Sharp R-403KK, Service Manual

Page 1: ...AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY INSIDE FRONT COVER BEFORE SERVICING INSIDE FRONT COVER WARNING TO SERVICE PERSONNEL 1 MICROWAVE MEASUREMENT PROCEDURE 2 FOREWORD AND WARNING 3 PRODUCT SPECIFICATIONS 4 GENERAL INFORMATION 4 OPERATION 6 TROUBLESHOOTING GUIDE 9 TEST PROCEDURE 10 TOUCH CONTROL PANEL 18 COMPONENTREPLACEMENTANDADJUSTMENTPROCEDURE 23 PICTORIALDIAGRAM 30 CPUUNITCIRCUI...

Page 2: ...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 BEFORE SERVICING Before servicing an operative unit perform a microwave emission check as per the Microwav...

Page 3: ...pacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that the leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord When the testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Reconne...

Page 4: ... of the oven cavity The water container shall be a low form of 600 ml 20 oz beaker with an inside diameter of approx 8 5 cm 3 1 2 in and made of an electrically nonconductive material such as glass or plastic The placing of this standard load in the oven is important not only to protect the oven but also to insure that any leakage is measured accurately 4 Set the cooking control on Full Power Cook...

Page 5: ... D The door is not deformed or warped E There is no other visible damage with the oven Servicing and repair work must be carried out only by trained service personnel DANGER Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing Service person nel Do not contact the following parts while the appliance is energized High Voltage Capacitor Po...

Page 6: ...avity Dimensions Width 15 Height 9 7 16 1 4 Cubic Feet Depth 16 3 4 ControlComplement Touch Control System Clock 1 00 12 59 Timer 0 99 min 99 seconds Microwave Power for Variable Cooking Repetition Rate P HI Full power throughout the cooking time P 90 approx 90 of Full Power P 80 approx 80 of Full Power P 70 approx 70 of Full Power P 60 approx 60 of Full Power P 50 approx 50 of Full Power P 40 app...

Page 7: ...by children or tripped over accidentally CAUTION DO NOT UNDER ANY CIRCUMSTANCES CUT OR RE MOVE THE ROUND GROUNDING PRONG FROM THIS PLUG OVEN DIAGRAM 1 One touch door open button Push to open door 2 Door latches The oven will not operate unless the door is securely closed 3 Removable turntable support 4 Removable turntable The turntable will rotate clockwise or counterclockwise 5 Oven lamp It will ...

Page 8: ...o the turntable motor the cooling fan motor and the high voltage componentsarede energized theovenlampremainson andthedigitalread outdisplaysthetimestillremainingin the cook cycle when the door was opened 7 The monitor switch electrically monitors the operation of theprimaryinterlockswitchandsecondaryinterlockrelay andismechanicallyassociatedwiththedoorsothatitwill function in the following sequen...

Page 9: ...NDARY INTERLOCK RELAY ORG BRN ORG ORG RED GRY GRY GND WHT F3 F2 F1 SENSOR RY1 OVEN LAMP RELAY COM N O HUMIDITY COM N C HIGH VOLTAGE RECTIFIER ORG H N RED RED PNK GRN GRN GRN GRN C3 C2 C1 BLK WHT NOISE FILTER MONITOR FUSE 20A R2 TO LOAD TO LOAD TO SOURCE TO SOURCE NOTES 1 CIRCUITS SUBJECT TO CHANGE WITHOUT NOTICE 2 TERMINAL WITH PROJECTION OR OPPOSITE BLUE MARK ON LAMP SOCKET MUST BE CONNECTED TO N...

Page 10: ... TEST THE DOOR SENSING SWITCH SECONDARYINTERLOCKRELAY RY2 RE LAY RY1 PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OP ERATION REFERTOCHAPTER TESTPRO CEDURE NOTE MONITOR FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY TURNTABLE MOTOR The turntable motor rotates the turntable located on the bottom of the oven cavity so that the foods on the turntable cook evenly during cooking The turnt...

Page 11: ... KIT as an assembly IMPORTANT Whenever troubleshooting is performed with the power supply cord disconnected It may in some cases be necessary to connect the power supply cord after the outer case has been removed in this event 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect the leads to the primary of t...

Page 12: ...ad is touched Oven seems to be operating but little or no heat is produced in oven load Food incompletely cooked or not cooked at all at end of cook cycle Oven goes into a cook cycle but extremely uneven heating is pro duced in oven load food Oven does not cook properly when programmed for Cooking Power P 50 mode Operates properly on Cooking P HI HIGH mode Oven goes into COMPU DEFROST but food is ...

Page 13: ...G THE COOK CYCLE SO EXTREME CAUTION SHOULD BE OBSERVED Power output of the magnetron can be measured by performing a water temperature rise test This test shouldonlybeusedifabovetestsdonotindicateafaultymagnetronandthereisnodefectinthefollowing componentsorwiring siliconrectifier highvoltagecapacitorandpowertransformer Thistestwillrequire a 16 ounce 453cc measuring cup and an accurate mercury ther...

Page 14: ...ally the cooling fan and air guide 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions MAGNETRON TEMPERATURE FUSE TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor...

Page 15: ... a closed circuit with the door closed If improper operation is indicated replace the door sensing switch 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions NOTE If the door sensing switch contacts fail in the open position and the door is closed t...

Page 16: ...ads a When touching the pads a certain group of pads do not produce a signal b When touching the pads no pads produce a signal I TThe touch control panel consists of circuits including semiconductors such as LSI ICs etc 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Before performing this test make sure that the ...

Page 17: ...econnect all leads removed from components during testing 5 Re install the outer case cabinet 6 Reconnect the power supply cord after the outer case is installed 7 Run the oven and check all functions TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST J KEY UNIT TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Us...

Page 18: ... open terminal of the relay RY2 on the control unit with an A C voltmeter The meter should indicate 120 volts if not check oven circuit RY1 and RY2 Relay Test These relays are operated by D C voltage Check voltage at the relay coil with a D C voltmeter during the microwave cooking operation DC voltage indicated Defective relay DC voltage not indicated Check diode which is connected to the relay co...

Page 19: ...1 L1 J1 a b c d 2 Followthetroubleshootingguidegivenbelow ifindicatordoesnotlightupafterabovecheckandrepairs are finished 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that these leads remain isolated from other components and oven chassis by ...

Page 20: ...ht LightemittingdiodesLD1 LD4 9 Night Light Circuit A circuit to drive the light emitting diode LD10 TOUCHCONTROLPANELASSEMBLY OUTLINEOFTOUCHCONTROLPANEL The touch control section consists of the following units 1 Key Unit 2 Control Unit The Control Unit consists of Power Unit and LSI Unit Theprincipalfunctionsoftheseunitsandthesignalscommu nicated among them are explained below KeyUnit Thekeyunit...

Page 21: ...s delivered to the RY1 driving circuit and RY2 control circuit 17 P51 OUT Terminal not used 18 P50 OUT Magnetron high voltage circuit driving signal To turn on and off the cook relay RY2 The signalsholds L levelduringmicrowavecook ing and H level while not cooking In other cooking modes variable cooking the signal turns to H level and L level in repetition according to the power level 19 P47 IN Si...

Page 22: ...put to P70 P71 P41 P45 P47 and AN3 terminal while one of G7 line keys on key matrix is touched 35 P25 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P70 P71 P41 P45 P47 and AN3 terminal while one of G6 line keys on key matrix is touched 36 P24 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P70 P71 P41 P45 P47 and AN3 termi...

Page 23: ...2 SEG 20 SEG10 62 SEG 10 SEG21 51 SEG 21 73 VCC IN Power source voltage GND 0V 74 VREF IN A D converter power source voltage GND 0V The power source voltage to drive the A D converter Connected to GND 75 AVSS IN A D converter power source voltage 5 0V The power source voltage to drive the A D converter 76 COM3 OUT Terminal not used 77 COM2 OUT Common data signal Connected to LCD signal COM1 78 COM...

Page 24: ...h control panel then it is possible to check and repair the controls of the touch control panel it is also possible to check the sensor related controls of the touch control panel by using the dummy resistor s 3 Servicing Tools Toolsrequiredtoservicethetouchcontrolpanelassembly 1 Solderingiron 30W Itisrecommendedtouseasolderingironwithagrounding terminal 2 Oscilloscope Singlebeam frequencyrange DC...

Page 25: ... power supply cord 2 Make sure that a definite click can be heard when the microwave oven door is unlatched Hold the door in a closed position with one hand then push the door open button with the other this causes the latch leads to rise it is then possible to hear a click as the door switches operate 3 Visuallycheckthedoorandcavityfaceplatefordamage dents cracks signs of arcing etc Carry out any...

Page 26: ...ead short one of the power transformer from the high voltage capacitor 7 Remove one 1 screw holding capacitor holder with the high voltage rectifier to the base plate 8 Disconnect rectifier terminal from capacitor High voltage rectifier assembly is now free 9 Remove capacitor holder Capacitor is now free CAUTION WHEN REPLACING HIGH VOLTAGE RECTI FIER AND HIGH VOLTAGE CAPACITOR GROUND SIDE TERMINAL...

Page 27: ...age capacitor 4 Disconnect the wire leads from panel components 5 Remove the one 1 screw holding the control panel assembly to the oven cavity front plate 6 Slide the control panel assembly upward and remove it 7 Now individual components can be removed NOTE 1 Beforeattachinganewkeyunit wipeoff remaining adhesive on the control panel frame surfaces completely with a soft cloth soaked in alcohol 2 ...

Page 28: ...e control panel frame with the three 3 screws NOTE Do not touch the contact surface of the ribbon cable edge and the rubber connector with a finger directly not to be oxidized If display digits are missing or scrambled remove control unit and make sure that there is not any trash or foreign substance on the contact surface of the rubber connector Use an adhesive tape to clean the contact surface o...

Page 29: ...ket which supports the shaft of the fan motor on the flat table 3 Apply the screw lock tight into the hole for shaft of the fan blade 4 Install the fan blade to the shaft of fan motor by pushing thefanbladewithasmall lightweight ballpeenhammer or rubber mallet CAUTION Do not hit the fan blade strongly when installed because the bracket may be disfigured Make sure that the fan blade rotates smooth ...

Page 30: ...screw and adjust the latch hook position After adjustment check the following 1 In and out play of door remains less than 0 5mm when in the latched position First check upper position of latch hook pushing and pulling upper portion of door toward the oven face Then check lower portion of the latch Figure C 3 Latch Switch Adjustments hook pushing and pulling upper portion of door toward the oven fa...

Page 31: ... to assure compliance with proper microwave radiation emission limitation standards After any service make sure of the following 1 Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of latch hole 2 Deviation of door alignment from horizontal line of cavity face plate is to be less than 1 0mm 3 Doorispositionedwithitsfacepressedtowardcavityface pl...

Page 32: ...USE MAGNETRON TEMP FUSE FAN MOTOR RED WHT WHT POWER SUPPLY CORD 120V 60Hz NOTE The neutral WHT GRY wire must be connected to the terminal with N mark on the power supply cord BLK WHT H N NOTE The grounding conductor of the power supply cord has been grounded by power supply cord fixing screw The screw must always be kept tight COM N O DOOR SENSING SWITCH PNK GRN GRN to Oven cavity GRN PNK GRN 2 1 ...

Page 33: ...31 R 405KS R 403KK 6 4 5 1 2 3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H Figure S 3 Control Unit Circuit Figure S 2 CPU Unit Circuit R 405KS ...

Page 34: ...32 R 405KS R 403KK 6 4 5 1 2 3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H Figure S 2 CPU Unit Circuit R 403KK ...

Page 35: ... D E F G H Figure S 5 Printed Wiring Board of Power Unit RY1 RY2 E C B E C B E C B VRS1 L1 D7 D3 P S D4 C2 D1 C1 D2 R8 R7 R2 R4 Q3 Q4 SP1 T1 D6 DZ1 WH 2 WH 2 LED Q2 D5 D8 D30 1 2 J1 J6 J2 J5 R5 C4 C5 CN B CN F 1 2 3 C10 DIP CHIP SIDE R90 J3 D31 R3 R6 E B 1 1 2 2 Q1 ...

Page 36: ... 3 2 FPNLCB503MRK0A M Control panel sub assembly 1 AU 3 3 PSHEPB192MRR0 M Key sheet assy 1 AP 3 4 FDECAB074MRK0 M Open button assy 1 AP 3 5 MSPRCA045WRE0 M Open button spring 1 AA 3 6 XEPSD30P08XS0 M Screw 3mm x 6mm 5 AB 3 7 PCOVPB144MRF0 M Night light cover 1 AH 3 8 QCNC A020WRZZ M Rubber connector 1 AC 3 9 PSHEPB037WREZ M LED sheet 1 AG 3 10 RLCDSA107DRZZ M LCD 1 AG 3 11 LANGQB060MRP0 M PWB supp...

Page 37: ...Main wire harnes 1 AS 6 2 FROLPB025MRK0 M Turntable support 1 AN 6 3 NTNT A108WREZ M Turntable tray 1 AM 6 4 TCAUAB050MRR0 M Monitor caution label 1 AA 6 5 TCAUAB053MRR0 M DHHS Screw caution label 1 AB 6 6 TINSEB418MRK0 M Operation manual 1 AD 6 7 QW QZB016MRE0 M High voltage wire A 1 AC SCREWS NUTSANDWASHERS 7 1 LX BZA041WRE0 M Special screw 5 AA 7 2 LX CZ0052WRE0 M Special screw 2 AA 7 3 XHTS740...

Page 38: ...Control unit assy 1 BF 3 2 HPNLCB211MRF0 M Control panel sub assembly 1 AW 3 3 FUNTKB448MRE0 M Key sheet assy 1 AS 3 4 JBTN B192MRF0 M Open button 1 AG 3 5 MSPRCA045WRE0 M Open button spring 1 AA 3 6 XEPSD30P08XS0 M Screw 3mm x 6mm 5 AB 3 7 PCOVPB148MRR0 M Night light cover 1 AM 3 8 QCNC A020WRZZ M Rubber connector 1 AC 3 9 PSHEPB037WREZ M LED sheet 1 AG 3 10 RLCDSA107DRZZ M LCD 1 AG 3 11 LANGQB06...

Page 39: ...Main wire harnes 1 AS 6 2 FROLPB025MRK0 M Turntable support 1 AN 6 3 NTNT A108WREZ M Turntable tray 1 AM 6 4 TCAUAB050MRR0 M Monitor caution label 1 AA 6 5 TCAUAB053MRR0 M DHHS Screw caution label 1 AB 6 6 TINSEB418MRK0 M Operation manual 1 AD 6 7 QW QZB016MRE0 M High voltage wire A 1 AC SCREWS NUTSANDWASHERS 7 1 LX BZA041WRE0 M Special screw 5 AA 7 2 LX CZ0052WRE0 M Special screw 2 AA 7 3 XHTS740...

Page 40: ...H OVEN AND CABINET PARTS 2 3 4 7 6 5 1 4 4 6 4 8 4 9 6 3 6 2 2 1 7 5 1 9 4 10 7 2 7 2 7 4 4 3 1 10 1 7 7 3 7 6 7 5 7 6 4 2 7 4 1 8 7 1 1 6 1 6 4 4 7 1 4 1 1 1 1 2 2 2 2 2 2 2 2 2 7 4 7 4 4 11 7 4 6 4 1 11 7 4 7 7 7 4 7 7 1 5 1 3 4 5 7 4 7 4 1 13 4 12 1 12 1 5 R 405KS R 403KK ...

Page 41: ... 5 1 2 3 A B C D E F G H A B C D E F G H CONTROL PANEL PARTS Actual wire harness may be different from illustration 6 7 6 1 3 4 3 9 3 10 3 2 3 3 3 5 3 6 3 1 3 11 3 7 3 8 5 1 5 3 5 2 5 5 5 6 5 8 5 4 5 7 5 DOOR PARTS MISCELLANEOUS R 405KS ...

Page 42: ...rness may be different from illustration 6 7 6 1 5 2 5 3 5 1 5 5 5 6 5 4 5 7 5 8 3 4 3 9 3 10 3 2 3 3 3 5 3 6 3 1 3 11 3 7 3 8 6 4 5 1 2 3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H R 403KK CONTROL PANEL PARTS DOOR PARTS MISCELLANEOUS ...

Page 43: ... ACCESSORIES DOOR PROTECTION SHEET PLASTIC BAG PACKING CASE TOP PAD ASSEMBLY INTO THE OVEN CAVITY 6 3 TURNTABLE TRAY 6 6 OPERATION MANUAL BOTTOM PAD ASSEMBLY TRAY HOLDER 6 2 TURNTABLE SUPPORT ON TOP OF THE OVEN Non replaceable items ...

Page 44: ...005 BY SHARP CORPORATION ALL RIGHTS RESERVED No part of this publication may be repro duced stored in retrieval systems or trans mitted in any form or by any means elec tronic mechanical photocopying recording orotherwise withoutpriorwrittenpermission of the publisher ...