R - 405KS
R- 403KK
SERVICE MANUAL
MICROWAVE OVEN MODELS
R-405KS
S45M250R405KE
R-403KK
In the interest of user-safety the oven should be restored to its original condition and only parts identical to those specified
should be used.
WARNING TO SERVICE PERSONNEL: Microwave ovens contain circuitry capable of producing very high voltage and
current, contact with following parts may result in a severe, possibly fatal, electrical shock. (High Voltage Capacitor,
High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..)
TABLE OF CONTENTS
Page
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO
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
COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE .................................................................. 23
PICTORIAL DIAGRAM ........................................................................................................................................ 30
CPU UNIT CIRCUIT ............................................................................................................................................. 31
PRINTED WIRING BOARD ................................................................................................................................. 33
PARTS LIST ........................................................................................................................................................ 34
PACKING AND ACCESSORIES ......................................................................................................................... 41
SHARP ELECTRONCS CORPORATION
This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135
R- 405KS
R-403KK
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.
BEFORE SERVICING
Before servicing an operative unit, perform a microwave emission check as per the
Microwave Measurement Procedure outlined in this service manual.
If microwave emissions level is in excess of the specified limit, contact SHARP
ELECTRONICS CORPORATION immediately @1-800-237-4277.
If the unit operates with the door open, service person should 1) tell the user
not to operate the oven and 2) contact SHARP ELECTRONICS CORPORATION and Food and
Drug Administration's Center for Devices and Radiological Health immediately.
Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit
found with emissions in excess of 4mW/cm2. The owner of the unit should be instructed
not to use the unit until the oven has been brought into compliance.
R-405KS
R-403KK
WARNING TO SERVICE PERSONNEL
Microwave ovens contain circuitry capable of producing very high voltage and current, contact with
following parts may result in a severe, possibly
fatal, electrical shock.
(Example)
High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..
Read the Service Manual carefully and follow all
instructions.
Don't Touch !
Danger High Voltage
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. Reconnect the leads to the primary of the power
transformer.
5. Reinstall the outer case (cabinet).
6. Reconnect the power supply cord after the outer case is
installed.
7. Run the oven and check all functions.
Before Servicing
1. Disconnect the power supply cord
remove outer case.
2. Open the door and block it open.
3. Discharge high voltage capacitor.
, and then
WARNING:RISK OF ELECTRIC SHOCK.
DISCHARGE THE HIGH-VOLTAGE
CAPACITOR BEFORE SERVICING.
After repairing
The high-voltage capacitor remains charged about 60
seconds after the oven has been switched off. Wait for 60
seconds and then short-circuit the connection of the highvoltage capacitor (that is the connecting lead of the highvoltage rectifier) against the chassis with the use of an
insulated screwdriver.
1. Reconnect all leads removed from components during
testing.
2. Reinstall the outer case (cabinet).
3. Reconnect the power supply cord after the outer case is
installed.
4. Run the oven and check all functions.
Whenever troubleshooting is performed the power supply
must be disconnected. It may, in some cases, be necessary
to connect the power supply 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 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.
Microwave ovens should not be operated empty. To test for
the presence of microwave energy within a cavity, place a
cup of cold water on the oven turntable, close the door and
set the power to HIGH and set the microwave timer for two
(2) minutes. When the two minutes has elapsed (timer at
zero) carefully check that the water is now hot. If the water
remains cold carry out Before Servicing procedure and reexamine the connections to the component being tested.
When all service work is completed and the oven is fully
assembled, the microwave power output should be checked
and a microwave leakage test should be carried out.
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R-405KS
R- 403KK
MICROWAVE MEASUREMENT PROCEDURE
A. Requirements:
1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven
should not exceed 1mW/cm2 at any point 5cm or more from the external surface of the oven, measured prior to acquisition
by a purchaser, and thereafter (through the useful life of the oven), 5 mW/cm2 at any point 5cm or more from the external
surface of the oven.
2) Safety interlock switches:
Primary interlock relay switch shall prevent microwave radiation emission in excess of the requirement as above
mentioned. Secondary interlock relay and door sensing switch shall prevent microwave radiation emission in excess of
5 mW/cm2 at any point 5cm or more from the external surface of the oven.
B. Preparation for testing:
Before beginning the actual measurement of leakage, proceed as follows:
1) Make sure that the actual instrument is operating normally as specified in its instruction booklet.
Important:
Survey instruments that comply with the requirement for instrumentation as prescribed by the performance standard for
microwave ovens, 21 CFR 1030.10(c)(3)(i), must be used for testing.
2) Place the oven tray in the oven cavity.
3) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5O C (68OF) in the center 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 Cooking Mode.
5) Close the door and select a cook cycle of several minutes. If the water begins to boil before the survey is completed, replace
it with 275 ml of cool water.
C. Leakage test:
Closed-door leakage test (microwave measurement):
1) Grasp the probe of the survey instrument and hold it perpendicular to the gap between the door and the body of the oven.
2) Move the probe slowly, not faster than 1 in./sec. (2.5 cm/sec.) along the gap, watching for the maximum indication on the
meter.
3) Check for leakage at the door screen, sheet metal seams and other accessible positions where the continuity of the metal
has been breached (eg., around the switches, indicator, and vents).
While testing for leakage around the door, pull the door away from the front of the oven as far as is permitted by the closed
latch assembly.
4) Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW/cm2, and
that the primary interlock switch/secondary interlock relay does turn the oven OFF before any door movement.
NOTE: After servicing, record data on service invoice and microwave leakage report.
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R-405KS
R-403KK
SERVICE MANUAL
PRODUCT DESCRIPTION
MICROWAVE OVENS
R-405KS & R-403KK
GENERAL INFORMATION
FOREWORD
This Manual has been prepared to provide Sharp Electronics Corp.
Service Personnel with Operation and Service Information for the SHARP
MICROWAVE OVENS R-405KS and R-403KK.
It is recommended that service personnel carefully study the entire text
of this manual so that they will be qualified to render satisfactory customer
service.
OPERATION
TROUBLESHOOTING GUIDE AND
TEST PROCEDURE
Check the interlock switches and the door seal carefully. Special attention
should be given to avoid electrical shock and microwave radiation hazard.
TOUCH CONTROL PANEL
WARNING
Never operate the oven until the following points are ensured:
(A) The door is tightly closed.
(B) The door brackets and hinges are not defective.
(C) The door packing is not damaged.
(D) The door is not deformed or warped.
(E) There is no other visible damage with the oven.
COMPONENT REPLACEMENT
AND ADJUSTMENT PROCEDURE
Servicing and repair work must be carried out only by trained service
personnel.
WIRING DIAGRAM
DANGER
Certain initial parts are intentionally not grounded and present
a risk of electrical shock only during servicing. Service personnel - Do not contact the following parts while the appliance is
energized;
High Voltage Capacitor, Power Transformer, Magnetron, High
Voltage Rectifier Assembly, High Voltage Harness;
If provided, Vent Hood, Fan assembly, Cooling Fan Motor.
All the parts marked “*” on parts list are used at voltages more than
250V.
Removal of the outer wrap gives access to voltage above 250V.
All the parts marked “∆” on parts list may cause undue microwave
exposure, by themselves, or when they are damaged, loosened or
removed.
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
3
PARTS LIST
R-405KS
R- 403KK
SPECIFICATION
ITEM
DESCRIPTION
PowerRequirements
120 Volts
14.0 Amperes, 1600 watts
60 Hertz
Single phase, 3 wire grounded
Power Output
1100 watts (IEC TEST PROCEDURE)
Operating frequency of 2450MHz
Case Dimensions
Width 21-11/16"
Height 12-3/8"
Depth 17-3/8"
Cooking Cavity Dimensions
Width 15"
Height 9-7/16"
Depth 16-3/4"
1.4 Cubic Feet
Control Complement
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 .................................................................... approx. 40% of Full Power
P-30 .................................................................... approx. 30% of Full Power
P-20 .................................................................... approx. 20% of Full Power
P-10 .................................................................... approx. 10% of Full Power
P-0 ...................................................... No power throughout the cooking time
R-405KS
START, MINUTE PLUS pad, Cook pad, Defrost pad, Number selection pads,
Power Level pad, Timer/Clock pad,Stop/Clear pad, Warm, Melt, Reheat,
Popcorn, Night light and Soften.
R-403KK
START, MINUTE PLUS pad, Cook center pad, Defrost center pad, Number
selection pads, Power Level pad, Timer/Clock pad,Stop/Clear pad, Warm, Melt,
Reheat center pad, Popcorn, Night light and Soften.
Oven Cavity Light
Yes
Safety Standard
UL Listed
FCC Authorized
DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J
GENERAL INFORMATION
GROUNDING INSTRUCTIONS
This oven is equipped with a three prong grounding plug. It must be plugged into a wall receptacle that is properly installed
and grounded in accordance with the National Electrical Code and local codes and ordinances.
In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric
current.
WARNING:
Improper use of the grounding plug can result in a risk of electric shock.
Electrical Requirements
The electrical requirements are a 120 volt 60 Hz, AC only,
4
R-405KS
R-403KK
15 or 20 amp. fused electrical supply. It is recommended that a separate
circuit serving only this appliance be provided. When installing this
appliance, observe all applicable codes and ordinances.
A short power-supply cord is provided to reduce risks of becoming
entangled in or tripping over a longer cord.
Where a two-pronged wall-receptacle is encountered, it is the personal
responsibility and obligation of the customer to contact a qualified
electrician and have it replaced with a properly grounded three-pronged
wall receptacle or have a grounding adapter properly grounded and
polarized. If the extension cord must be used, it should be a 3-wire, 15
amp. or higher rated cord. Do not drape over a countertop or table where
it can be pulled on by children or tripped over accidentally.
Grounded
Receptacle Box
3-Pronged
Plug
Grounding Pin
3-Pronged Receptacle
CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE ROUND GROUNDING PRONG FROM THIS
PLUG.
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 light when oven is operating or
door is opened.
6. Oven door with see-through window.
7. Ventilation openings. (Rear)
8. Auto-Touch control panel.
9. Time display: Digital display, 99
minutes 99 seconds.
OVEN DIAGRAM
5
6
7
9
11
8
2
10
1
4
3
10. Wave guide cover.
11. Power supply cord
TOUCH CONTROL PANELS
NOTE:
The directed features are disabled after one minute when the
oven is not in use. These features
are automatically enabled when
the door is opened and closed or
the STOP/ CLEAR pad is pressed.
R-405KS
R-403KK
5
R-405KS
R- 403KK
OPERATION
DESCRIPTION OF OPERATING SEQUENCE
The following is a description of component functions during
oven operation.
and is mechanically associated with the door so that it will
function in the following sequence.
(1) When the door opens from the closed position, the
secondary interlock relay (RY2) and primary interlock
switch open their contacts. And contacts of the relay
(RY1) remains closed. Then the monitor switch contacts
close.
(2) When the door is closed from the open position, the
monitor switch contacts open first. Then the contacts of
the primary interlock switch and door sensing switch
close. And contacts of the relay (RY1) open.
If the primary interlock switch and secondary interlock relay
(RY2) fail with the contacts closed when the door is opened,
the closing of the monitor switch contacts will form a short
circuit through the monitor fuse, primary interlock switch,
relay (RY1) and secondary interlock relay (RY2), causing the
monitor fuse to blow.
OFF CONDITION
Closing the door activates the door sensing switch and
primary interlock switch. (In this condition, the monitor switch
contacts are opened.)
When oven is plugged in, 120 volts A.C. is supplied to the
control unit. (Figure O-1).
1. The display will show flashing "88:88".
To set any program or set the clock, you must first touch
the STOP/CLEAR pad. The display will clear, and " : "
will appear.
COOKING CONDITION
Program desired cooking time by touching the NUMBER
pads. Program the power level by touching the POWER
LEVEL pad and then a Number pad.
When the START pad is touched, the following operations
occur:
POWER LEVEL P-0 TO P-90 COOKING
When Variable Cooking Power is programmed, the 120 volts
A.C. is supplied to the power transformer intermittently
through the contacts of relay (RY-2) which is operated by the
control unit within a 32 second time base. Microwave power
operation is as follows:
1. The contacts of relays are closed and components
connected to the relays are turned on as follows.
(For details, refer to Figure O-2)
RELAY
RY-1
RY-2
VARI-MODE
Power 10(P-HI)
(100% power)
Power 9(P-90)
(approx. 90% power)
Power 8(P-80)
(approx. 80% power)
Power 7(P-70)
(approx. 70% power)
Power 6(P-60)
(approx. 60% power)
Power 5(P-50)
(approx. 50% power)
Power 4(P-40)
(approx. 40% power)
Power 3(P-30)
(approx. 30% power)
Power 2(P-20)
(approx. 20% power)
Power 1(P-10)
(approx. 10% power)
Power 0(P-0)
(0% power)
CONNECTED COMPONENTS
oven lamp/turntable motor/fan motor
power transformer
2. 120 volts A.C. is supplied to the primary winding of the
power transformer and is converted to about 3.3 volts
A.C. output on the filament winding, and approximately
2370 volts A.C. on the high voltage winding.
3. The filament winding voltage heats the magnetron filament
and the H.V. winding voltage is sent to a voltage doubler
circuit.
4. The microwave energy produced by the magnetron is
channelled through the waveguide into the cavity feedbox, and then into the cavity where the food is placed to
be cooked.
5. Upon completion of the cooking time, the power
transformer, oven lamp, etc. are turned off, and the
generation of microwave energy is stopped. The oven
will revert to the OFF condition.
6. When the door is opened during a cook cycle, the monitor
switch, door sensing switch, primary interlock switch,
relay (RY1) and secondary interlock relay are activated
with the following results. The circuits to the turntable
motor, the cooling fan motor, and the high voltage
components are de-energized, the oven lamp remains on,
and the digital read-out displays the time still remaining in
the cook cycle when the door was opened.
7. The monitor switch electrically monitors the operation of
the primary interlock switch and secondary interlock relay
Note:
6
ON TIME
32 sec.
OFF TIME
0 sec.
30 sec.
2 sec.
26 sec.
6 sec.
24 sec.
8 sec.
22 sec.
10 sec.
18 sec.
14 sec.
16 sec.
16 sec.
12 sec.
20 sec.
8 sec.
24 sec.
6 sec.
26 sec.
0 sec.
32 sec.
The ON/OFF time ratio does not correspond with the
percentage of microwave power, because approx. 2
seconds are needed for heating of the magnetron
filament.
R-405KS
R-403KK
Note:* Indicates component
SCHEMATIC
NOTE: CONDITION OF OVEN
1. Door Closed
2. CLOCK APPEARS ON DISPLAY
CAVITY
TEMPERATURE
FUSE
MAGNETRON
TEMPERATURE
FUSE
ORG
ORG
RED
RED
BRN
ORG
RED
N.O.
GRN
GRN
COM.
GRN
B2
GRN
(RY1)
MAGNETRON
RED
RED
CONTROL UNIT
COM.
ORG
ORG
BRN
COM.
GRY
MONITOR
SWITCH
N.C.
FM FAN
MOTOR
WHT
WHT
WHT
GRY
"TO LOAD"
"TO SOURCE"
TURN
TTM TABLE
MOTOR
OVEN
LAMP
OL
HIGH
VOLTAGE
RECTIFIER
COM.
WHT
WHT
ORG
C3
NOISE
FILTER
HIGH
VOLTAGE
CAPACITOR
xx µF
F1
OVEN
LAMP
RELAY
C1
WHT
WHT
N.O.
C2
R2
F3
F2
GND
N
HUMIDITY
SENSOR
B1
(RY2)
SECONDARY
INTERLOCK
RELAY
WHT
GRN
120VAC
60Hz
POWER
TRANSFORMER
PNK
MONITOR
FUSE (20A)
H
"TO LOAD"
"TO SOURCE"
BLK
RED
DOOR
SENSING
SWITCH
N.O.
WHT
GRY
WHT PRIMARY WHT
INTERLOCK
SWITCH
NOTES:
1.CIRCUITS SUBJECT TO CHANGE WITHOUT NOTICE.
2. TERMINAL WITH PROJECTION OR OPPOSITE BLUE MARK ON LAMP SOCKET
MUST BE CONNECTED TO NEUTRAL WIRE.
3. ONLY CERTAIN MODELS USE THE ABSOLUTE HUMIDITY SENSOR.
4. POWER TRANSFORMER TOP (FINISH LEAD) TERMINAL MUST BE CONNECTED TO THE NEUTRAL (WHT) WIRE.
Figure O-1 Oven Schematic - Off Condition
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. COOKING TIME PROGRAMMED
3. VARIABLE COOKING CONTROL "HIGH"
4. "START" PAD TOUCHED
RED
MAGNETRON
TEMPERATURE
FUSE
ORG
ORG
RED
RED
BRN
ORG
CAVITY
TEMPERATURE
FUSE
N.O.
GRN
GRN
COM.
"TO LOAD"
(RY1)
GRY
COM.
ORG
ORG
RED
MONITOR
SWITCH
N.C.
WHT
WHT
FM FAN
MOTOR
COM.
WHT
WHT
BRN
TURN
TTM TABLE
MOTOR
OVEN
LAMP
WHT
OL
GRY
"TO LOAD"
WHT
WHT
ORG
C3
NOISE
FILTER
HIGH
VOLTAGE
CAPACITOR
xx µF
F1
OVEN
LAMP
RELAY
C1
"TO SOURCE"
HUMIDITY
SENSOR
CONTROL UNIT
COM.
WHT
N.O.
C2
R2
F3
F2
GND
N
PNK
B1
(RY2)
SECONDARY
INTERLOCK
RELAY
MONITOR
FUSE (20A)
GRN
POWER
TRANSFORMER
RED
RED
"TO SOURCE"
BLK
H
120VAC
60Hz
DOOR
SENSING
SWITCH
MAGNETRON
GRN
GRN
B2
N.O.
WHT
GRY
WHT PRIMARY WHT
INTERLOCK
SWITCH
NOTES:
1.CIRCUITS SUBJECT TO CHANGE WITHOUT NOTICE.
2. TERMINAL WITH PROJECTION OR OPPOSITE BLUE MARK ON LAMP SOCKET
MUST BE CONNECTED TO NEUTRAL WIRE.
3. ONLY CERTAIN MODELS USE THE ABSOLUTE HUMIDITY SENSOR.
4. POWER TRANSFORMER TOP (FINISH LEAD) TERMINAL MUST BE CONNECTED TO THE NEUTRAL (WHT) WIRE.
Figure O-2 Oven Schematic - Cooking Condition
7
HIGH
VOLTAGE
RECTIFIER
R-405KS
R- 403KK
DESCRIPTION AND FUNCTION OF COMPONENTS
DOOR OPEN MECHANISM
3. If the door is opened, and the secondary interlock relay
(RY2) and primary interlock switch contacts fail to open,
the monitor fuse blows simultaneously with closing of the
monitor switch contacts.
CAUTION: BEFORE REPLACING A BLOWN MONITOR
FUSE TEST THE DOOR SENSING SWITCH,
SECONDARY INTERLOCK RELAY (RY2), RELAY (RY1), PRIMARY INTERLOCK SWITCH
AND MONITOR SWITCH FOR PROPER OPERATION. (REFER TO CHAPTER "TEST PROCEDURE").
NOTE: MONITOR FUSE AND MONITOR SWITCH ARE
REPLACED AS AN ASSEMBLY.
The door is opened by pushing the open button on the control
panel, refer to the Figure D-1. When the open button is
pushed, the open button pushes up the switch lever, and
then the switch lever pushes up the latch head. The latch
heads are moved upward and released from latch hook.
Now the door will open.
Latch Heads
Door
Door S ens ing
S witch
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 turntable may turn in either
direction.
Monitor S witch
S witch Lever
P rimary Interlock
S witch
COOLING FAN MOTOR
The cooling fan motor drives a blade which draws external cool
air. This cool air is directed through the air vanes surrounding
the magnetron and cools the magnetron. This air is channeled
through the oven cavity to remove steam and vapors given off
from the heating foods. It is then exhausted through the
exhausting air vents at the oven cavity.
Figure D-1. Door Open Mechanism
DOOR SENSING AND PRIMARY INTERLOCK
SWITCHES
The primary interlock switch is mounted in the lower position
of the latch hook and the door sensing switch in the secondary interlock system is mounted in the upper position of the
latch hook. They are activated by the latch heads on the door.
When the door is opened, the switches interrupt the power to
all high voltage components. A cook cycle cannot take place
until the door is firmly closed thereby activating both interlock
switches. The secondary interlock system consists of the
door sensing switch and secondary interlock relay located on
the control circuit board.
CAVITY TEMPERATURE FUSE
The cavity temperature fuse located on the top of the oven
cavity, is designed to prevent damage to the oven by fire. If the
food load is overcooked, by either error in cook time or defect
in the control unit, the cavity temperature fuse will open.
Under normal operation, the cavity temperature fuse remains
closed. However, when abnormally high temperatures are
reached within the oven cavity, the cavity temperature fuse will
open at 302OF(150OC) causing the oven to shut down.
NOTE: This is a fuse. It does not reset.
MONITOR SWITCH
MONITOR FUSE
The monitor switch is activated (the contacts opened) by the
latch head on the door while the door is closed. The switch
is intended to render the oven inoperative, by means of
blowing the monitor fuse, when the contacts of the secondary
interlock relay (RY2) and primary interlock switch fail to open
when the door is opened.
1. The monitor fuse blows when the contacts (COM-NO) of
the primary interlock relay (RY2) and secondary interlock
switch remain closed with the oven door open and when
the monitor switch closes.
2. If the wire harness or electrical components are shortcircuited, this monitor fuse blows to prevent an electric
shock or fire hazard.
Functions:
1. When the door is opened, the monitor switch contact close
(to the ON condition) due to their being normally closed. At
this time the secondary interlock relay (RY2) and primary
interlock switch are in the OFF condition (contacts open)
due to their being normally open contact switches.
2. As the door goes to a closed position, the monitor switch
contacts are first opened and then the door sensing switch
and the primary interlock switch contacts close. (On opening
the door, each of these switches operate inversely.)
Magnetron TEMPERATURE FUSE
The magnetron temperature fuse located near the magnetron is
designed to prevent damage to the magnetron if an over heated
condition develops in the tube due to cooling fan failure,
obstructed air guide, dirty or blocked air intake, etc.
Under normal operation, the magnetron temperature fuse
remains closed. However, when abnormally high temperatures
are reached within the magnetron, the magnetron temperature
fuse will open at 302OF(150OC) causing the oven to shut down.
NOTE: This is a fuse. It does not reset.
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R-403KK
TROUBLESHOOTING GUIDE
Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected.
When troubleshooting the microwave oven, it is helpful to follow the Sequence of Operation in performing the checks. Many
of the possible causes of trouble will require that a specific test be performed. These tests are given a procedure letter which
will be found in the "Test Procedure "section.
IMPORTANT: If the oven becomes inoperative because of a blown monitor fuse, check the monitor switch, relay (RY1)
secondary interlock relay (RY2), door sensing switch and primary interlock switch before replacing the monitor
fuse. If the monitor fuse is replaced, the monitor switch must also be replaced. Use part FFS-BA016/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 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. Reconnect the leads to the primary of the power transformer.
5. Reinstall the outer case (cabinet).
6. Reconnect the power supply cord after the outer case is installed.
7. Run the oven and check all functions.
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CK = Check / RE = Replace
Home fuse or circuit breaker blows
when power cord is plugged into wall
receptacle
C/T fuse blows when power cord is
plugged into wall receptacle.
OFF
CONDITION
All letters and indicators do not appear in display when power cord is
first plugged into wall outlet.
Display does not operate properly
when STOP/CLEAR key is touched.
(Buzzer should sound and ":" or time
of day should appear in display.)
Oven lamp does not light when door
is opened.
Oven lamp does not go out when
door is closed.
Oven lamp lights but fan motor and
turntable motor do not operate.
Oven does not go into cook cycle
when START pad 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.)
COOKING
CONDITION
Oven goes into a cook cycle but
extremely uneven heating is produced in oven load (food).
Oven does not cook properly when
programmed for Cooking Power P50 mode. (Operates properly on
Cooking P-HI (HIGH) mode.)
Oven goes into COMPU DEFROST
but food is not defrosted well.
TEST PROCEDURES
PROCEDURE
LETTER
A
COMPONENT TEST
MAGNETRON ASSEMBLY 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.
10
M
FOIL PATTERN ON PWB.
COMPU DEFROST
RELAY (RY1)
KEY UNIT
DIRTY OVEN CAVITY
LOW VOLTAGE
WRONG OPERATION
TOUCH CONTROL PANEL
TURNTABLE MOTOR
COOLING FAN MOTOR
OVEN LAMP OR SOCKET
MONITOR FUSE
MONITOR SWITCH
PRIMARY INTERLOCK SWITCH
SECONDARY INTERLOCK SYSTEM
MAGNETRON TEMP FUSE
CAVITY TEMPERATURE FUSE
HIGH VOLTAGE CAPACITOR
H.V. RECTIFIER ASSEMBLY
POWER TRANSFORMER
MAGNETRON
SHORT OR OPENED WIRING
PROBLEM
CONDITION
RE RE A B C D E E F F G H RE RE CK I CK CK CK J K L
SHORT IN POWER CORD
POSSIBLE CAUSE
AND
DEFECTIVE PARTS
TEST PROCEDURE
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TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
4. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check
across the magnetron filament leads should indicate less than 1 ohm.
5. To test for a shorted magnetron, connect the ohmmeter leads between the magnetron filament leads
and chassis ground. This test should indicate an infinite resistance. If there is little or no resistance
the magnetron is grounded and must be replaced.
6. Reconnect all leads removed from components during testing.
7. Reinstall the outer case (cabinet).
8. Reconnect the power supply cord after the outer case is installed.
9. Run the oven and check all functions.
MICROWAVE OUTPUT POWER
The following test procedure should be carried out with the microwave oven in a fully assembled condition
(outer case fitted).
HIGH VOLTAGES ARE PRESENT DURING 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
should only be used if above tests do not indicate a faulty magnetron and there is no defect in the following
components or wiring: silicon rectifier, high voltage capacitor and power transformer. This test will require
a 16 ounce (453cc) measuring cup and an accurate mercury thermometer or thermocouple type
temperature tester. For accurate results, the following procedure must be followed carefully:
1. Fill the measuring cup with 16 oz. (453cc) of tap water and measure the temperature of the water with
a thermometer or thermocouple temperature tester. Stir the thermometer or thermocouple through the
water until the temperature stabilizes. Record the temperature of the water.
2. Place the cup of water in the oven. Operate oven at POWER 10(HIGH) selecting more than 60
seconds cook time. Allow the water to heat for 60 seconds, measuring with a stop watch, second hand
of a watch or the digital read-out countdown.
3. Remove the cup from the oven and again measure the temperature, making sure to stir the
thermometer or thermocouple through the water until the maximum temperature is recorded.
4. Subtract the cold water temperature from the hot water temperature. The normal result should be 33
to 62OF(18.6 to 34.5OC) rise in temperature. If the water temperatures are accurately measured and
tested for the required time period the test results will indicate if the magnetron tube has low power output
(low rise in water temperature) which would extend cooking time or high power output (high rise in water
temperature) which would reduce cooking time. Because cooking time can be adjusted to compensate
for power output, the magnetron tube assembly should be replaced only if the water temperature rise
test indicates a power output well beyond the normal limits. The test is only accurate if the power supply
line voltage is 120 volts and the oven cavity is clean.
B
POWER TRANSFORMER TEST
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Disconnect the primary input terminals and measure the resistance of the transformer with an
ohmmeter. Check for continuity of the coils with an ohmmeter. On the R x 1 scale, the resistance of
the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be
approximately 90 ohms; the resistance of the filament coil should be less than 1 ohm.
Reconnect all leads removed from components during testing.
Reinstall the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
(HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO
MEASURE THE FILAMENT AND HIGH VOLTAGE.)
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TEST PROCEDURES
PROCEDURE
LETTER
C
COMPONENT TEST
HIGH VOLTAGE RECTIFIER TEST
1.
2.
3.
4.
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Isolate the rectifier from the circuit. Using the highest ohm scale of the meter, read the resistance
across the terminals and observe, reverse the leads to the rectifier terminals and observe meter
reading. If a short is indicated in both directions, or if an infinite resistance is read in both directions,
the rectifier is probably defective and should be replaced.
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: Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6.3 volts.
D
HIGH VOLTAGE CAPACITOR TEST
1.
2.
3.
4.
5.
6.
7.
8.
E
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
If the capacitor is open, no high voltage will be available to the magnetron. Disconnect input leads and
check for short or open between the terminals using an ohmmeter.
Checking with a high ohm scale, if the high voltage capacitor is normal, the meter will indicate continuity
for a short time and should indicate an open circuit once the capacitor is charged. If the above is not
the case, check the capacitor with an ohmmeter to see if it is shorted between either of the terminals
and case. If it is shorted, replace the capacitor.
Reconnect all leads removed from components during testing.
Reinstall the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
CAVITY TEMPERATURE FUSE TEST
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
A continuity check across the cavity temperature fuse terminals should indicate a closed circuit unless
the temperature of the cavity temperature fuse reaches approximately 302OF(150OC). An open cavity
temperature fuse indicates overheating of the oven, exchange the cavity temperature fuse and check
inside of oven cavity and for improper setting of cooking time or operation of control unit. Check for
restricted air flow through the vent holes of the oven cavity, especially the cooling fan and air guide.
Reconnect all leads removed from components during testing.
Reinstall the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
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.
4. A continuity check across the magnetron temperature fuse terminals should indicate a closed circuit
unless the temperature of the magnetron temperature fuse reaches approximately 302OF(150OC). An
open magnetron temperature fuse indicates overheating of the magnetron. Check for restricted air flow
to the magnetron, especially the cooling fan 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.
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TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
CAUTION: IF THE TEMPERATURE FUSE INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE, REPLACE TEMPERATURE FUSE.
F
PRIMARY INTERLOCK SWITCH TEST
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal
of the switch. The meter should indicate an open circuit with the door open and a closed circuit with
the door closed. If improper operation is indicated, replace the primary interlock switch.
Reconnect all leads removed from components during testing.
Reinstall the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
SECONDARY INTERLOCK SYSTEM TEST
DOOR SENSING SWITCH
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. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal
of the switch. The meter should indicate an open circuit with the door open and 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, the cooling fan,
turntable and oven light will be activated by RY1.
SECONDARY INTERLOCK RELAY (RY2)
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 two (2) wire leads from the male tab terminals of the Secondary Interlock Relay. Check the
state of the relay contacts using a ohmmeter. The relay contacts should be open. If the relay contacts
are closed, replace the circuit board entirely or the relay itself.
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.
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TEST PROCEDURES
PROCEDURE
LETTER
G
MONITOR SWITCH TEST
1.
2.
3.
4.
5.
6.
7.
8.
COMPONENT TEST
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Before performing this test, make sure that the primary interlock switch and the secondary interlock
relay are operating properly, according to the above Switch Test Procedure. Disconnect the wire lead
from the monitor switch (COM) terminal. Check the monitor switch operation by using the ohmmeter
as follows. When the door is open, the meter should indicate a closed circuit. When the monitor switch
actuator is pushed by a screw driver through the lower latch hole on the front plate of the oven cavity
with the door opened (in this condition the plunger of the monitor switch is pushed in), the meter should
indicate an open circuit. If improper operation is indicated, the switch may be defective. After testing
the monitor switch, reconnect the wire lead to the monitor switch (COM) terminal and check the
continuity of the monitor circuit.
Reconnect all leads removed from components during testing.
Reinstall the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
R ed
White/ White
S crew Driver
Ohmmeter
P rimary
Interlock S witch
I
Monitor S witch
TThe touch control panel consists of circuits including semiconductors such as LSI, ICs, etc.
Therefore, unlike conventional microwave ovens, proper maintenance cannot be performed
with only a voltmeter and ohmmeter.
In this service manual, the touch control panel assembly is divided into two units, Control Unit and Key
Unit, and also the Control Unit is divided into two units, LSI Unit and Power Unit, and troubleshooting by
unit replacement is described according to the symptoms indicated.
Before testing,
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 using
insulation tape.
1. Key Unit.
NOTE ;
1) Re-install the outer case (cabinet).
2) Reconnect the power supply cord after the outer case is installed.
3) Run the oven and check all functions.
The following symptoms indicate a defective key unit.
a) When touching the pads, a certain pad produces no signal at all.
b) When touching a number pad, two figures or more are displayed.
c) When touching the pads, sometimes a pad produces no signal.
2.
Control Unit
The following symptoms indicate a defective control unit.
2-1 In connection with pads.
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.
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TEST PROCEDURES
PROCEDURE
COMPONENT TEST
LETTER
2-2 In connection with indicators
a) At a certain digit, all or some segments do not light up.
b) At a certain digit, brightness is low.
c) Only one indicator does not light.
d) The corresponding segments of all digits do not light up; or they continue to light up.
e) Wrong figure appears.
f) A certain group of indicators do not light up.
g) The figure of all digits flicker.
2-3 Other possible problems caused by defective control unit.
a) Buzzer does not sound or continues to sound.
b) Clock does not operate properly.
c) Cooking is not possible.
3. If the Key unit or the Control unit is defective.
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) Replace the Control unit assembly.
5) Reconnect all leads removed from components during testing.
6) Re-install the outer case (cabinet).
7) Reconnect the power supply cord after the outer case is installed.
8) Run the oven and check all functions.
4. When 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) Reconnect 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.
J
KEY UNIT TEST
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Using an ohmmeter and referring to the key unit matrix indicated on the control unit circuit, check the
circuit between the pins of the key unit that correspond to the STOP/CLEAR pad. When the pad is
pressed, the ohmmeter should indicate short circuit. When the pad is released, the ohmmeter should
indicate open circuit. If incorrect readings are obtained, the key unit is faulty and must be replaced.
About the other pads, the above method may be used.
Reconnect all leads removed from components during testing.
Re-install the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
TEST PROCEDURES
G8
G7
G6
G5
G4
G3
G2
G1
DEFROST REHEAT
NIGHT
LIGHT
COOK
G13
G12
G11
G10
G9
Pin
NO. G1
1
4
SOFTEN
MELT
7
2
START
5
TIMER
CLOCK
9
8
0
STOP
CLEAR
3
6
POWER
LEVEL
WARM
Pin
NO. G13
Key unit ribbon cable
MINUTE
PLUS
POPCORN
R-405KS
Key Unit
15
Key unit (Membrane Switch) front view
R-405KS
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TEST PROCEDURES
PROCEDURE
LETTER
G8
G7
COMPONENT TEST
G6
G5
G4
G3
G2
G1
REHEAT
2
START
1
5
TIMER
CLOCK
9
8
0
STOP
CLEAR
3
6
G12
NIGHT
LIGHT
DEFROST
G13
G11
G10
G9
Pin
NO. G1
SOFTEN
4
MELT
COOK
7
POWER
LEVEL
Key unit ribbon cable
WARM
MINUTE
PLUS
Key unit (Membrane Switch) front view
POPCORN
Key Unit
R-403KK
K
Pin
NO. G13
RELAY 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. Disconnect the leads to the primary of the power transformer.
5. Ensure that these leads remain isolated from other components and oven chassis by using insulation
tape.
6. After that procedure, re-connect the power supply cord.
7. Remove the outer case and check voltage between the normal open terminal of the relay RY1 and the
normal 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 coil. If diode is good,
control unit is defective.
RELAY SYMBOL
OPERATIONAL VOLTAGE
CONNECTED COMPONENTS
RY1
RY2
Approx. 12.0V D.C.
Approx. 12.0V D.C.
Oven lamp / Turntable motor / Cooling fan motor
Power transformer
8. Disconnect the power supply cord, and then remove outer case.
9. Open the door and block it open.
10. Discharge high voltage capacitor.
11. Reconnect all leads removed from components during testing.
12. Re-install the outer case (cabinet).
13. Reconnect the power supply cord after the outer case is installed.
14. Run the oven and check all functions.
L
COMPU DEFROST TEST
WARNING : The oven should be fully assembled before following procedure.
(1) Open the door.
(2) Place one cup of water in the center of the turntable tray in the oven cavity
(3) Touch the " Defrost " pad once.
(4) Press "2", then press "5".
(5) Touch the "START " pad.
(6) The oven is in Defrost cooking condition.
(7) The oven will operate as follows
MENU
1ST STAGE
STEAKS/CHOPS LEVEL
TIME
0.5lb
60%
20sec.
2ND STAGE
LEVEL
TIME
40%
20sec.
3RD STAGE
LEVEL TIME
30%
45sec.
(8) If improper operation is indicated, the control unit is probably defective and should be checked.
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TEST PROCEDURES
PROCEDURE
LETTER
M
COMPONENT TEST
FOIL PATTERN ON THE PRINTED WIRING BOARD TEST
To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the
PWB, this foil pattern acts as a fuse.
1. Foil pattern check and repairs.
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) Follow the troubleshooting guide given below for repair.
STEPS
OCCURRENCE
CAUSE OR CORRECTION
1
Only pattern at "a" is broken.
*Insert jumper wire J1 and solder.
2
Pattern at "a" and "b" are broken.
*Insert the coil RCILF2003YAZZ between "c" and "d".
RY2
5) Make a visual inspection of the varistor.
Check for burned damage and examine the
transformer with a tester for the presence of
layer short-circuit (check the primary coil
resistance which is approximately 563ý ±
10%). If any abnormal condition is detected,
replace the control unit assembly.
6) Reconnect all leads removed from
components during testing.
7) Re-install the outer case (cabinet).
8) Reconnect the power supply cord after the
outer case is installed.
9) Run the oven and check all functions.
a
J1
c
b
d
L1
VRS1
2. Follow the troubleshooting guide given below, if indicator does not light up after above check and repairs
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 using
insulation tape.
6) After that procedure, re-connect the power supply cord.
7) Follow the troubleshooting guide given below for repair.
STEPS
OCCURRENCE
CAUSE OR CORRECTION
1
The rated AC voltage is not present between
the normal open terminal of the relay RY1 and
the normal open terminal of the relay RY2.
2
The rated AC voltage is present at primary side Low voltage transformer or secondary circuit defective.
of low voltage transformer.
Check and replace control unit assembly.
Check supply voltage and oven power cord.
8) Disconnect the power supply cord, and then remove outer case.
9) Open the door and block it open.
10) Discharge high voltage capacitor.
11) Reconnect all leads removed from components during testing.
12) Re-install the outer case (cabinet).
13) Reconnect the power supply cord after the outer case is installed.
14) Run the oven and check all functions.
(5) The oven will operate for the first 16 seconds, without generating microwave energy.
17
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TOUCH CONTROL PANEL ASSEMBLY
OUTLINE OF TOUCH CONTROL PANEL
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).
3) Power Source Circuit
This circuit generates voltages necessary in the control
unit from the AC line voltage.
In addition, the synchronizing signal is available in order
to compose a basic standard time in the clock circuit.
The principal functions of these units and the signals communicated among them are explained below.
Key Unit
The key unit is composed of a matrix, signals generated in the
LSI are sent to the key unit through P20-P27.
When a key pad is touched, a signal is completed through the
key unit and passed back to the LSI through P70, P71, P41,
P45, P47 and AN3 to perform the function that was requested.
Control Unit
Control unit consists of LSI, reset circuit, indicator circuit,
power source circuit, relay circuit, buzzer circuit, synchronizing signal circuit and back light circuit.
1) Reset Circuit
This circuit generates a signal which resets the LSI to the
initial state when power is supplied.
2) Indicator Circuit
This circuit consists of 22 segments and 3 common
electrodes using a Liquid Crystal Display.
Symbol
Voltage
VSS
-5V
Application
LSI(IC1)
4) Relay Circuit
A circuit to drive the magnetron, fan motor, turntable
motor and light the oven lamp.
5) Buzzer Circuit
The buzzer is responsive to signals from the LSI to emit
audible sounds (key touch sound and completion sound).
6) Synchronizing Signal Circuit
The power source synchronizing signal is available in
order to compose a basic standard time in the clock
circuit. It accompanies a very small error because it
works on commercial frequency.
7) Door Sensing Switch
A switch to “tell” the LSI if the door is open or closed.
8) Back Light Circuit
A circuit to drive the back light (Light emitting diodes LD1LD4).
9) Night Light Circuit
A circuit to drive the light emitting diode (LD10).
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DESCRIPTION OF LSI
LSI
The I/O signal of the LSI is detailed in the following table.
Pin No.
Signal
I/O
Description
1-2
VL2-VL1
IN
Power source voltage input terminal.
Standard voltage for LCD.
3-6
AN7-AN4
IN
Terminal to change cooking input according to the Model.
By using the A/D converter contained in the LSI, DC voltage in accordance with the Model
in operation is applied to set up its cooking constant.
7
AN3
IN
Signal coming from touch key.
When either G13 line on key matrix is touched, a corresponding signal out of P20 - P27
will be input into AN3. When no key is touched, the signal is held at “H” level.
8
AN2
IN
To input signal which communicates the door open/close information to LSI.
Door close "H" level signal (0V). Door Open "L" level (-5V).
9
AN1
IN
Terminal not used.
10
AN0
IN
Terminal not used.
11-13
P57-P55
OUT
Terminal not used.
14
CNTR0
OUT
Signal to sound buzzer (2.0 kHz).
A: key touch sound.
B: Completion sound.
0.1 sec.
H : GND
A
2.0 sec.
L : -5V
H : GND
B
L : -5V
15
P53
OUT
Terminal not used.
16
P52
OUT
Oven lamp, fan motor and turntable motor driving signal
16.7 msec.
To turn on and off shut off relay (RY1). The
square waveform voltage is delivered to the
RY1 driving circuit and RY2 control circuit.
H : GND
L : -5V
During cooking
17
P51
OUT
Terminal not used.
18
P50
OUT
19
P47
IN
Magnetron high-voltage circuit driving signal.
OFF
H : GND
To turn on and off the cook relay (RY2). The Maximum
ON
signals holds “L” level during microwave cook- output
L : -5V
ing and “H” level while not cooking. In other
OFF
OFF
H : GND
cooking modes (variable cooking) the signal 70% of maximum
24 sec.
turns to “H” level and “L” level in repetition output
8 sec.
ON
L : -5V
according to the power level.
Signal similar to AN3.
When either G13 line on key matrix is touched, a corresponding signal will be input into
P46.
20
P46
OUT
21
P45
IN
22-23
P44-P43
OUT
24
INT0
IN
Night light circuit (Light emitting diode) driving signal.
Signal similar to AN3.
When either G12 line on key matrix is touched, a corresponding signal will be input into
P45.
Terminal not used.
Signal synchronized with commercial power source frequency.
This is the basic timing for time processing of LSI.
H : GND
L : -5V
16.7 msec.
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Pin No.
Signal
I/O
25
P41
IN
Signal similar to AN3.
When either G11 line on key matrix is touched, a corresponding signal will be input into
P41.
26
P40
IN
Connected to GND through the pull-down resistor.
27
RESET
IN
Auto clear terminal.
Signal is input to reset the LSI to the initial state when power is applied.
28
P71
IN
Signal similar to AN3.
When either G10 line on key matrix is touched, a corresponding signal will be input into
P71.
29
P70
IN
Signal similar to ANI3.
When either G9 line on key matrix is touched, a corresponding signal will be input into P70.
30
XIN
IN
Internal clock oscillation frequency control input setting.
The internal clock frequency is set by inserting the ceramic filter oscillation circuit with
respect to XOUT terminal.
31
XOUT
OUT
32
VSS
IN
33
P27
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 G8 line keys on key matrix is touched.
34
P26
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 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 terminal while one of G5 line keys on key matrix is touched.
37
P23
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 G4 line keys on key matrix is touched.
38
P22
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 G3 line keys on key matrix is touched.
39
P21
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 G2 line keys on key matrix is touched.
40
P20
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 G1 line keys on key matrix is touched.
41
P17
OUT
Back light signal. (Light emitting diodes) driving signal
42-46
P16-P12
OUT
Terminal not used.
47-50
51-72
SEG25-SEG22
OUT
OUT
Terminal not used.
Segment data signal.
SEG21-SEG0
Description
Internal clock oscillation output.
Output to control oscillation input to XIN.
Power source voltage : -5.0V.
The power source voltage to the drive LSI is input to VSS terminal.
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Pin No.
Signal
I/O
Description
Connected to LCD.
The relation between signals are as follows:
LSI signal (Pin No.)
LCD (Pin No.)
SEG0 (72) ................................ SEG 0
SEG1 (71) ................................ SEG 1
SEG2 (70) ................................ SEG 2
SEG3 (69) ................................ SEG 3
SEG4 (68) ................................ SEG 4
SEG5 (67) ................................ SEG 5
SEG6 (66) ................................ SEG 6
SEG7 (65) ................................ SEG 7
SEG8 (64) ................................ SEG 8
SEG9 (63) ................................ SEG 9
SEG10 (62) ............................... SEG 10
LSI signal (Pin No.)
LCD (Pin No.)
SEG11 (61) ............................... SEG 11
SEG12 (60) ............................... SEG 12
SEG13 (59) ............................... SEG 13
SEG14 (58) ............................... SEG 14
SEG15 (57) ............................... SEG 15
SEG16 (56) ............................... SEG 16
SEG17 (55) ............................... SEG 17
SEG18 (54) ............................... SEG 18
SEG19 (53) ............................... SEG 19
SEG20 (52) ............................... SEG 20
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
COM1
OUT
Common data signal.
Connected to LCD signal COM2.
79
COM0
OUT
Common data signal.
Connected to LCD signal COM3.
80
VL3
IN
Power source voltage input terminal.
Standard voltage for LCD. Connected to GND.
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TOUCH CONTROL PANEL SERVICING
1. Precautions for Handling Electronic Components
This unit uses CMOS LSI in the integral part of the
circuits. When handling these parts, the following
precautions should be strictly followed. CMOS LSI have
extremely high impedance at its input and output terminals.
For this reason, it is easily influenced by the surrounding
high voltage power source, static electricity charge in
clothes, etc. and sometimes it is not fully protected by the
built-in protection circuit.
In order to protect CMOS LSI.
1) When storing and transporting, thoroughly wrap them in
aluminium foil. Also wrap all PW boards containing them
in aluminium foil.
2) When soldering, ground the technician as shown in the
figure and use grounded soldering iron and work table.
approx. 1M ohm
2. Servicing of Touch Control Panel
We describe the procedures to permit servicing of the
touch control panel of the microwave oven and the
precautions you must take when doing so. To perform the
servicing, power to the touch control panel is available
either from the power line of the oven itself or from an
external power source.
(1) Servicing the touch control panel with power supply
of the oven:
CAUTION:
THE HIGH VOLTAGE TRANSFORMER OF THE
MICROWAVE OVEN IS STILL LIVE DURING
SERVICING AND PRESENTS A HAZARD.
Therefore, before checking the performance of the touch
control panel,
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 using insulation
tape.
6) After that procedure, re-connect the power supply
cord.
After checking the performance of the touch control panel,
1) Disconnect the power supply cord.
2) Open the door and block it open.
3) Re-connect the leads to the primary of the power
transformer.
4) Re-install the outer case (cabinet).
5) Re-connect the power supply cord after the outer case
is installed.
6) Run the oven and check all functions.
A. On some models, the power supply cord between the
touch control panel and the oven itself is so short that the
two can’t be separated. For those models, check and
repair all the controls (sensor-related ones included) of
the touch control panel while keeping it connected to the
oven.
B. On some models, the power supply cord between the
touch control panel and the oven proper is long enough
that they may be separated from each other. For those
models, it is possible to check and repair the controls of
the touch control panel while keeping it apart from the
oven proper; in this case you must short both ends of the
door sensing switch (on PWB) of the touch control panel
with a jumper, which activates an operational state that is
equivalent to the oven door being closed. As for the
sensor-related controls of the touch control panel, checking
them is possible if dummy resistor(s) with resistance
equal to that of the controls are used.
(2) Servicing the touch control panel with power supply
from an external power source:
Disconnect the touch control panel completely from the
oven proper, and short both ends of the door sensing
switch (on PWB) of the touch control panel, which
activates an operational state that is equivalent to the
oven door being closed. Connect an external power
source to the power input terminal of the touch 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
Tools required to service the touch control panel assembly.
1) Soldering iron: 30W
(It is recommended to use a soldering iron with a grounding
terminal.)
2) Oscilloscope: Single beam, frequency range: DC-10MHz
type or more advanced model.
3) Others: Hand tools
4. Other Precautions
1) Before turning on the power source of the control unit,
remove the aluminium foil applied for preventing static
electricity.
2) Connect the connectors of the key unit to the control unit
being sure that the lead wires are not twisted.
3) After aluminium foil is removed, be careful that abnormal
voltage due to static electricity etc. is not applied to the
input or output terminals.
4) Attach connectors, electrolytic capacitors, etc. to PWB,
making sure that all connections are tight.
5) Be sure to use specified components where high precision
is required.
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COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE
WARNING AGAINST HIGH VOLTAGE:
Microwave ovens contain circuitry capable of producing very high voltage and current. Contact with the following parts
may result in severe, possibly fatal, electric shock.
(Example)
High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..
WARNING:
To Avoid possible exposure to microwave energy, please follow the instructions below
before operating the oven.
1. Disconnect the 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. Visually check the door and cavity face plate for damage
(dents, cracks, signs of arcing etc.).
1.
2.
3.
4.
5.
6.
Door does not close firmly.
Door hinge, support or latch hook is damaged.
The door gasket or seal is damaged.
The door is bent or warped.
There are defective parts in the door interlock system.
There are de fective parts in the microwave generating
and transmission assembly.
7. There is visible damage to the oven.
Do not operate the oven:
1. Without the RF gasket (Magnetron).
2. If the wave guide or oven cavity are not intact.
3. If the door is not closed.
4. If the outer case (cabinet) is not fitted.
Carry out any remedial work that is necessary before
operating the oven.
Do not operate the oven if any of the following conditions
exist:
WARNING FOR WIRING
To prevent an electric shock, take the following precautions:
1. Before wiring:
1) Disconnect the power supply cord.
2) Open the door block it open.
3) Wait 60 seconds, then discharge the high voltage
capacitor.
2. Don’t let the wire leads touch to the following parts:
1) High voltage parts:
Magnetron, High voltage transformer, High voltage
capacitor and High voltage rectifier assembly.
2) Hot parts:
Oven lamp, Magnetron, High voltage transformer and
Oven cavity.
3) Sharp edge:
Bottom plate, Oven cavity, Waveguide flange,
Chassis support and other metallic plate.
4) Movable parts (to prevent a fault):
Fan blade, Fan motor, Switch, Switch lever, Open
button.
3. Do not catch the wire leads in the outer case cabinet.
4. Insert the positive lock connector until its pin is locked
and make sure that the wire leads do not come off even
if the wire leads are pulled.
5. To prevent an error function, connect the wire leads
correctly, referring to the Pictorial Diagram.
Please refer to ‘OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS’, when carrying out any of
the following removal procedures:
OUTER CASE REMOVAL
To remove the outer case, proceed as follows.
1. Disconnect the power supply cord.
2. Open the oven door and block it open.
3. Remove the two (2) screws from the lower portion of the
rear cabinet using a T20H Torx type or GTXH20-100
screw driver.
4. Remove the remaining two (2) screws from rear.
5. Slide the entire outer case back out about 1 inch (3 cm)
to free it from retaining clips on the cavity face plate.
6. Lift entire outer case from the unit.
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CAUTION: 1. DISCONNECT OVEN FROM POWER SUPPLY BEFORE REMOVING OUTER CASE.
2. DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN
COMPONENTS OR WIRING.
NOTE: When replacing the outer case, the 2 special
Torx screws must be reinstalled in the same
locations.
Special screw
Screw Driver
(Type: TORX T20 H or
GTXH20-100)
POWER TRANSFORMER REMOVAL
Re-install
1. Rest transformer on the bottom plate with its primary
terminals toward the oven face plate.
2. Secure transformer with four screws to bottom plate.
3. Re-connect wire leads (primary and high voltage) to
power transformer and filament leads of transformer to
magnetron and high voltage capacitor. Refer to
"PICTORIAL DIAGRAM" on page 30.
4. Re-install outer case and check that oven is operating
properly.
1. Disconnect the power supply cord and then remove outer
case.
2. Open the oven door and block it open.
3. Discharge high voltage capacitor.
4. Disconnect wire leads (primary and high voltage) from
power transformer and the filament leads from the
magnetron and capacitor terminals.
5. Remove two (2) screws holding transformer to bottom
plate.
6. Remove transformer from bottom plate.
HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR REMOVAL
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.
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 high voltage wire A from the high voltage
capacitor.
5. Disconnect the high voltage wire of high voltage rectifier
assembly from the magnetron.
6. Disconnect the filament lead (short one) of the power
transformer from the high voltage capacitor.
CAUTION: WHEN REPLACING HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR,
GROUND SIDE TERMINAL OF THE HIGH
VOLTAGE RECTIFIER MUST BE SECURED
FIRMLY WITH A GROUNDING SCREW.
MAGNETRON REMOVAL
Removal
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 wire leads from magnetron.
5. Remove the two (2) screws holding the chassis support
to the magnetron and the oven cavity front flange.
6. Slide the magnetron duct slightly so that the two (2)
screws at left hand side of the magnetron appear.
7. Carefully remove the four (4) screws holding magnetron
to waveguide flange.
8. Remove the magnetron with care so that the magnetron
antenna is not hit by any metal object around the antenna.
9. Now, the magnetron is free.
Re-install
1. Re-install the magnetron to waveguide flange with care
to prevent damage to the magnetron antenna.
2. Secure the magnetron with the four (4) screws.
3. Hold the chassis support to the oven cavity front plate and
the magnetron with the two (2) screws.
4. Reconnect the wire leads to the magnetron. Refer to
"PICTORIAL DIAGRAM" on page 30.
5. Re-install outer case and check that the oven is operating
properly.
CAUTION: WHEN REPLACING MAGNETRON, BE SURE
THE R.F. GASKET IS IN PLACE AND MOUNTING SCREWS ARE TIGHTENED SECURELY
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OVEN LAMP AND LAMP SOCKET REMOVAL
1.
2.
3.
4.
5.
Disconnect the power supply cord and remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Remove the oven lamp from the oven lamp socket.
Pull the wire leads from the oven lamp socket by pushing
the terminal hole of the oven lamp socket with the small
flat type screw driver.
6. Remove the oven lamp socket from the magnetron duct
by turning the socket counterclockwise.
7. Remove the oven lamp from the socket by turning the
oven lamp.
8. Now, the oven lamp and the oven lamp socket are free.
Terminal
Oven lamp
socket
Figure C-1. Oven lamp socket
POSITIVE LOCK® CONNECTOR (NO-CASE TYPE) REMOVAL
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. Push the lever of positive lock® connector.
5. Pull down on the positive lock® connector.
CAUTION: WHEN CONNECTING THE POSITIVE LOCK®
CONNECTORS TO THE TERMINALS, CONNECT THE POSITIVE LOCK® SO THAT THE
LEVER FACES YOU.
Figure C-2. Positive lock® connector
CONTROL PANEL ASSEMBLY REMOVAL
NOTE: 1. Before attaching a new key unit, wipe off remaining
adhesive on the control panel frame surfaces
completely with a soft cloth soaked in alcohol.
2. When attaching the key unit to the control panel
frame, adjust the upper edge and right edge of the
key unit to the correct position of control panel
frame.
3. Place the key unit firmly to the control panel frame
by rubbing with soft cloth not to scratch.
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 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.
GRAPHIC SHEET AND MEMBRANE SWITCH REPLACEMENT
Removal
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. Remove the control panel assembly, referring to chapter of CONTROL PANEL ASSEMBLY REMOVAL.
5. Remove the three (3) screws holding the control unit to the control panel frame. And remove the control unit by releasing
from tabs.
6. Remove the rubber connector from the long slit on the control panel frame.
7. Remove the night light cover (release tabs from back side).
8. Remove the graphic sheet from the control panel frame. (*See special note)
9. Remove away the membrane switch from the control panel frame. (*See special note)
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Installation
1. Remove remaining adhesive on the control panel frame surfaces with a soft cloth soaked in alcohol.
2. Make sure that the LCD sheet and the liquid crystal display is installed in position.
3. Remove the backing paper from the new membrane switch and ribbon cable.
4. Insert the ribbon cable of the membrane switch into the slit of the control panel frame.
5. Adjust the upper edge and right edge of the membrane switch to the small depression on the surface of the control panel
frame.
6. Attach the membrane switch to the control panel frame by rubbing with a soft cloth not to scratch.
7. Remove the backing paper from the new graphic sheet.
8. Adjust the upper edge and right edge of the graphic sheet to the large depression on the surface of the control panel frame.
9. Attach the graphic sheet to the control panel frame by rubbing with a soft cloth not to scratch.
10. Attach the ribbon cable to the control panel frame rear side.
11. Place the edge of the membrane switch’s ribbon cable on the lower portion of the liquid crystal display.
12. Insert the rubber connector into the long slit on the control panel frame.
13. Reinstall the control unit to the 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 of the
rubber connector.
(* Heat gun will soften adhesive.)
Control panel frame
LCD sheet
Liquid crystal
displa y
Ribbon cable
Liquid crystal
of membr ane
displa y
switch
Contact
surface
Control panel frame
(Rear side)
Ribbon
cab le
Slit
Graphic
sheet
Membrane
switch
Contact surface
Long slit
Rubber connector
R-405KS Graphic Sheet and Membrane Switch Replacement
TURNTABLE MOTOR REMOVAL
1. Disconnect the power supply cord.
2. Remove turntable and turntable support from oven cavity.
3. Lay the oven on it's backside. Remove the turntable motor
cover by snipping off the material in four corners.
4. Where the corners have been snipped off bend corner
areas flat. No sharp edges must be evident after removal
of the turntable motor cover.
5. Disconnect wire leads from turntable motor.
(See "Positive lock connector removal")
6. Remove one (1) screw holding turntable motor to oven
cavity.
7. Now the turntable motor is free.
8. After replacement, use the one (1) screw provided with the
TTM Kit, to attach the turntable motor cover.
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COOLING FAN MOTOR REMOVAL
REMOVAL
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 wire leads from the fan motor.
5. Remove the two (2) screws holding the fan motor to the
oven cavity back plate.
6. Remove the fan blade from the fan motor shaft according
to the following procedure.
7. Hold the edge of the rotor of the fan motor by using a pair
of groove joint pliers.
CAUTION:
* Make sure that no metal pieces enter the gap between
the rotor and the stator of the fan motor because the
rotor is easily shaven by pliers and metal pieces may
be produced.
* Do not touch the pliers to the coil of the fan motor
because the coil may be cut or injured.
* Do not disfigure the bracket by touching with the
pliers.
8. Remove the fan blade from the shaft of the fan motor by
pulling and rotating the fan blade with your hand.
9. Now, the fan blade and the fan motor will be free.
Rear View
CAUTION:
* Do not reuse the removed fan blade because the hole
(for shaft) may be larger than normal.
INSTALLATION
1. Install the fan blade to the fan motor shaft according to the
following procedure.
2. Hold the center of the bracket 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
the fan blade with a small, light weight, ball peen hammer
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 after
installation.
* Make sure that the axis of the shaft is not slanted.
5. Install the fan motor to the oven cavity back plate with the
two (2) screws.
6. Connect the wire leads to the fan motor, referring to the
pictorial diagram.
Side View
DOORSENSINGSWITCH/PRIMARYINTERLOCKSWITCHANDMONITORSWITCHREMOVAL
1.
2.
3.
4.
5.
6.
7.
Disconnect the power supply cord and remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Disconnect wire leads from the switches.
Remove two (2) screws holding latch hook to oven flange.
Remove latch hook assembly from oven flange.
Push outward on the two (2) retaining tabs holding switch
in place.
8. Switch is now free.
At this time switch lever will be free, do not lose it.
Re-install
1. Re-install each switch in its place. The primary interlock/
monitor switches are in the lower position and the door
sensing switch is in the upper position.
2. Re-connect wire leads to each switch.
Refer to pictorial diagram.
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3. Secure latch hook (with two (2) mounting screws) to oven
flange.
4. Make sure that the monitor switch is operating properly
and check continuity of the monitor circuit. Refer to chapter
"Test Procedure" and Adjustment procedure.
DOORSENSINGSWITCH/PRIMARY INTERLOCKSWITCHANDMONITORSWITCHADJUSTMENT
1. Disconnect the power supply cord, and then remove
outer case.
2. Open the door and block it open.
3. Discharge high voltage capacitor.
If the door sensing switch, primary interlock switch and
monitor switch do not operate properly due to a misadjustment,
the following adjustment should be made.
4. Loosen the two (2) screws holding latch hook to the oven
cavity front flange.
5. With door closed, adjust latch hook by moving it back and
forth, and up and down. In and out play of the door
allowed by the upper and lower position of the latch hook
should be less than 0.5mm. The vertical position of the
latch hook should be adjusted so that the door sensing
switch and primary interlock switch are activated with the
door closed. The horizontal position of the latch hook
should be adjusted so that the plunger of the monitor
switch is pressed with the door closed.
6. Secure the screws with washers firmly.
7. Check the operation of all switches. If each switch has not
activated with the door closed, loosen screw and adjust
the latch hook position.
hook, pushing and pulling upper portion of door toward
the oven face. Both results (play in the door) should be
less than 0.5mm.
2. The door sensing switch and primary interlock switch
interrupt the circuit before the door can be opened.
3. Monitor switch contacts close when door is opened.
4. Re-install outer case and check for microwave leakage
around door with an approved microwave survey meter.
(Refer to Microwave Measurement Procedure.)
Latch Heads
Door S ens ing
S witch
Door
Monitor S witch
S witch Lever
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
P rimary Interlock
S witch
Figure C-3. Latch Switch Adjustments
DOOR REPLACEMENT
REMOVAL
1. Disconnect the power supply cord.
2. Push the open button and open the door slightly.
3. Insert a putty knife (thickness of about 0.5mm) into the
gap between the choke cover and door frame as shown in
Figure C-4 to free engaging parts.
4. Pry the choke cover by inserting a putty knife as shown
Figure C-4.
5. Release choke cover from door panel.
6. Now choke cover is free.
7. Release two (2) pins of door panel from two (2) holes of
upper and lower oven hinges by lifting up.
8. Now, door panel with door frame is free from oven cavity.
Choke Cover
Door Frame
Putty Knife
Figure C-4. Door Disassembly
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9. Release the door panel from twelve (12) tabs of door
frame.
10.Remove the door panel from the door frame.
11.Now, door panel with sealer film is free.
12.Tear sealer film from door panel.
13.Now, door panel is free.
14.Slide latch head upward and remove it from door frame
with releasing latch spring from door frame and latch head.
15.Now, latch head and latch spring are free.
16.Remove door screen from door frame
17.Now, door frame is free.
RE-INSTALL
1. Re-install door screen to door frame.
2. Re-install the latch spring to the latch head. Re-install the
latch spring to the door frame. Re-install latch head to door
frame.
3. Re-install door panel to door frame by fitting twelve (12)
tabs of door frame to twelve (12) holes of door panel.
4. Put sealer film on door panel. Refer to “Sealer Film” about
how to handle new one.
5. Catch two (2) pins of door panel on two (2) hole of upper
and lower oven hinges.
6. Re-install choke cover to door panel by pushing.
Note: After any service to the door;
(A) Make sure that door sensing switch and primary
interlock switch are operating properly. (Refer to
chapter “Test Procedures”.).
(B) An approved microwave survey meter should be
used 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. Door is positioned with its face pressed toward cavity face
plate.
4. Check for microwave leakage around door with an approved
microwave survey meter. (Refer to Microwave
Measurement Procedure.)
Note: The door on a microwave oven is designed to act as
an electronic seal preventing the leakage of microwave
energy from oven cavity during cook cycle. This
function does not require that door be air-tight,
moisture (condensation)-tight or light-tight. Therefore,
occasional appearance of moisture, light or sensing
of gentle warm air movement around oven door is not
abnormal and do not of themselves indicate a leakage
of microwave energy from oven cavity.
Note:
When carring out any repair to the door, do not bend or
wrap the slit choke (tabs on the door panel assembly)
to prevent microwave leakage.
SEALER FILM
Installation
1. Put the adhesive tape on the backing film of the sealer
film as shown in Fig. C-6.
2. Tear the backing film by pulling the adhesive tape.
3. Put the pasted side of the sealer film on the door panel
Figure C-6. Sealer film
29
1
2
3
30
RY2
2
4
GRY
WHT
N.O.
RY1
COM.
COM.
N.O.
T1
ORG
F
BRN
SECONDARY
INTERLOCK
RELAY
WHT
GRY
OVEN LAMP
AND SOCKET
PRIMARY
SWITCH
WHT
WHT
GRY
COM.
NO
WHT
WHT
COM.
WHT
RED
RED
RED
WHT
5
WHT
WHT
ORG
CN-B
1 PNK
2 GRN
WHT
TURNTABLE
MOTOR
BRN
MAGNETRON
POWER
TRANSFORMER
H.V. RECTIFIER
HIGH VOLTAGE
WIRE A
N.O.
HIGH
VOLTAGE
CAPACITOR
HIGH VOLTAGE COMPONENTS
FAN MOTOR
ORG
NOTE:
The neutral (WHT/GRY) wire must
be connected to the terminal with
"N" mark on the power supply
cord.
GRN
GRN
COM.
DOOR
SENSING
SWITCH
PNK
GRN
4
5
Figure S-1. Pictorial Diagram
N.C.
RED
RED
POWER SUPPLY
CORD 120V 60Hz
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.
to Oven cavity
3
ORG
RED
RED
G
(POWER UNIT)
E
MAGNETRON TEMP FUSE
ORG
ORG
D
CAVITY TEMP. FUSE
N
B
CN-B
RED
GRY
BLK
H
C
BLK
WHT
2
1
1
MONITOR
SWITCH
WHT
R-405KS
R- 403KK
6
A
A
B
C
H
6
D
E
F
G
H
D
E
Figure
Unit
Circuit
FigureS-3.
S-2.Control
CPU Unit
Circuit
(R-405KS)
R-405KS
R-403KK
1
1
2
2
3
4
3
4
31
5
5
6
A
A
B
B
C
C
6
D
E
F
F
G
G
H
H
R-405KS
R- 403KK
1
2
4
3
5
6
A
B
B
C
C
Figure S-2. CPU Unit Circuit (R-403KK)
A
D
E
D
E
F
F
G
G
H
H
1
2
4
3
32
5
6
R-405KS
R-403KK
1
2
4
3
5
6
A
A
B
B
DIP
C
C
CHIP
SIDE
J3
CN-F
C10
R90
C4
1 2 3
D
LED
D31
CN-B
D
R3
R5
C5 R6
2
J1
E C B
E
Q2
E C B
D30
2
1
B1 2
E
E
J2
D5
D8
WH-2
Q1
Q4 SP1
Q3
DZ1
E C B
1
WH-2
J5
J6
T1
R4
D6
R2
R7
RY2
C1
R8
F
F
D1 D2
P
S
L1
D3 D4
VRS1
G
G
C2
D7
RY1
H
H
Figure S-5 . Printed Wiring Board of Power Unit
1
2
4
3
33
5
6
R-405KS
R- 403KK
R-405KS
PARTS LIST
∆” may cause undue microwave exposure.
Note: The parts marked “∆
The parts marked “*” are used in voltage more than 250V. "§" MARK: PARTS DELIVERY SECTION.
REF. NO.
PART NO.
§
DESCRIPTION
Q'TY CODE
ELECTRIC PARTS
*
∆
1- 1
1- 2
1- 3
1- 4
1- 5
1- 6
1- 7
1- 8
1- 9
1-10
1-11
1-12
1-13
RC-QZB018MRE0
FH-DZB013MRY0
RLMPTA085WRZZ
RMOTEA346WRE0
FFS-BA016/KIT
QSW-MA085WRE0
QFS-TA014WRE0
RV-MZA323WRZZ
RMOTDA264/KIT
RTRN-B078MRE0
FACCDB003MRE0
QFS-TA013WRE0
FPWBFA380WRKZ
M
M
M
M
M
M
M
M
M
M
M
M
M
High voltage capacitor
High voltage rectifier assembly
Oven lamp/socket
Fan motor
Monitor switch (V-16G-2C25)and fuse assembly (20A 250V AC)
Primary interlock switch and door sensing switch (V-5230Q)
Cavity temperature fuse 150OC
Magnetron
Turntable motor
Power transformer
Power supply cord
Magnetron temperature fuse
Noise filter unit
2- 1
2- 2
2- 3
GDAI-B068MRP0
GLEGPB004MRF0
GCABUB091MRP0
M
M
M
Base plate
Foot
Outer case cabinet
3- 1
3- 2
3- 3
3- 4
3- 5
3- 6
3- 7
3- 8
3- 9
3-10
3-11
CPWBFB091MRU0
FPNLCB503MRK0A
PSHEPB192MRR0
FDECAB074MRK0
MSPRCA045WRE0
XEPSD30P08XS0
PCOVPB144MRF0
QCNC-A020WRZZ
PSHEPB037WREZ
RLCDSA107DRZZ
LANGQB060MRP0
M
M
M
M
M
M
M
M
M
M
M
Control unit assy
Control panel sub assembly
Key sheet assy
Open button assy
Open button spring
Screw; 3mm x 6mm
Night light cover
Rubber connector
LED sheet
LCD
PWB support angle
4- 1
4- 2
4- 3
4- 4
4- 5
4- 6
4- 7
4- 8
4- 9
4-10
4-11
4-12
LBNDKB007MRP0
LANGTB060MRP0
PHOK-B018MRF0
MLEVPB016MRF0
PDUC-B125MRF0A
NFANPB001MRE0
PDUC-B088MRF0
------------PCOVPB073MRP0
PPACGB014MRF0
PCUSU0464MRE0
LANGQB025MRP0
M
M
M
M
M
M
M
M
M
M
M
M
H.V. Capacitor band
Chassis support
Latch hook
Switch lever
Magnetron duct
Fan blade
Fan duct
Oven cavity
(Not a replaceable part)
Waveguide cover
Turntable motor packing
Cushion
Noise unit angle
5
5 -1
5 -2
5 -3
5 -4
5 -5
5- 6
5- 7
5- 8
CDORFB392MRK0
FCOV-B294MRK0
LSTPPB023MRF0
MSPRTA046WRE0
FDORFB074MRT0
PSHEPB021MRE0
GCOVHB046MRF0
LSTPPB044MRF0
HPNL-B120MRE0
M
M
M
M
M
M
M
M
M
Door assembly
Door frame assembly
Latch head
Latch spring
Door panel
Sealer film
Choke cover
Door stopper
Door screen
1
1
1
1
1
2
1
1
1
1
1
1
1
AQ
AM
AE
AR
AF
AE
AF
AZ
AL
AY
AM
AE
AM
1
4
1
AN
AB
AX
1
1
1
1
1
5
1
1
1
1
1
BF
AU
AP
AP
AA
AB
AH
AC
AG
AG
AE
1
1
1
1
1
1
1
1
1
1
1
1
AB
AD
AF
AD
AD
AC
AC
-AC
AA
AC
AE
1
1
1
1
1
1
1
1
1
BF
BB
AC
AB
AQ
AE
AG
AA
AP
CABINET PARTS
CONTROL PANEL PARTS
OVEN PARTS
DOOR PARTS
34
R-405KS
R-403KK
REF. NO.
PART NO.
§
DESCRIPTION
Q'TY CODE
MISCELLANEOUS
6666666-
1
2
3
4
5
6
7
FW-VZB268MRE0
FROLPB025MRK0
NTNT-A108WREZ
TCAUAB050MRR0
TCAUAB053MRR0
TINSEB418MRK0
QW-QZB016MRE0
M
M
M
M
M
M
M
Main wire harnes
Turntable support
Turntable tray
Monitor caution label
DHHS/Screw caution label
Operation manual
High voltage wire A
1
1
1
1
1
1
1
AS
AN
AM
AA
AB
AD
AC
5
2
1
11
3
3
2
AA
AA
AB
AB
AB
AB
AC
SCREWS,NUTS AND WASHERS
7777777-
1
2
3
4
5
6
7
LX-BZA041WRE0
LX-CZ0052WRE0
XHTS740P12RV0
XOTS740P12000
XCBS730P08000
XHTS740P08RV0
LX-CZA070WRE0
M
M
M
M
M
M
M
Special
Special
Screw :
Screw :
Screw :
Screw :
Special
screw
screw
4mm x
4mm x
3mm x
4mm x
screw
12mm
12mm
8mm
8mm
(Torx tamper proof screw)
HOW TO ORDER REPLACEMENT PARTS
To have your order filled promptly and correctly, please furnish the following information.
1. MODEL NUMBER
2. REF. NO.
3. PART NO.
4. DESCRIPTION
Order Parts from the authorized SHARP parts Distributor for your area.
Defective parts requiring return should be returned as indicated in the Service Policy.
35
R-405KS
R- 403KK
R-403KK
PARTS LIST
∆” may cause undue microwave exposure.
Note: The parts marked “∆
The parts marked “*” are used in voltage more than 250V. "§" MARK: PARTS DELIVERY SECTION.
REF. NO.
PART NO.
§
DESCRIPTION
Q'TY CODE
ELECTRIC PARTS
*
∆
1- 1
1- 2
1- 3
1- 4
1- 5
1- 6
1- 7
1- 8
1- 9
1-10
1-11
1-12
1-13
RC-QZB018MRE0
FH-DZB013MRY0
RLMPTA085WRZZ
RMOTEA433WRZZ
FFS-BA016/KIT
QSW-MA085WRE0
QFS-TA014WRE0
RV-MZA293WRE0
RMOTDA264/KIT
RTRN-B078MRE0
FACCDB003MRE0
QFS-TA013WRE0
FPWBFA380WRKZ
M
M
M
M
M
M
M
M
M
M
M
M
M
High voltage capacitor
High voltage rectifier assembly
Oven lamp/socket
Fan motor
Monitor switch (V-16G-2C25)and fuse assembly (20A 250V AC)
Primary interlock switch and door sensing switch (V-5230Q)
Cavity temperature fuse 150OC
Magnetron
Turntable motor
Power transformer
Power supply cord
Magnetron temperature fuse
Noise filter unit
1
1
1
1
1
2
1
1
1
1
1
1
1
AQ
AM
AE
AL
AF
AE
AF
BC
AL
AY
AM
AE
AM
1
4
1
AN
AB
AT
1
1
1
1
1
5
1
1
1
1
1
BF
AW
AS
AG
AA
AB
AM
AC
AG
AG
AE
1
1
1
1
1
1
1
1
1
1
1
1
AB
AD
AF
AD
AD
AC
AC
-AC
AA
AC
AE
1
1
1
1
1
1
1
1
AY
AC
AB
AQ
AE
AG
AA
AT
CABINET PARTS
2- 1
2- 2
2- 3
GDAI-B068MRP0
GLEGPB004MRF0
GCABUB097MRP0
M
M
M
Base plate
Foot
Outer case cabinet
3- 1
3- 2
3- 3
3- 4
3- 5
3- 6
3- 7
3- 8
3- 9
3-10
3-11
CPWBFB092MRU0
HPNLCB211MRF0
FUNTKB448MRE0
JBTN-B192MRF0
MSPRCA045WRE0
XEPSD30P08XS0
PCOVPB148MRR0
QCNC-A020WRZZ
PSHEPB037WREZ
RLCDSA107DRZZ
LANGQB060MRP0
M
M
M
M
M
M
M
M
M
M
M
Control unit assy
Control panel sub assembly
Key sheet assy
Open button
Open button spring
Screw; 3mm x 6mm
Night light cover
Rubber connector
LED sheet
LCD
PWB support angle
CONTROL PANEL PARTS
OVEN PARTS
4- 1
4- 2
4- 3
4- 4
4- 5
4- 6
4- 7
4- 8
4- 9
4-10
4-11
4-12
LBNDKB007MRP0
LANGTB060MRP0
PHOK-B018MRF0
MLEVPB016MRF0
PDUC-B125MRF0A
NFANPB001MRE0
PDUC-B088MRF0
------------PCOVPB073MRP0
PPACGB014MRF0
PCUSU0464MRE0
LANGQB025MRP0
M
M
M
M
M
M
M
M
M
M
M
M
H.V. Capacitor band
Chassis support
Latch hook
Switch lever
Magnetron duct
Fan blade
Fan duct
Oven cavity
(Not a replaceable part)
Waveguide cover
Turntable motor packing
Cushion
Noise unit angle
5 -1
5 -2
5 -3
5 -4
5 -5
5- 6
5- 7
5- 8
FCOV-B296MRK0
LSTPPB021MRF0
MSPRTA046WRE0
FDORFB074MRT0
PSHEPB021MRE0
GCOVHB046MRF0
LSTPPB044MRF0
HPNL-B122MRE0
M
M
M
M
M
M
M
M
Door frame assembly
Latch head
Latch spring
Door panel
Sealer film
Choke cover
Door stopper
Door screen
DOOR PARTS
36
R-405KS
R-403KK
REF. NO.
PART NO.
§
FW-VZB268MRE0
FROLPB025MRK0
NTNT-A108WREZ
TCAUAB050MRR0
TCAUAB053MRR0
TINSEB418MRK0
QW-QZB016MRE0
M
M
M
M
M
M
M
DESCRIPTION
Q'TY CODE
MISCELLANEOUS
6666666-
1
2
3
4
5
6
7
Main wire harnes
Turntable support
Turntable tray
Monitor caution label
DHHS/Screw caution label
Operation manual
High voltage wire A
1
1
1
1
1
1
1
AS
AN
AM
AA
AB
AD
AC
5
2
1
11
3
3
2
AA
AA
AB
AB
AB
AB
AC
SCREWS,NUTS AND WASHERS
7777777-
1
2
3
4
5
6
7
LX-BZA041WRE0
LX-CZ0052WRE0
XHTS740P12RV0
XOTS740P12000
XCBS730P08000
XHTS740P08RV0
LX-CZA070WRE0
M
M
M
M
M
M
M
Special
Special
Screw :
Screw :
Screw :
Screw :
Special
screw
screw
4mm x
4mm x
3mm x
4mm x
screw
12mm
12mm
8mm
8mm
(Torx tamper proof screw)
HOW TO ORDER REPLACEMENT PARTS
To have your order filled promptly and correctly, please furnish the following information.
1. MODEL NUMBER
2. REF. NO.
3. PART NO.
4. DESCRIPTION
Order Parts from the authorized SHARP parts Distributor for your area.
Defective parts requiring return should be returned as indicated in the Service Policy.
37
R-405KS
R- 403KK
R-405KS & R-403KK
2
1
4
3
6
5
OVEN AND CABINET PARTS
7-4
A
A
7-4
7-7
2-3
B
B
4-7
7-7
6-5
7-5
1-7
C
C
1-4
1-5
7-4
4-6
7-3
1-11
1-13
7-6
4-12
1-12
D
D
4-8
7-6
4-2
7-4
E
1-8
4-9
6-4
E
7-4
7-2
7-2
6-3
1-3
7-4
7-1
1-6
4-3
4-10
4-5
1-9
1-10
F
7-5
2-1
6-2
F
1-5
1-6
7-1
4-4
4-1
1-1
1-2
G
G
7-4
7-4
2-2
2-2
7-4
2-2
4-11
2-2
H
H
1
2
4
3
38
5
6
R-405KS
R-403KK
R-405KS
2
1
4
3
6
5
CONTROL PANEL PARTS
3-11
3-1
A
3-2
A
3-8
3-9
3-10
3-3
3-6
3-7
B
B
3-5
C
C
3-4
DOOR PARTS
5-7
D
5-6
D
5
5-4
E
E
5-8
5-5
F
F
5-2
5-3
MISCELLANEOUS
5-1
G
G
6-1
6-7
Actual wire harness may be different from illustration.
H
H
1
2
4
3
39
5
6
R-405KS
R- 403KK
R-403KK
2
1
4
3
CONTROL PANEL PARTS
6
5
3-11
3-1
A
3-2
A
3-8
3-9
3-10
3-7
3-6
3-3
B
B
3-5
C
C
3-4
5-7
DOOR PARTS
5-6
D
D
5-4
5-1
E
E
5-5
F
F
5-8
MISCELLANEOUS
5-3
5-2
6-1
G
G
6-7
Actual wire harness may be different from illustration.
H
H
1
2
4
3
40
5
6
R-405KS
R-403KK
PACKING AND ACCESSORIES
TOP PAD ASSEMBLY
DOOR PROTECTION SHEET
6-3 TURNTABLE TRAY
PLASTIC BAG
ON TOP OF THE OVEN
TRAY HOLDER
6-6 OPERATION MANUAL
IN
TO
TH
EO
NC
VE
AV
ITY
BOTTOM PAD ASSEMBLY
6-2 TURNTABLE SUPPORT
PACKING CASE
Non-replaceable items
41
R-405KS
R- 403KK
COPYRIGHT © 2005 BY SHARP CORPORATION
ALL RIGHTS RESERVED.
No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording,
or otherwise, without prior written permission
of the publisher.
2005 SHARP CORP. (5M2.00E) Printed in U.S.A
42