510311700 BASE SBHG T0.8 1 F27 7112410011 SCREW TAPPING T1 TRS 4X10 MFZN 5 F28 3512100900 FOOT PP DASF-130 2 F29 7S422X4081 SPECIAL SCREW TT2 TRS 4X8 MFZN 1 F30 3515201101 STOPPER HINGE *U SCP-1 T2.5 1 F31 4415A17352 SW MICRO VP-533A-OF SPNO #187 200G 1 F32 4415A66910 SW MICRO VP-531A-OF/SZM-V16-FA-61 1 F33 4415A17352 SW MICRO VP-533A-OF SPNO #187 200G 2 F34 3513702600 LEVER LOCK POM 1 F35 3513811710 LOCK POM 1 F36 3513601600 LAMP BL 240V 25W T25 C7A H187 1 F37 7121400611 SCREW TAPPING T2S PAN 4X6 MFZN 1

F38

3516109000 CAVITY WELD AS KOR-63150S 1 3516119600 CAVITY JOINT AS KOR-63150S

4415D67620 FUSE 250V 12A 65TS 1 4415D67120 FUSE 250V 12A MDA

3963513100 MOTOR SHADED POLE 230V 17W OEM-10DWC2-A07 1 3963512310 MOTOR SHADED POLE 230V 20W MW 10CA-M02

3966310100 MOTOR SYNCRO 220V 2.5W GM-16-24FD12 1 3966310100 MOTOR SYNCRO 220V 2.5W M2LJ49ZT52

Page 35

EXPLODED VIEW AND PARTS LIST

NO PART CODE PART NAME DESCRIPTION Q’TY

F39 3518905300 THERMOSTAT OFF:75 ON:65 H #187 NB 1 F40 3513003400 HOLDER THERMOSTAT PBT 1 F41 3516003700 SPECIAL SCREW TT3 HEX 4X8 FLG MFZN 1 F42 3511406200 COVER WAVE GUIDE HEATPROOF PP 1 F43 3717400620 COUPLER XAREC 1 F44 3514700710 ROLLER TEFLON 3 F45 3512517300 GUIDE ROLLER PP 5113MF6 A353B 1 F46 3517203600 TRAY GLASS 1

Page 36

EXPLODED VIEW AND PARTS LIST

(2) KOR-863R0S

NO PART CODE PART NAME DESCRIPTION Q’TY

A00 3511712170 DOOR AS KOR-86350S 1 B00 3516720990 CONTROL-PANEL AS KOR-863R0S 1 F01 3510801310 CABINET PCM T0.36 GE 1 F02 7112401011 SCREW TAPPING T1 TRS 4X10 MFZN 3

F03 F04 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 1

F11 F12 3518606200 NOISE-FILTER DWLF-M12 1

F13 7121403011 SCREW TAPPING T2S PAN 4X30 MFZN 2 F14 F15 3512517000 GUIDE WIND PP 1

F16 3511800300 FAN PP+30% GLASS 1 F17 3518002200 MAGNETRON 2M218HF 1 F18 3516004000 SPECIAL SCREW T2 BOLT FLANGE 5X12 DACRO 1 F19 7S422X4081 SPECIAL SCREW TT2 TRS 4X8 SE MFZN 1 F20 3513003200 HOLDER HV CAPACITOR SECC T0.6 1 F21 3518302200 CAPACITOR HV 2100VAC 0.98uF #187 1 F22 3518400400 DIODE HV HVR-1X-3AB 12KV #187 1 F23 3518114000 FUSE HV 5KV 0.55A HV-41A55-02 1 F24 3518113700 TRANS HV DW-N90S0-86T 1 F25 3516003700 SPECIAL SCREW TT3 HEX 4X8 FLG MFZN 4 F26 3510311700 BASE SBHG T0.8 1 F27 7112410011 SCREW TAPPING T1 TRS 4X10 MFZN 5 F28 3512100900 FOOT PP DASF-130 2 F29 7S422X4081 SPECIAL SCREW TT2 TRS 4X8 MFZN 1 F30 3515201101 STOPPER HINGE *U SCP-1 T2.5 1 F31 4415A17352 SW MICRO VP-533A-OF SPNO #187 200G 1 F32 4415A66910 SW MICRO VP-531A-OF/SZM-V16-FA-61 1 F33 4415A17352 SW MICRO VP-533A-OF SPNO #187 200G 2 F34 3513702600 LEVER LOCK POM 1 F35 3513811710 LOCK POM 1 F36 3513601600 LAMP BL 240V 25W T25 C7A H187 1 F37 7121400611 SCREW TAPPING T2S PAN 4X6 MFZN 1

F38

3516109000 CAVITY WELD AS KOR-86150S 1 3516119600 CAVITY JOINT AS KOR-86150S

4415D67620 FUSE 250V 12A 65TS 1 4415D67120 FUSE 250V 12A MDA

3963513100 MOTOR SHADED POLE 230V 17W OEM-10DWC2-A07 1 3963512310 MOTOR SHADED POLE 230V 20W MW 10CA-M02

3966310100 MOTOR SYNCRO 220V 2.5W GM-16-24FD12 1 3966310100 MOTOR SYNCRO 220V 2.5W M2LJ49ZT52

Page 37

EXPLODED VIEW AND PARTS LIST

NO PART CODE PART NAME DESCRIPTION Q’TY

Page 38

DAEWOO ELECTRONICS CO., LTD

686, AHYEON-DONG MAPO-GU SEOUL, KOREA C.P.O. BOX 8003 SEOUL, KOREA TELEX : DWELEC K28177-8 CABLE : “DAEWOOELEC” FAX : 02)360-7877 TEL : 02)360-7804 E-mail : jnpark@web.dwe.co.kr

PRINTED DATE : MAR. 2000

Daewoo KOR-633R0S, KOR-633, KOR-863R0S Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual