AX-1100(R)M, AX-1100(SL)M (serv.man11). Component Replacement And Adjustment Procedure - Sharp Home Appliance Service Manual (repair manual)

ax-1100(r)m, ax-1100(sl)m (serv.man11) service manual
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AX-1100(R)M AX-1100(SL)M (serv.man11)
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9
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Service Manual
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Device
Home Appliance / Microwave Oven / Component Replacement And Adjustment Procedure
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ax-1100rm-ax-1100slm-sm11.pdf
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Read Sharp AX-1100(R)M / AX-1100(SL)M (serv.man11) Service Manual online

AX1100(R)M
12 – 1
AX1100(R)M
Service Manual
 
CHAPTER 12. 
COMPONENT REPLACEMENT AND ADJUSTMENT PROCE-
DURE
[1] BEFORE OPERATING
Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in severe, possibly fatal,
electric shock.
(Example)
High Voltage Capacitor, High Voltage Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..
WARNING:
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 grip the door lever in door handle 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.).
Carry out any remedial work that is necessary before operating the
oven.
Do not operate the oven if any of the following conditions exist;
1) Door does not close firmly.
2) Door hinge, support or latch hook is damaged.
3) The door gasket or seal is damaged.
4) The door is bent or warped.
5) There are defective parts in the door interlock system.
6) There are defective parts in the microwave generating and trans-
mission 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.
To prevent an electric shock, take the following manners.
1. Before wiring, 
1) Disconnect the power supply cord.
2) Open the door and block it open.
3) Discharge the high voltage capacitor and wait for 60 seconds.
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:
Engine unit, Grill heating element, 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, Antenna motor, Damper motor
and pump motor.
3. Do not catch the wire leads in the outer case cabinet.
4. Insert the positive lock connector certainly until its pin is locked.
And make sure that the wire leads should not come off even if the
wire leads is pulled.
5. To prevent an error function, connect the wire leads correctly, refer-
ring to the Pictorial Diagram. 
Please refer to ‘OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS’, when carrying out any of the following removal proce-
dures:
[2] OUTER CASE CABINET REMOVAL
To remove the outer case cabinet, procedure as follows.
1. Disconnect oven from power supply.
2. Open the oven door and wedge it open.
3. Remove the one (1) screw from right side of the outer case cabinet.
4. Remove the two (2) screws from the lower portion of the rear of
cabinet.
5. Remove the three (3) screws from rear and along the side edge of
outer case cabinet.
6. Slide the entire case back about 3 cm to free it from retaining clips
on the cavity face plate.
7. Lift the entire outer case cabinet from the oven.
8. Discharge the H.V. capacitor before carrying out any further work.
9. Do not operate the oven with the outer case cabinet removed.
NOTE: Step 1, 2 and 8 form the basis of the 3D checks.
CAUTION: DISCHARGE HIGH VOLTAGE CAPACITOR BEFORE
TOUCHING ANY OVEN COMPONENT OR WIRING.
 
WARNING AGAINST HIGH VOLTAGE:
WARNING FOR WIRING
AX1100(R)M
12 – 2
[3] HIGH VOLTAGE COMPONENTS REMOVAL
(HIGH VOLTAGE CAPACITOR AND HIGH VOLTAGE RECTIFIER ASSEMBLY)
To remove the components, proceed as follows.
1. CARRY OUT 3D CHECKS.
2. Disconnect the filament lead of the high voltage transformer and
the high voltage transformer secondary wire from the high voltage
capacitor.
3. Remove one (1) screw holding the capacitor holder to the bottom
plate.
4. Remove the high voltage capacitor with the capacitor band from the
bottom plate.
5. Remove one (1) screw holding earth side terminal of the high volt-
age rectifier assembly.
6. Remove the capacitor holder from the high voltage capacitor.
7. Disconnect the high voltage rectifier assembly from the high volt-
age capacitor.
8. Now, the high voltage rectifier assembly and the high voltage
capacitor should be free.
CAUTION: WHEN REPLACING HIGH VOLTAGE RECTIFIER
ASSEMBLY, ENSURE THAT THE CATHODE (EARTH)
CONNECTION IS SECURELY FIXED TO THE CAPACI-
TOR HOLDER WITH AN EARTHING SCREW.
[4] HIGH VOLTAGE TRANSFORMER REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the main wire harness from the high voltage trans-
former.
3. Disconnect the two (2) filament leads from the magnetron.
4. Disconnect the high voltage transformer secondary wire from the
high voltage capacitor.
5. Disconnect the filament lead with the high voltage wire from the
high voltage capacitor.
6. Remove the two (2) screws holding the transformer to the bottom
plate.
7. Remove the transformer from the bottom plate.
8. Now, the high voltage transformer is free.
[5] MAGNETRON REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the two (2) filament leads from the magnetron.
3. Remove the one (1) screw holding the air duct to the magnetron.
4. Carefully remove the four (4) screws holding the magnetron to the
waveguide. When removing the screws hold the magnetron to pre-
vent it from falling.
5. Remove the magnetron from the waveguide with care so the mag-
netron antenna is not hit by any metal object around the antenna.
CAUTION: WHEN REPLACING THE MAGNETRON, BESURE THE
R.F. GASKET IS IN PLACE AND THE MAGNETRON
MOUNTING SCREWS ARE TIGHTENED SECURELY.
[6] ANTENNA MOTOR REPLACEMENT
1. REMOVAL
1. Disconnect the oven from the power supply.
2. Wait for 60 seconds to discharge the high voltage capacitor.
3. Remove the drip tray and the water tank.
4. Turn the oven over.
5. Remove the two (2) screws holding the bottom plate cover to the
bottom plate.
6. Remove the bottom plate cover from the bottom plate.
7. Disconnect the wire leads from the antenna motor.
8. Remove the two (2) screws holding the antenna motor to the TT
motor mount angle.
9. Now, the antenna motor is free.
2. REINSTALLATION
1. Reinstall the antenna motor by locating shaft onto the shaft assem-
bly to the TT mount angle with the two (2) screws.
2. Reconnect the wire leads to the antenna motor.
3. Insert the three (3) tabs of the bottom plate cover into the slits of the
bottom plate as shown.
4. Reinstall the bottom plate cover to the bottom plate with the two (2)
screws.
5. Reinstall the water tank and the drip tray.
[7] FAN MOTOR REPLACEMENT
1. REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the wire leads from the fan motor.
3. Remove the two (2) screws holding the fan motor to the back plate. 
4. Remove the fan blade from the fan motor shaft according to the fol-
lowing procedure.
i)
Hold the edge of the rotor of the fan motor by using a pair of
groove joint pliers.
CAUTION: • Make sure that no swarf from the rotor enters the gap
between the rotor & stator of the fan motor.
• Avoid touch the coil of the fan motor with the pliers as
the coil may become cut or damaged.
• Avoid deforming the bracket whilst using the pliers.
ii) Remove the fan blade assembly from the shaft of the fan motor
by pulling and rotating the fan blade with your hand.
iii) Now, the fan blade is free.
CAUTION: Do not reuse the removed fan blade as the fixing hole may
be oversize.
5. Now, the fan motor is free.
2. INSTALLATION
1. Install the fan blade to the fan motor shaft according to the following
procedure.
AX1100(R)M
12 – 3
i)
Hold the centre of the bracket which supports the shaft of the
fan motor on a flat table.
ii) Apply the screw lock tight into the hole (for shaft) of the fan
blade.
iii) 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 when installing because the
bracket may be deformed.
• Make sure that the fan blade rotates smoothly after
installation.
• Make sure that the axis of the shaft is not slanted.
2. Install the fan motor to the back plate with the two (2) screws.
3. Reconnect the wire leads to the fan motor.
[8] PUMP MOTOR REMOVAL
1. Disconnect the power supply cord.
2. Wait for 60 seconds to discharge the high voltage capacitor.
3. Remove the water tank and the drip tray from the oven.
4. Turn the oven over.
5. Remove the two (2) screws holding the bottom plate cover to the
bottom plate.
6. Remove the bottom plate cover from the bottom plate.
7. Disconnect the wire leads from the pump motor.
8. Remove the one (1) screw holding the tube pump assembly to the
bottom plate.
9. Release the two (2) tabs of the tube pump assembly from the holes
of the bottom plate.
10.Move the tube pump assembly toward the control panel side and
then release other two (2) tabs of the tube pump assembly from the
slots of the bottom plate.
11.Remove the tube pump assembly from the bottom plate.
12.Turn the tube pump assembly over so that the pump motor can be
seen.
13.Remove the two (2) screws holding the pump motor to the tube
pump assembly.
14.Now, the pump motor is free.
[9] INTAKE DAMPER MOTOR AND INTAKE DAMPER SWITCH REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the wire leads from the intake damper motor and the
intake damper switch.
3. Remove the two (2) screws holding the support angle to the oven
cavity top plate.
4. Remove the two (2) screws holding the separate angle to the oven
cavity top plate.
5. Remove the separate angle.
6. Remove the two (2) screws holding the air damper motor angle to
the oven cavity right side.
7. Remove the one (1) screw holding the air duct to the magnetron.
8. Remove the air duct with the intake damper motor and the switch
from the oven cavity right side.
9. Remove the two (2) screws holding the intake damper motor to the
air damper motor angle.
10.Now, the intake damper motor is free. 
11.Remove the one (1) screw holding the intake damper switch to the
air damper motor angle.
12.Now, the intake damper switch is free.
[10] BACK PLATE REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the wire leads from the noise filter and the fan motor.
3. Remove the one (1) screw holding the chassis support to the back
plate.
4. Remove the one (1) screw holding the fan duct to the thermal cover
right.
5. Remove the two (2) screws holding the back plate to the bottom
plate.
6. Remove the two (2) screws holding the back plate to the oven cav-
ity.
7. Now, the back plate is free. But the back plate still has the power
supply cord, fan motor and noise filter in it.
[11] BOTTOM PLATE REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the water tank and the drip tray.
3. Remove the door assembly from the oven cavity, referring to the
“DOOR REPLACEMENT”.
4. Remove the high voltage transformer, referring to “HIGH VOLTAGE
TRANSFORMER REMOVAL”.
5. Remove the back plate, referring to “BACK PLATE REMOVAL”.
6. Remove the joint tube from the engine unit.
Gap
Rotor
Bracket
Stator
Groove joint pliers
Coil
Shaft
Axis
Stator
Rotor
These are the positions
that should be pinched
with pliers.
Shaft
Table
Center of
bracket
Rear View
Side View
AX1100(R)M
12 – 4
7. Remove the one (1) screw holding the tank joint to the tank cover.
8. Remove the tank joint from the tank cover.
CAUTION: When the joint tube or pump tube L is removed from the
engine unit or tank joint, remained water may bleed from
the engine unit.
9. Loosen the pin band and remove the steam exhaust tube from the
oven cavity.
10.Turn the oven over. 
11.Remove the bottom plate cover by removing the two (2) screws.
12.Disconnect the wire leads from the pump motor.
13.Remove the two (2) screws holding the lower hinge to the bottom
plate, and remove the lower hinge.
14.Remove the one (1) screw holding the tank cover to the bottom
plate (right side).
15.Remove the four (4) screws holding the bottom plate to the oven
cavity.
16.Lift up the bottom plate from the oven.
17.Now, bottom plate is free. But the bottom plate still has the high
voltage capacitor, tube pump assembly, dew tray guide left, dew
tray guide right, steam exhaust duct and back dew guide in it.
[12] ENGINE UNIT ASSEMBLY REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the back plate, referring to “BACK PLATE REMOVAL”.
3. The joint tube should be removed from the engine unit assembly
now.
CAUTION: When the joint tube is removed from the engine unit,
remained water may bleed from the engine unit.
4. Remove the wire harness from the heater terminal of engine unit
assembly by removing the tow (2) screws.
5. Disconnect the wire leads from the engine thermal cut-out.
6. Remove the three (3) screws which are holding the engine unit
assembly from inside of the oven cavity.
NOTE: Hold the engine unit with your hand when removing, otherwise
the engine unit will fall.
7. Remove the engine packing B from the engine unit.
8. Remove the one (1) screw holding the thermistor (engine) to the
engine unit assembly.
9. Remove the one (1) screw and the one (1) nut holding the engine
thermo angle to the engine unit assembly.
10.Now, the engine unit assembly is free.
CAUTION: CAUTION: When the new engine unit assembly is
installed, carry out a shakedown operation, referring to
“SHAKEDOWN OPERATION OF NEW ENGINE UNIT
ASSEMBLY”.
NOTE: NOTE: When the new engine unit is installed, the thermistor
(engine) and engine packing B should be reinstalled.
[13] SHAKEDOWN OPERATION OF NEW ENGINE UNIT ASSEMBLY
After the new engine unit assembly is installed, carry out the following
three procedures to avoid the error operation.
1. Remove the two (2) screws holding the back plate cover and
remove the back plate cover. This is to cool the engine unit.
2. Fill the water tank with water and carry out the 1st. stage of “DES-
CALE” function, referring to “Descale Function” on page 5-4. (citric
acid or lemon juice are not necessary.)
3. Then, carry out Drain water function (refer to “Drain Water Func-
tion” on page 5-4).
4. At last, fill the water tank with water and carry out Steam high cook-
ing again for about ten (10) minutes. And check that the error does
not appear on the display.
5. If the error is appeared and the oven stops at above step 4, carry
out step 2, step 3 and step 4.
6. After shakedown operation, reinstall the back plate cover with the
two (2) screws.
REASON 
Inside walls of the engine unit assembly have been painted to protect
the engine unit assembly with special paint. And special paint will shed
water initially. By carrying out Steam cooking, paint can be accus-
tomed to water. If this operation is not carried out, the oven will judge
that there is no water in the tank assembly.
And the display will show the error and then the oven will stop.
Because this oven judges that there is water or not by checking on/off
time ratio of the engine unit assembly.
If paint is not accustomed to water, off time will become longer than on
time. At this time, the oven will judge no water.
[14] THERMISTOR (ENGINE) REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the engine unit, referring to “ENGIEN UNIT REMOVAL”.
3. Remove the bottom plate, referring to “BOTTOM PLATE
REMOVAL”.
4. Disconnect the connector of the thermistor (engine) from the con-
nector of the main wire harness.
5. Now, the thermistor (engine) is free.
[15] OVEN LAMP REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the wire leads from the oven lamp.
3. Remove the one (1) screw holding the oven lamp to the air duct.
4. Remove the oven lamp from the air duct.
5. Now, the oven lamp is free.
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Here you can read online and download Sharp AX-1100(R)M / AX-1100(SL)M (serv.man11) Service Manual in PDF. AX-1100(R)M / AX-1100(SL)M (serv.man11) service manual will guide through the process and help you recover, restore, fix, disassemble and repair Sharp AX-1100(R)M / AX-1100(SL)M (serv.man11) Microwave Oven. Information contained in service manuals typically includes schematics / circuit diagrams, wiring diagrams, block diagrams, printed wiring boards, exploded views, parts list, disassembly / assembly, pcb.