MICROWAVE OVEN SERVICE MANUAL

MODEL: MC-767W
CAUTION
BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

SAFETY PRECAUTIONS
This device is to be serviced only by properly qualified service personnel. Consult the service manual for proper service procedures to assure continued safety operation and for precautions to be taken to avoid possible exposure to excessive microwave energy.

PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
A) Do not operate or allow the oven to be operated with the door open. B) Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source, and make repairs as necessary; (1) interlock operation, (2) proper door closing, (3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and latches, (5) evidence of dropping or abuse. C) Before turning on microwave power for any service test or inspection within the microwave generating compartments, check the magnetron, wave guide or transmission line, and cavity for proper alignment, integrity, and connections. D) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave generation and transmission systems shall be repaired, replaced, or adjusted by procedures described in this manual before the oven is released to the owner. E) A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner.

CAUTION
MICROWAVE RADIATION
DO NOT BECOME EXPOSED TO RADIATION FROM THE MICROWAVE GENERATOR OR OTHER PARTS CONDUCTING MICROWAVE ENERGY.

CONTENTS
(Page)

SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inside front cover SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 CAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 INSTALLATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
FEATURES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 CONTROL PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 OPERATING SEQUENCE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2 SCHEMATIC DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3 CIRCUIT DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4

SERVICE INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

TOOLS AND MEASURING INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 MICROWAVE LEAKAGE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 MEASUREMENT OF MICROWAVE POWER OUTPUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3 DISASSEMBLY AND ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3 INTERLOCK CONTINUITY TEST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7 COMPONENT TEST PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8 TROUBLE SHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13

EXPLODED VIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 REPLACEMENT PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1 SCHEMATIC DIAGRAM OF P.C.B. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
PRINTED CIRCUIT BOARD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2

P.C.B. PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1

SPECIFICATIONS
ITEM
MODEL
Power Requirement

DESCRIPTION
MC-767W
230 Volts AC 50 Hz Single phase, 3 wire grounded Microwave Grill Combination Convection 1300W 1250W 2650W 1350W (Max. 2550W)

Power Output Microwave Frequency Magnetron Timer Outside Dimensions Cavity Dimensions Net Weight Shipping weight Control Complement

900 Watts full microwave power (IEC60705) 2450 MHz 2M214 - 39F 0 ~ 99 min. 515 (W) x 303 (H) x 510 (D) mm 342 (W) x 215 (H) x 350 (D) mm 21,0 kg 23,0 kg Microwave Power for Variable Cooking Power level MAX (900W) ...................................... Full power throughout the cooking time MED.-HIGH (720W) ............................ approx. 80% of Full power MEDIUM (540W) ................................ approx. 60% of Full power DEFROST (360W) .............................. approx. 40% of Full power LOW/WARM (180W)........................... approx. 20% of Full power CONVECTION..................................Max 250C GRILL COMBINATION

Nameplate Location Back side

Accessories

Owner's manual Glass turntable Rotating ring Grill rack, Convection rack Metal tray

This microwave oven is designed for household use only. It is not recommended for commercial purposes.

1-1

CAUTIONS
Unlike other appliances, the microwave oven is high-voltage and high-current equipment. Though it is free from danger in ordinary use, extreme care should be taken during repair.
DO NOT operate on a 2-wire extension cord during repair and use. NEVER TOUCH any oven components or wiring during operation. BEFORE TOUCHING any parts of the oven, always remove the power plug from the outlet. For about 30 seconds after the oven stops, an electric charge remains in the high voltage capacitor. When replacing or checking, you must discharge the high voltage capacitor by shorting across the two terminals with an insulated screwdriver.

MICROWAVE RADIATION
Personnel should not be exposed to the microwave energy which may radiate from the magnetron or other microwave generating device if it is improperly used or connection. All input and output microwave connections, waveguide, flange and gasket must be secure never operate the device without a microwave energy absorbing load attached. Never look into an open waveguide or antenna while the device is energized. Proper operation of the microwave oven requires that the magnetron be assembled to the waveguide and cavity. Never operate the magnetron unless it is properly installed. Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron.

ANTENNA

Gasket

COOLING FIN FILAMENT TERMINALS MAGNETRON CHASSIS GROUND

Remove your watches whenever working close to or replacing the Magnetron. NEVER operate the oven with no load. NEVER injure the door seal and front plate of the oven cavity. NEVER put iron tools on the magnetron. NEVER put anything into the latch hole and the interlock switches area.

MAGNETRON

THE OVEN IS TO BE SERVICED ONLY BY PROPERLY QUALIFIED SERVICE PERSONNEL.

2-1

INSTALLATIONS
BEFORE YOU BEGIN, READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY.

INSTALLING
1. Empty the microwave oven and clean inside it with a soft, damp cloth. Check for damage such as misaligned door, damage around the door or dents inside the cavity or on the exterior. 2. Put the oven on a counter, table, or shelf that is strong enough to hold the oven and the food and utensils you put in it. (The control panel side of the oven is the heavy side. Use care when handling.) 3. Do not block the vent and the air intake openings. Blocking vent or air intake openings can cause damage to the oven and poor cooking results. Make sure the microwave oven legs are in place to ensure proper air flow. 4. The oven should not be installed in any area where heat and steam are generated, because they may damage the electronic or mechanical parts of the unit. Do not install the oven next to a conventional surface unit or above a conventional wall oven. 5. Use microwave oven in an ambient temperature less than 104F(40C). 6. Place the microwave oven on a sturdy and flat surface at least 10 cm(4 inches) from the wall. 7. Place the microwave oven as far away as possible from TV, RADIO, COMPUTER, etc., to prevent interference. 8. Do not touch the front glass during or after cooking of the Grill and Combination mode. This glass is very hot during heater operating. 9. Do not operate the oven at microwave and combination mode with Grill rack placed in the cavity when the oven is empty.
10cm

EARTHING INSTRUCTIONS
This microwave oven is designed to be used in a fully earthed condition. It is imperative, therefore, to make sure it is properly earthed before servicing

WARNINGTHIS APPLIANCE MUST BE EARTHED

IMPORTANT
The wires in this mains lead are colored in accordance with the following code: Green-and-yellow: Blue: Brown: Earth Neutral Live

As the colors of the wires in the mains lead of this appliance may not correspond with the colored markings identifying the terminals in your plug, proceed as follows. The wire which is colored green-and-yellow must be connected to the terminal in the plug which is marked with the letter E or by the earth symbol ( ) or colored green or green-and-yellow. The wire which is colored blue must be connected to the terminal in the plug which is marked with the letter N or colored black. The wire which is colored brown must be connected to the terminal in the plug which is marked with the letter L or colored red.

3-1

OPERATING INSTRUCTIONS
FEATURES
Oven Front Plate Window Door Screen Door Seal

Control Panel

Safety Door Lock System Turntable Rotating Ring High Rack Low Rack Metal Tray

CONTROL PANEL
1. POWER: Used to select the desired power level for cooking.
540W 180W 720W Max

2. AUTO COOK: Used to cook the foods listed by one touch. 3. INDICATORS 4. AUTO ROAST: Used to select the auto weight roast.
4 8

1
2 1
2 6

Auto Cook

1 5

3 7

5. AUTO DEFROST: Used to select the auto weight defrost. 6. STOP/CLEAR: Used to stop over and clear all entries except time of day.

3 7
Auto Roast

7. CLOCK: Used to set the time of day. 8. START/QUICK START: One tap allows over to begin functioning. 9. DIAL

4 5

1 3 1 3

2 4 2 4

8 9

4-1

OPERATING SEQUENCE
The following is a description of component functions during oven operation.

6. COMBINATION COOKING
To Grill Combi Stop/Clear Function Combi Function Grill Desired cooking time Start

1. SETTING THE CLOCK

Stop/Clear Clock Desired minute Desired hour Start

Desired power level (20%, 40%, 60%) To Convection Combi Stop/ Clear Function Combi

2. MICROWAVE COOKING
Stop/ Clear Start Function MWO Desired power level Desired cooking time

Desired convection temp

(40C, 100C~250C)

Desired power level (20%, 40%, 60%)

Desired cooking time

Start

7. AUTO WEIGHT DEFROST

Stop/Clear Desired defrost category Food weight Start

3. MULTI STAGE COOKING

Stage 1 Stop/ Clear Desired power level Desired cooking time Stage 2 Desired power level Desired cooking time

8. AUTO WEIGHT ROAST

Stop/Clear Desired roast category Food weight Start

9. AUTO COOK
Start Stop/Clear Desired auto cook category Food weight Start

4. GRILL COOKING
Stop/ Clear Function Grill Desired cooking time Start

10. CHILD LOCK

This oven has a CHILD LOCK feature. To Set CHILD LOCK Stop/Clear Stop/Clear (Touch and Hold)

5. CONVECTION COOKING
To pre-heat Stop/ Clear To cook Stop/ Clear Function Convection Desired convection temp(40C, 100C~250C) Desired cooking time Start Function Convection Desired convection temp(40C, 100C~250C) Start

To Cancel CHILD LOCK Stop/Clear Stop/Clear (Touch and Hold)

11. QUICK START

Stop/Clear Start

Start

12. MORE AND LESS

Stop/Clear Desired auto cook More Less

4-2

SCHEMATIC DIAGRAM

4-3

CIRCUIT DESCRIPTION
GENERAL DETAILS
The low voltage transformer supplies the necessary voltage to the micom controller when power cord is plugged in. When the door is closed, the primary switch is ON, the secondary switch is ON, and the monitor switch opens (contact COM and NO). power of microwave oven as POWER LEVEL. (refer to page 1-1) One complete cycle of relay 2 is 22 seconds.

WHEN THE DOOR IS OPENED DURING COOKING

Both the primary switch and relay 2 are cut off primary winding voltage of the high voltage transformer. ON-OFF of relay 2 is coupled electrically with opening and closing of the secondary switch. When the door is opened, the secondary switch is opened and when the door is closed, the secondary switch is closed. The cooking time stops counting down. Relay stops functioning. As the door is opened, if the contact of primary switch fails to open, the fuse opens due to the large current surge caused by the monitor switch activation, which in turn stops magnetron oscillation.
FUSE PRIMARY SWITCH

WHEN SELECTING COOKING POWER LEVEL AND TIME

The micom controller memorizes the function you set. The time you set appears in the display window. Each indicator light turns on to indicate that the stage has been set.

WHEN TOUCHING THE START PAD

The coil of the relay is energized by the micom controller. Power input is supplied to the high voltage transformer through the fuse to the primary switch and relay 2. Turntable rotates.
FUSE PRIMARY SWITCH

L
MONITOR SWITCH H.V. TRANSFORMER

L
MONITOR SWITCH H.V. TRANSFORMER

N
SECONDARY SWITCH

N
RELAY 2
RELAY 2 MICOM CONTROLLER SECONDARY SWITCH

MICOM CONTROLLER

The fan motor rotates and cools the magnetron by blowing the air (coming from the intake on the baseplate). The air is also directed into the oven to exhaust the vapor in the oven through the upper plate. Cooking time starts counting down. 3.2 volts AC is generated from the filament winding of the high voltage transformer. This 3.2 volts is applied to the magnetron to heat the magnetron filament through two noise-preventing choke coils. A high voltage of approximately 2100 volts AC is generated in the secondary of the high voltage transformer which is increased by the action of the high voltage diode and charging of the high voltage capacitor. The negative 4,000 Volts DC is applied to the filament of the magnetron.

WHEN TOUCHING THE START KEY WITH THE GRILL COOKING FUNCTION SELECTED
The contacts of the primary switch and the secondary switch close the circuit. A.C. voltage is applied to the grill heater through grill thermostat as shown by the solid line.
RELAY 3
L

L N

G -Y

GRILL HEATER

WHEN THE OVEN IS SET AT ANY LEVEL EXCEPT MAXIMUM.

The micom controller controls the ON-OFF time of relay 2 by the applied signal to vary the average output

Turntable rotates. The fan motor rotates. The air is also directed into the oven to exhaust the vapor in the oven through the base plate and upper plate.

4-4

SERVICE INFORMATION
TOOLS AND MEASURING INSTRUMENTS
NECESSARY TOOLS
Tools normally used for TV servicing are sufficient. Standard tools are listed below. Diagonal pliers Long nose pliers Phillips screwdriver Flat blade screwdriver Wrench (size 5mm) Nutdriver (size 5mm) Adjustable wrench Soldering iron Solder Vinyl insulation tape Polishing cloth

NECESSARY MEASURING INSTRUMENTS

TESTER(VOLTS-DC, AC., Ohmmeter) Microwave survey meter - Holaday HI-1500 HI-1501 - Narda 8100 8200 Inch scale 600 cc non conductive material beaker (glass or plastic), inside diameter: approx. 8.5 cm(31/2 in.) Cylindrical and made of borosilicate glass vessel. max. thickness: 3 mm outside diameter: approx. 190mm height: approx. 90mm Glass thermometer: 100C or 212F (1 deg scale)

MICROWAVE LEAKAGE TEST

CAUTIONS
Be sure to check microwave leakage prior to servicing the oven if the oven is operative prior to servicing. The service personnel should inform the manufacture importer, or assembler of any certified oven unit found to have a microwave emission level in excess of 5 mW/cm2 and should repair any unit found to have excessive emission levels at no cost to the owner and should ascertain the cause of the excessive leakage. The service personnel should instruct the owner not to use the unit until the oven has been brought into compliance. If the oven operates with the door open, the service personnel should: - Tell the user not to operate the oven. - Contact the manufacturer. The service personnel should check all surface and vent openings for microwave leakage. Check for microwave leakage after every servicing. The power density of the microwave radiation leakage emitted by the microwave oven should not exceed 4 mW/cm2. Always start measuring of an unknown field to assure safety for operating personnel from radiation leakage.

MEASURING MICROWAVE ENERGY LEAKAGE

Pour 27515cc of 205C(689F) water in a beaker which is graduated to 600 cc, and place the beaker on the center of the turntable. Set the energy leakage monitor to 2,450 MHz and use it following the manufacturer's recommended test procedure to assure correct result. When measuring the leakage, always use the 2inch (5cm) spacer supplied with the probe. Operate the oven at its maximum output. Measure the microwave radiation using and electromagnetic radiation monitor by holding the probe perpendicular to the surface being measured Move probe along shaded area Probe scanning speed Less than 2.5 cm/sec ( 1in/sec)

5-1

MEASUREMENT WITH OUTER CASE REMOVED

When you replace the magnetron, measure for microwave energy leakage before the outer case is installed and after all necessary components are replaced or adjusted. Special care should be taken in measuring the following parts. (Circled area of below Fig.) - Around the magnetron - The waveguide

NOTES WHEN MEASURING

Do not exceed meter full scale deflection. The test probe must be removed no faster than 1 inch/sec (2.5 cm/sec) along the shaded area, otherwise a false reading may result. The test probe must be held with the grip portion of the handle. A false reading may result if the operator's hand is between the handle and the probe. When testing near a corner of the door, keep the probe perpendicular to the surface making sure the probe horizontally along the oven surface, this may possibly cause probe damage.

WARNING : AVOID CONTACTING ANY HIGH VOLTAGE PARTS

RECORD KEEPING AND NOTIFICATION AFTER MEASUREMENT

After adjustment and repair of any microwave energy interruption or microwave energy blocking device, record the measured values for future reference. Also enter the information on the service invoice. The microwave energy leakage should not be more than 4 mW/cm.sq. after determining that all parts are in good condition, functioning properly and genuine replacement parts which are listed in this manual have been used. At least once a year, have the electromagnetic energy leakage monitor checked for calibration by its manufacturer.

MEASUREMENT WITH A FULLY ASSEMBLED OVEN

After all components, including the outer case, are fully assembled, measure for microwave energy leakage around the door viewing window, the exhaust opening, and air inlet openings. Microwave energy leakage must not exceed the values prescribed below. NOTE: Leakage with the outer case removedless than 5 mW/cm.sq. Leakage for a fully assembled oven (Before the latch switch (primary) is interrupted) with the door in a slightly opened position-less than 2 mW/cm.sq.

5-2

MEASUREMENT OF MICROWAVE POWER OUTPUT

Microwave power output measurement is made with the microwave oven supplied at its rated voltage and operated at its maximum microwave power setting with a load of (1000 5)g potable water. The water is contained in a cylindrical borosilicate glass vessel having a maximum material thickness of 3 mm and an outside diameter of approximately 190 mm. The oven and the empty vessel are at ambient temperature prior to the start of the test. The initial temperature (1) of the water is (102)C. 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 position and the microwave power switched on. The time T for the temperature of the water to rise by a value T of (102)K is measured, where T is the time in seconds and T is the temperature rise. The initial and final water temperatures are selected so that the maximum difference between the final water temperature and the ambient temperature is 5K. The microwave power output P in watts is calculated from the following formula: P=

4187 X (T) + 0.55 X (T2 - T0) X M T

T2: Temperature after heating T0: Temperature of bowl M: Weight of bowl

is measured while the microwave generator is operating at full power. Magnetron filament heat-up time is not included. The water is stirred, to equalize temperature throughout the vessel, prior to measuring the final water temperature. Stirring devices and measuring instruments are selected in order to minimize addition or removal of heat.
WATER LOAD

TURNTABLE

DISASSEMBLY AND ADJUSTMENT

A. OUTER CASE REMOVA
1) Disconnect the power supply cord from the outlet. 2) Remove the screws from the rear and along side edges of the case. The outer case must be moved backward to be lifted off.

C. CONTROL PANEL ASSEMBL

1) Disconnect the leadwire from the PCB SUB ASSY. 2) Remove the screws for the earth and securing the control panel. 3) Lift control panel ASSY from the oven by the tab unhooked.

B. POWER SUPPLY CORD

1) Remove the outer case. 2) Disconnect two terminals, and remove one screw of the earth terminal.

CAUTION: DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE SERVICING (refer to page 2-1)

5-3

D. DOOR GROSS ASSEMBLY REMOVAL

1) Open the door. 2) Remove the choke cover very carefully with a flatblade screwdriver. CAUTION : Be careful not to damage door seal plate by screwdriver. 3) Lift up and push the door. NOTE: 1. After replacing the door, be sure to check that the primary switch, monitor switch, and secondary switch operate normally. 2. After replacing the door, check for microwave energy leakage with a survey meter. Microwave energy must be below the limit of 5 mW/cm. (with a 275 ml water load) 3. When mounting the door assembly to the oven assembly, be sure to adjust the door assembly parallel to the chassis. Also adjust so the door has no play between the inner door surface and oven frame assembly. If the door assembly is not mounted properly, microwaves may leak from the clearance between the door and the oven.

F. AIR DUCT ASSEMBLY REMOVAL

1) Disconnect the leadwire from lamp and MGT thermostat. 2) Remove the mounting screw to the magnetron.

G. MAGNETRON REMOVAL
1) Disconnect the leadwire from the high voltage transformer and high voltage capacitor. 2) Carefully remove the mounting screws holding the magnetron and the waveguide. 3) Remove the magnetron ASSY until the tube is clear from the waveguide. NOTE: 1. When removing the magnetron, make sure its dome does not hit any adjacent parts, or it may be damaged. 2. When replacing the magnetron, be sure to install the magnetron gasket in the correct position and be sure that the gasket is in good condition. 3. After replacing the magnetron, check for microwave leakage with a survey meter around the magnetron. Microwave energy must be below the limit of 5 mW/cm2. (With a 275 ml. water load). Make sure that gasket is rigidly attached to the magnetron. To prevent microwave leakage, tighten the mounting screws properly, making sure there is no gap between the waveguide and the magnetron.

Magnetron

E. HIGH VOLTAGE TRANSFORMER REMOVAL

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.
Air Duct

5-4

H. FAN MOTOR ASSEMBLY REMOVAL

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 the suction guide ASSY 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 ASSY to the suction guide ASSY.

J. REMOVING THE TURNTABLE MOTOR

1) Remove the turntable. 2) Remove the turntable shaft VERY CAREFULLY with a slotted screwdriver. 3) Lay the unit down on its back. 4) Remove the turntable motor cover. The turntable 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 ASSY 7) After repairing the motor, rotate the removed turntable motor cover. 8) Fit the turntable motor covers projecting part to the base plate slit. NOTE: 1. Remove the wire lead from the turntable motor VERY CAREFULLY. 2. Be sure to grasp the connector, not the wires, when removing.

I. HIGH VOLTAGE CAPACITOR AND DIODE REMOVAL

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 suction guide ASSY to the oven cavity and remove the high voltage diode earth screw. 4) Remove the screw holding the high voltage capacitor bracket.

Fan Motor ASSY

Suction Guide H.V. Transformer H.V. Capacitor

Wire Leads Turntable Motor

5-5

K. C-MOTOR, THERMISTOR AND SHEATH HEATER REMOVAL

1) Remove the two screws securing the cover assembly to the oven cavity. 2) Disconnect the leadwire from the circulation motor terminal and the sheath heater. 3) Remove the screws of the thermistor, guide assychamber and lift up the guide assy-chamber. 4) Remove a hex nut securing the circulation fan to shaft of the C-motor. 5) Remove screws securing the motor bracket to the guide assy-chamber. 6) Remove two hex nuts securing the C-motor to the motor bracket.

M. INTERLOCK SYSTEM
1) INTERLOCK MECHANISM The door lock mechanism is a device which has been specially designed to eliminate completely microwave activity when the door is opened during cooking and thus to prevent the danger resulting from the microwave leakage. 2) MOUNTING OF THE PRIMARY/MONITOR/ SECONDARY SWITCHES TO THE LATCH BOARD 3) INSTALLATION AND ADJUSTMENT OF THE LATCH BOARD TO THE OVEN ASSEMBLY

L. PCB ASSEMBLY REMOVAL

1) Remove the control panel assembly from the cavity. (Refer to control panel assembly removal on previous page.) 2) Remove screws which hold the PCB SUB ASSY to the control panel. 3) Disconnect the flat cable from the PCB SUB ASSY and take off the PCB SUB ASSY.

Latch Board

Primary Interlock Switch

Interlock Monitor Switch

Secondary Interlock Switch

Mount the latch board to the oven assembly. Adjust the latch board in the arrow direction so that oven door will not have any play in it when the door is closed. Tighten the mounting screw.

5-6

INTERLOCK CONTINUITY TEST

WARNING : FOR CONTINUED PROTECTION AGAINST EXCESSIVE RADIATION EMISSION, REPLACE ONLY WITH IDENTICAL REPLACEMENT PARTS.
TYPE NO. SZM-V 16-FA-63 OR VP-533A-OF FOR PRIMARY SWITCH TYPE NO. SZM-V 16-FA-61 OR VP-531A-OF FOR MONITOR SWITCH TYPE NO. SZM-V 16-FA-63 OR VP-533A-OF FOR SECONDARY SWITCH

A. PRIMARY INTERLOCK SWITCH TEST

When the door release button is depressed slowly with the door closed, an audible click should be heard at the same time or successively at intervals. When the button is released slowly, the latches should activate the switches with an audible click. If the latches do not activate the switches when the door is closed, the switches should be a adjusted in accordance with the adjustment procedure. Disconnect the wire lead from the primary switch. Connect the ohmmeter leads to the common (COM) and normally open (NO) terminal of the switch. The meter should indicate an open circuit in the door open condition. When the door is closed, the meter should indicate a closed circuit. When the primary switch operation is abnormal, make the necessary adjustment or replace the switch only with the same type of switch.

B. SECONDARY INTERLOCK SWITCH TEST

Disconnect the wire lead from the secondary switch. Connect the ohmmeter leads to the common (COM) and normally open (NO) terminals of the switch. The meter should indicate a open circuit in the door open condition. When the door is closed, meter should indicate an closed circuit. When the secondary switch operation is abnormal, make the necessary adjustment or replace the switch only with the same type of switch.

C. MONITOR SWITCH TEST

Disconnect the wire lead from the monitor switch. Connect the ohmmeter leads to the common (COM) and normally closed (NC) terminals of the switch. The meter should indicate closed circuit in the door open condition. When the door is closed, meter should indicate an open circuit. When the monitor switch operation is abnormal, replace with the same type of switch. NOTE: After repairing the door or the interlock system, it is necessary to do this continuity test before operating the oven.
RESULTS Door open Door close

COMPONENTS SWITCHES (Wire leads removed)

TEST PROCEDURE Check for continuity of the switch with a Multi-meter

Primary Switch

NO COM

NC

Monitor Switch

COM

Secondary Switch

NO COM

NOTE: After checking for the continuity of switches, make sure that are correctly connected.

5-7

COMPONENT TEST PROCEDURE

CAUTIONS
1. DISCONNECT THE POWER SUPPLY CORD FROM THE OUTLET WHENEVER REMOVING THE OUTER CASE FROM THE UNIT. PROCEED WITH THE TEST ONLY AFTER DISCHARGING THE HIGH VOLTAGE CAPACITOR AND REMOVING THE WIRE LEADS FROM THE PRIMARY WINDING OF THE HIGH VOLTAGE TRANSFORMER. (SEE PAGE 2-1) 2. ALL OPERATIONAL CHECKS WITH MICROWAVE ENERGY MUST BE DONE WITH A LOAD (1 LITER OF WATER IN CONTAINER) IN THE OVEN.

COMPONENTS
HIGH VOLTAGE TRANSFORMER (Wire leads removed)

TEST PROCEDURE

RESULTS

FILAMENT WINDING TERMINAL SECONDARY TERMINAL

PRIMARY TERMINAL

1. Measure the resistance. (Ohm-meter scale: Rx1 and Rx100) Primary winding Secondary winding Filament winding 2. Measure the resistance. (Ohm-meter scale: Rx1000) Primary winding to ground Filament winding to ground MAGNETRON (Wire leads removed) 1. Measure the resistance. (Ohm-meter scale: Rx1) Filament terminal 2. Measure the resistance. (Ohm-meter scale: Rx1000) Filament to chassis

Approx.: 1.8 ohm Approx.: 112 ohm Less than: 1 ohm

Normal: Infinite Normal: Infinite

Normal: Less than 1 ohm

Normal: Infinite

5-8

COMPONENTS

TEST PROCEDURE
Antenna Gasket Chassis

RESULTS

Filament

NOTE: When testing the magnetron, be sure to install the magnetron gasket in the correct position and be sure that the gasket is in good condition. HIGH VOLTAGE CAPACITOR Measure the resistance. (Ohm-meter scale: Rx1000) Terminal to terminal. Normal: Momentarily indicates several ohms, and then gradually returns to infinite.

Measure the resistance. (Ohm-meter scale: Rx1000) Terminal to case.

Normal: Infinite.

HIGH VOLTAGE DIODE

Measure the continuity (Forward). (Ohm-meter scale: Rx10000)

Normal: Infinite. Abnormal: Continuity.

NOTE : Some inexpensive meters may indicate infinite resistance in both direction.

Measure the continuity (Reverse). (Ohm-meter scale: Rx10000)

Normal: Continuity. Abnormal: Infinite.

5-9

COMPONENTS
FUSE

TEST PROCEDURE
Check for continuity of the fuse with an multi-meter.

RESULTS
Normal Abnormal

NOTE: If the fuse is blown, check the primary, the secondary, and the monitor switches, H.V.D. and H.V.C. before replacing the fuse. If the fuse is blown by improper switch operation replace the defective switch and the fuse at the same time. Replace just the fuse if the switches operate normally. HEATER ELEMENT (Wire leads removed.) Measure the resistance. (Multi-meter scale: Rx1) Normal: *Grill heater Approx. 42 ohm (at 20 ~ 30oC)

Measure the resistance with 500V-100M ohm insulation resistance meter. Normal: more than 0.5 Mohm

NOTE: Make sure heater is fully cooled when tested. MAGNETRON THERMOSTAT 0C~Approx.90C Approx.90C

0C~Approx.145C Approx.145C

5-10

COMPONENTS
Disconnect the 8 pin connector from P.C.B. (Refer to schemetic diagram)

TEST PROCEDURE
Check for P.C.B. connector.

RESULTS
Cooking Start OFF

RELAY 2, RELAY 3 OF P.C.B. (Wire leads removed.) Note: Relay Relay 1: Turntable motor Oven lamp Relay 2: Microwave Relay 3: Grill

Cooking Start
Relay 3

OFF

Relay 1

Relay 2

FAN MOTOR (Wire leads removed)

Measure the resistance. (Ohm-meter scale: R x 1)

Normal: Approx. 200 ~400 ohm A B Approx. 30 ~ 50 ohm Approx. 300 ~ 500 ohm

Abnormal: Infinite or several ohm.

TURNTABLE MOTOR (Wire leads removed)

Measure the resistance. (Ohm-meter scale: R x 1000)

Normal: Approx. 10~20 kohm Abnormal: Infinite or several ohm.

NOTE : A MICROWAVE LEAKAGE TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS SERVICED FOR ANY REASON. MAKE SURE THE WIRE LEADS ARE IN THE CORRECT POSITION. WHEN REMOVING THE WIRE LEADS FROM THE PARTS, BE SURE TO GRASP THE CONNECTOR, NOT THE WIRES.

5-11

COMPONENTS
CIRCULATION MOTOR (Wire leads removed)

TEST PROCEDURE
Measure the resistance. (Multi-meter scale : R x 1)

RESULTS
Normal : COM-230V : Approx. 150 COM-24V : Approx. 20 Abnormal : Infinite or several ohm.

NOTE: *( ) = WIRE COLOR

24V (BN) COM (YL)

230V(BL)

RELAY 4, 6, OF P.C.B (Disconnect the 9 pin connector from P.C.B) See Schematic Dagram on page 4-3)

Cooking Start
CN2
1 3 5 7 9 Relay 6 Relay 4

OFF

Cooking Start RELAY 2, 3, 5 OF P.C.B (Wire leads removed.) RY2 : Microwave RY3 : Grill RY5 : Convection

OFF

Relay 2 Relay 3 Relay 5

KEY PCB

Key P.C.B.
1 2 3 4 5 6 7 8 9 10 ~ 18

Main P.C.B
1 2 3 4 5 6 7 8 9 10 ~ 18

Check continuity between switch terminals, by pressing an appropriate pad on key board. The contacts assignment of the respective pads on the key board is as shown left figures.

NOTE : A MICROWAVE ENERGY LEAKAGE TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS SERVICED FOR ANY REASON. MAKE SURE THE WIRE LEADS ARE CORRECT POSITION. WHEN REMOVING THE WIRE LEAD FROM THE PARTS, BE SURE TO GRASP THE CONNECTOR, NOT THE WIRES.

5-12

TROUBLE SHOOTING
WHEN YOU GET A COMPLAINT FROM YOUR CUSTOMER, EVALUATE THE COMPLAINT CAREFULLY. IF THE FOLLOWING SYMPTOMS APPLY, PLEASE INSTRUCT THE CUSTOMER IN THE PROPER USE OF THE MICROWAVE OVEN. THIS CAN ELIMINATE AN UNNECESSARY SERVICE CALL.

CAUTIONS
1. Check grounding before checking for trouble. 2. Be careful of the high voltage circuit. 3. Discharge the high voltage capacitor. (See page 2-1) 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.

CONDITION
Microwave oven does not work.

CAUSE
Inserting many plug into one plug outlet and using them at the same time (causes overloading). Microwave oven plug is not inserted tightly.

REMEDY
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. 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.

Output power is too low.

Low AC input voltage.

Food temperature is too low.

Sparks occurring.

Using metallic ware and allowing it to touch the oven wall. Ceramic ware trimmed in gold or silver powder is used.

Uneven cooking.

Inconsistent intensity of microwave by their characteristics.

5-13

(TROUBLE 1) The following visual conditions indicate a probable defective control circuit.
1. Incomplete segments. Segment missing. Partial segment missing. Digit flickering (NOTE: Slight flickering is normal.) 2. Colon does not turn on or blink. 3. A distinct change in the brightness of one or more numbers in display. 4. One or more digits in the display are not lighting. 5. Display indicates a number different from one touched, for example, key in 5 and 3 appears in the display. 6. Specific numbers (for example 7 or 9) will not display when key pad is touched. 7. Display does not count down with time blinking or up with clock operation. 8. Display obviously jumps in time while counting down. 9. Display counts down too fast while cooking. 10. Each indicator light does not turn on after setting cooking cycle. 11. Display time of day does not reappear when cooking is finished. 12. Beep sound is not heard when correct key is touched.

CONDITION
1. No input can be programmed.

CHECK
Check the connection between membrane key assembly and PCB assembly. Replace key membrane assembly and check operation.

RESULT
Continuity.

CAUSE
Defective PCB assembly. Loose connection. Defective key membrane assembly. Defective PCB assembly.

REMEDY
Replace PCB assembly. Connect them tightly. Replace key membrane assembly. Replace PCB assembly.

No continuity.

2. Some inputs cannot be programmed. 3. Display shows a number or figure different from one touched.

Everything works as specified.

Still have trouble.

4. Random programming when touching other pads. 5. Display is fixed at some figure and can not accept any input.

5-14

(TROUBLE 2) Oven does not operate at all ; Display window does not display any figures and no input is accepted. CONDITION
1. Fuse blows.

CHECK
Check continuity of monitor switch (with door closed).

RESULT
Continuity.

CAUSE
Malfunction of the monitor switch.

REMEDY
Replace primary and monitor switches.

No continuity.

Replace fuse

Check continuity of primary switch (with door opened).

Continuity.

Shorted contact at the primary switch.

Replace primary and monitor switches.

No continuity.

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

Normal.

Defective high voltage capacitor. Defective high voltage transformer.

Replace high voltage capacitor. Replace high voltage transformer.

Fuse blows again

NOTE : All these switches must be replaced at the same time. Refer to page 5-6, 5-7

2. Fuse does not blow.

Check continuity of magnetron thermostat.

No continuity.

Defective magnetron thermostat.

Replace magnetron thermostat.

Continuity.

Check continuity of power supply cord.

No continuity.

Defective power supply cord.

Replace power supply cord.

5-15

(TROUBLE 3) Display shows all figures set, but oven does not start cooking while desired program times are set and START pad is touched. CONDITION
1.Setting time does not count down when touching START pad.

CHECK
Check continuity of secondary switch (with door closed).

RESULT
No continuity.

CAUSE
Defective secondary switch.

REMEDY
Replace secondary switch.

continuity.

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

No continuity.

Defective P.C.B assembly. Loose connection.

Replace P.C.B assembly. Connection then tightly. Replace fan motor. Replace fan motor.

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

Check fan motor.

Abnormal.

Defective fan motor. Defective fan motor.

Check oven lamp.

Abnormal. Normal.

(TROUBLE 4) Oven seems to be operation but little heat is produced in oven load. CONDITION
Output is low.

CHECK
Check the power source voltage.

RESULT
Lower than 90% of rating voltage. Normal.

CAUSE
Decrease in power source voltage with load.

REMEDY
Suggest customer contact local electric power utility co. or qualified electrician. Replace P.C.B assembly.

Disconnect the wire leads from relay 2 and check on and off time with multitester.

Abnormal. Normal.

Defective P.C.B assembly.

Measure the output power.

Abnormal.

Defective magnetron.

Replace magnetron.

NOTE: Simple test of power output-conducted by heating one liter water for one min. if available. Minimum 8.5oC temperature rise is normal condition.

5-16

(TROUBLE 5) No microwave oscillation even though oven lamp and fan motor run (Display operates properly) CONDITION
No microwave oscillation.

CHECK
Disconnect the wire leads from relay 2 and check continuity of relay2. (Operate the unit)

RESULT
No continuity.

CAUSE
Defective P.C.B assembly

REMEDY
Replace P.C.B assembly

Continuity.

Check H.V. transformer.

Abnormal

Defective high voltage transformer.

Replace high voltage transformer .

normal

Check H.V. capacitor.

Abnormal

Defective high voltage capacitor.

Replace high voltage capacitor.

normal

Check H.V. diode.

Abnormal

Defective high voltage Diode.

Replace high voltage Diode.

normal

Check Magnetron.

Abnormal

Defective magnetron.

Replace magnetron .

5-17

(TROUBLE 6) Oven does not cook properly when programmed for the set power level (Operates properly on HIGH) CONDITION
Output is full when you set lower power level.

CHECK
Disconnect the wire leads from relay 2 and check continuity relay 2. (Operate the unit)

RESULT
Abnormal.

CAUSE
Defective P.C.B. assembly.

REMEDY
Replace P.C.B. assembly.

(TROUBLE 7) Grill/Convection CONDITION

1. Heater is not operating.

CHECK
Heater.

RESULT
Abnormal.

CAUSE
Malfunction the heater.

REMEDY
Replace.

Normal.

Relay3, 5.

Abnormal.

Malfunction the relay.

Replace.

Normal. Replace or connect tightly.

Wire connection.

No continuity.

Open or loosen.

2. Under or over cooking in conv. mode.

Heater.

Abnormal.

Malfunction the heater.

Replace.

Normal.

Thermistor

Abnormal.

Malfunction the thermistor.

Replace.

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.

5-18

EXPLODED VIEW
INTRODUCTION

OVEN CAVITY PARTS INTERIOR PARTS DOOR PARTS BASE PLATE PARTS LATCH BOARD PARTS CONTROL PANEL PARTS

6-1

DOOR PARTS

13581A

15006A

13552A

13213A

14890A 13720D

14026A

14970A

6-2

CONTROL PANEL PARTS

24781S 268711

23572A

249401

WTP004

250203

WTP015 23790D 250202

249402 250201

6-3

OVEN CAVITY PARTS

33112U WTT021 WTT021 35264A

33550H WNZ015

WSZ092

33052M

WTT010

35026G
35300S

35026C

34960A WSZ184

33390M

36549S

33390G 34370T 35889A

WTP013

6-4

LATCH BOARD PARTS

WSZ085 43501A

466001

466003

43500A 44510A

466001

6-5

INTERIOR PARTS
33808A WSZ002 56411A 568771 WTT022 54975G 55900C 54350S WWP008 WNH003 WWS005 55300S WTT028 56201A 56549F WSZ002 55900A WTT037 54980A WTP004 WSZ002 34930W 54974S 56851D 55900N 568772 WTT021

56322A WTT010

36549C 54810S WNH002

53504A 56208A WMT002 50FZZA

56912B

56930M WSZ002

56324A 948501 WSZ002 55262A 56851C 50CZZH

WSZ002

6-6

BASE PLATE PARTS

56170D

63302A

63303A

647781

WTT030

WSZ002

WTT021

6-7

SCHEMATIC DIAGRAM OF P.C.B

8-1

PRINTED CIRCUIT BOARD

8-2

P/NO : 3828W5S2927

Feb., 2003 Printed in Korea