R-22AMM (serv.man10). Component Replacement And Adjustment Procedure - Sharp Home Appliance Service Manual (repair manual)

r-22amm (serv.man10) service manual
Model
R-22AMM (serv.man10)
Pages
7
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416.52 KB
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PDF
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Service Manual
Brand
Device
Home Appliance / Microwave Oven / Component Replacement And Adjustment Procedure
File
r-22amm-sm10.pdf
Date

Read Sharp R-22AMM (serv.man10) Service Manual online

R22AMM
10 – 1
R22AMM
Service Manual
 
CHAPTER 10. 
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 oven from power supply.
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 handle and the door lever assembly 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.). 
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.
Please refer to ‘OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS’, when carrying out any of the following removal proce-
dures:
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,
High voltage rectifier assembly and High voltage fuse.
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)
Blower fan blade, Blower fan motor, Switches, Switch levers,
Antenna motors and Stirrer antennas.
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. 
[2] OUTER CASE, REAR CABINET AND POWER SUPPLY CORD REMOVAL
To remove the outer case cabinet, proceed as follows.
1. Disconnect oven from power supply.
2. Open the oven door and wedge it open.
3. Remove the screws from the rear and along side the edge of the
outer case.
4. Slide the case back about 1 inch (3 cm) to free it from the oven cav-
ity.
5. Lift entire case from the unit.
6. DISCHARGE TWO HIGH VOLTAGE CAPACITORS BEFORE
TOUCHING ANY OVEN COMPONENTS OR WIRING.
7. Now, outer case is free.
N.B.; Step 1, 2 and 9 form the basis of the 3D checks.
CAUTION: DISCHARGE TWO HIGH VOLTAGE CAPACITORS
BEFORE TOUCHING ANY OVEN COMPONENTS OR
WIRING.
To remove rear cabinet and power supply cord:
8. Disconnect the power supply cord from the noise filter.
9. Remove the one (1) screws holding the grounding wire of power
supply cord to the oven cavity.
10.Remove the screws holding the rear cabinet to the oven cavity and
blower motor.
11.Remove the rear cabinet with the power supply cord from the oven
cavity.
12.Loosen the tab of the cord bushing, and remove the power supply
cord with the cord bushing from the rear cabinet.
 
WARNING AGAINST HIGH VOLTAGE:
WARNING FOR WIRING
R22AMM
10 – 2
13.Remove the cord bushing from the power supply cord,
14.Now, the power supply cord and rear cabinet are free.
[3] HIGH VOLTAGE TRANSFORMER(S) REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the rear cabinet, too.
3. Disconnect wire lead(s) of high voltage transformer(s) from magne-
tron(s).
4. Remove the wire lead(s) of high voltage transformer(s) from the
wire holder.
5. Pull out the wire lead(s) of high voltage transformer(s) from the
tube.
6. Disconnect wire lead(s) of high voltage transformer(s) from high
voltage capacitor(s).
7. Disconnect the high voltage fuse(s) from high voltage trans-
former(s).
8. Disconnect the main wire harness from high voltage transformer(s).
9. Remove two (2) screws holding each power transformer to base
plate.
10.Remove the high voltage transformer(s) from base plate.
11.Now, high voltage transformer(s) are free.
[4] MAGNETRON(S) REMOVAL
1. Removal
1. CARRY OUT 3D CHECKS.
2. Remove the rear cabinet, too.
3. Remove the two (2) screws holding magnetron exhaust duct to
upper and lower waveguide.
4. Remove the magnetron exhaust duct from oven cavity.
5. Disconnect wire leads from magnetron(s).
6. Disconnect magnetron thermistor from the connector of the stop
switch harness.
7. Remove the one (1) screw holding the thermistor angle to the
upper magnetron.
8. Remove the four (4) screws holding each magnetron to upper and/
or lower waveguide. When removing the screws, hold the magne-
tron to prevent it from falling.
9. Remove the magnetron(s) from upper and/or lower waveguide with
care so magnetron antenna is not hit by any metal object around
antenna.
10.Pull out the thermistor angle from the upper magnetron.
11.Now, the magnetron(s) is (are) free.
CAUTION: WHEN REPLACING MAGNETRON, BE SURE THE R.F.
GASKET IS IN PLACE AND MOUNTING SCREWS ARE
TIGHTENED SECURELY.
NOTE: When the magnetron MG1 and/or MG2 is replacing, the
relays (RY3 and RY4) on control unit must be replaced at
the same time. Because if the magnetron's life has been
over, the relay's life may also be over.
[5] MAGNETRON THERMISTOR REPLACEMENT
1. Removal
1. CARRY OUT 3D CHECKS.
2. Remove the rear cabinet, too.
3. Remove the magnetron from the waveguide flange, referring to
“MAGNETRON(S) REMOVAL”.
4. Now, the magnetron with the magnetron thermistor should be free.
5. Remove the thermistor angle from the magnetron by pulling out.
6. Straighten the tab of the magnetron thermistor angle holding the
magnetron thermistor.
7. Remove the magnetron thermistor from the thermistor angle.
8. Now, the magnetron thermistor is free.
2. Re-install
1. Install the magnetron thermistor to the thermistor angle as shown in
Figure C-1.
2. Hold the magnetron thermistor to the thermistor angle by bending
the tab of the thermistor angle.
3. Insert the thermistor angle between the 2nd. fin and 3rd. fin from
the upper fin of the magnetron and push it until the thermistor angle
stops.
NOTE: The magnetron thermistor should be between the upper fin
and the 2nd. fin.
4. Re-install the magnetron to the waveguide flange with four (4)
screws.
5. Re-install the thermistor angle to the waveguide flange with one (1)
screw.
6. Re-install the magnetron exhaust duct to the upper and lower
waveguide flanges with two (2) screws.
7. Route the thermistor harness under the magnetron temperature
fuse.
8. Connect the thermistor harness to the stop switch harness.
9. Connect the wire leads to the upper magnetron, referring to the pic-
torial diagram.
10.Re-install the power supply cord, rear cabinet and outer case cabi-
net to the oven by reversing the procedures of “OUTER CASE,
REAR CABINET AND POWER SUPPLY CORD REMOVAL”.
Figure C-1. Magnetron thermistor installation
Upper magnetron
Upper fin
T ab
T hermis tor
angle
Magnetron
thermis tor
R22AMM
10 – 3
[6] HIGH VOLTAGE CAPACITOR, HIGH VOLTAGE FUSE AND HIGH VOLTAGE RECTIFIER
ASSEMBLY REMOVAL
To remove the components, proceed as follows.
1. CARRY OUT 3D CHECKS.
2. Remove the rear cabinet, too.
3. Remove two (2) screws holding earth side terminals of high voltage
rectifier assembly to the capacitor holder and oven cavity.
4. Disconnect all wire leads from the high voltage capacitor.
5. Disconnect high voltage fuse(s) from the high voltage trans-
former(s). Now, high voltage fuse(s) is (are) free.
6. Remove the three (3) screws holding the blower motor to the top of
oven cavity, the chassis support and air duct.
7. Disconnect high voltage wire lead(s) of the high voltage rectifier
assembly from the magnetron(s). Now, the high voltage rectifier
assembly is free.
8. Remove two (2) screws holding the capacitor holder to oven cavity.
Now, the capacitors are free.
CAUTION: 1) DISCHARGE THE TWO HIGH VOLTAGE CAPACI-
TORS BEFORE TOUCHING ANY OVEN COMPO-
NENTS OR WIRING.
2) DO NOT REPLACE ONLY THE HIGH VOLTAGE REC-
TIFIER. IF IT IS DEFECTIVE, REPLACE THE HIGH
VOLTAGE RECTIFIER ASSEMBLY.
3) WHEN REPLACING THE HIGH VOLTAGE RECTIFIER
ASSEMBLY AND THE HIGH VOLTAGE CAPACITOR,
THE CATHODE (EARTH) SIDE TERMINAL OF THE
HIGH VOLTAGE RECTIFIER MUST BE SECURED
FIRMLY WITH A EARTHING SCREW.
[7] BLOWER MOTOR REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the rear cabinet, too.
3. Disconnect the wire leads from the blower motor and noise filter.
4. Remove the one (1) screw holding the blower motor angle to the
oven cavity.
5. Remove the one (1) screw holding the blower motor angle to the
chassis support. 
6. Remove the one (1) screw holding the air duct to the blower motor.
7. Remove the four (4) screws holding the blower motor angle to the
blower motor.
8. Now, the blower motor is free.
[8] STIRRER MOTORS (UPPER AND LOWER) REMOVAL
1. UPPER
1. CARRY OUT 3D CHECKS.
2. Disconnect the wire leads from the stirrer motor (upper).
3. Remove the one (1) screw holding the stirrer motor (upper) to the
oven cavity.
4. Turn and lift up the stirrer motor (upper). 
5. Now, the stirrer motor (upper) is free.
2. LOWER
1. Disconnect oven from the power supply.
2. Remove the stirrer motor cover by snipping off the material in four
portions.
3. Where the portions have been snipped off bend the portions flat.
No sharp edge must be evident after removal of the stirrer motor
cover.
4. Disconnect the wire leads from the stirrer motor (lower).
5. Remove the one (1) screw holding the stirrer motor (Lower) to the
oven cavity.
6. Now, the stirrer motor (lower) is free.
7. After replacement use one (1) screw (XOTWW40P08000) to fit the
stirrer motor cover.
[9] HOW TO RELEASE THE POSITIVE LOCKR CONNECTOR.
1. CARRY OUT 3D CHECKS.
2. Pushing the lever of positive lock
®
 connector, pull down the posi-
tive lock
®
 connector from the terminal.
3. Now, the connector is free.
CAUTION: WHEN CONNECTING THE POSITIVE LOCK
®
 CONNEC-
TORS TO THE TERMINALS, CONNECT THE POSITIVE
LOCK
®
 CONNECTOR SO THAT THE LEVER FACES
YOU.
Figure C-1. Positive lock
® connector
Terminal
Push
Pull down
1
Lever
Positive lock®
connector
2
R22AMM
10 – 4
[10] OVEN LAMP AND LAMP SOCKET REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the oven lamp.
3. Pull the wire leads from the oven lamp socket by pushing the termi-
nal hole of the oven lamp socket with the small flat type screw
driver.
4. Lift up the oven lamp socket.
5. Now, the oven lamp socket is free.
Figure C-3. Oven lamp socket
[11] TERMINAL INSULATOR REPLACEMENT
1. Removal
1. Open covers of the terminal insulator by using small flat type screw
driver.
2. Remove the receptacle from the terminal insulator.
3. Now, the terminal insulator is free.
2. Installation
1. Insert the receptacle into terminal insulator.
2. Close covers of the terminal insulator, as shown illustrated below.
[12] CONTROL PANEL ASSEMBLY AND CONTROL UNIT REMOVAL
CONTROL PANEL ASSEMBLY REMOVAL
The complete control panel should be removed for replacement of
components. To remove the control panel, proceed as follows:
1. Disconnect the oven from power supply.
2. Wait for 60 seconds to discharge the high voltage capacitor.
3. Remove the air intake filter assembly from the base plate.
4. Remove two (2) screws holding the control panel to the base plate.
5. Pull down the control panel and remove it forward.
6. Disconnect connectors and wire leads from the control unit.
7. Now the control panel assembly is free.
CAUTION FOR CONTROL PANEL REMOVAL
1) Hold the lower end (Position A, Fig. 1) of the touch control panel
assembly firmly while sliding it down and toward you.
2) If the Touch Control Panel is hard to remove; 
a) Insert a flat head screw driver into space B. (Fig. 1)
b) Rotate the screwdriver clockwise while holding position C of the
Touch Control Panel. (Fig. 2)
TO AVOID DAMAGE TO TOUCH CONTROL PANEL, COVER THE
TIP OF SCREWDRIVER WITH TAPE.
Replacement of individual component is as follows:
CONTROL UNIT AND CONTROL PANEL FRAME
(WITH SWITCH UNIT)
8. Remove three (3) screws holding the control panel mounting angle
to the panel frame.
9. Lift up the control panel mounting angle from the panel
10.Disconnect the connectors (G) and (E) from the control unit.
11.Remove four (4) screws holding the control unit to the panel frame
assembly.
12.Now, the control unit and control panel frame (with switch unit) are
free.
CAUTION: :At installing control panel unit assembly to main body set:
1) Ensure the installation of wiring-related parts without
negligence.
2) When inserting wire cable to main body set, ensure
them free from caught-in trouble. In addition, when
installing the control panel assembly to base plate with
screws, be sure of pushing the control panel unit
upward to fix with screws firmly. 
3) Do not allow any wire leads to come near the varistor
works, because it will explode and the wire leads near
by the varistor will be damaged.
SWITCH UNIT
13.Remove the three (3) screws holding the switch unit (Main) to the
control panel frame.
14.Remove the two (2) screws holding the switch unit (Sub.) to the
control panel frame.
15.Now, the switch unit is free
ROTARY ENCODER UNIT
13. Remove the two (2) screws holding the rotary encoder unit to the
      control panel frame.
Oven lamp
socket
Terminal
Wire lead
Terminal hole
Flat type small
screw driver
Flat type screw driver
Terminal insulator
RECEPTACLE
COVERS
B
A
C
B
Fig. 1
Fig. 2
TOUCH CONTROL PANEL
SCREW DRIVER
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