Read Sharp R-90GCK (serv.man10) Service Manual online
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R-90GCK
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..
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.
operating the oven.
WARNING AGAINST HIGH VOLTAGE:
COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE
To prevent an electric shock, take the following
precautions.
1. Before wiring,
precautions.
1. Before wiring,
1) Disconnect the oven from power supply.
2) Open the door and wedge the door open.
3) Discharge the high voltage capacitor and wait for 60
2) Open the door and wedge the door 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.
capacitor and High voltage rectifier assembly.
2) Hot parts:
Oven lamp, Magnetron, High voltage transformer,
Oven cavity and Heating element.
Oven cavity and Heating element.
WARNING FOR WIRING
1. Disconnect the oven from power supply.
2. Make sure that a definite” click” can be heard when
2. Make sure that a definite” click” can be heard when
the microwave oven door is unlatched. (Pull down the
door handle in a closed position with one hand, then
push the door with the other, this causes the latch
leads to rise, it is then possible to hear a “click’ as the
door switches operate.)
door handle in a closed position with one hand, then
push the door 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;
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
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 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.
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.
3) Sharp edge:
Bottom plate, Oven cavity, Waveguide flange,
Chassis support and other metallic plate.
Chassis support and other metallic plate.
4) Moveable parts (to prevent a fault)
Fan blade, Fan motor, Switch, Door cam,
Convection motor, Convection fan, Turntable
motor, Damper motor, Damper door assembly.
Convection motor, Convection fan, Turntable
motor, Damper motor, Damper door assembly.
3. Do not catch the wire leads in the outer case cabinet.
4. Insert the positive lock connector until its pin is locked
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.
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:
of the following removal procedures:
1. Disconnect the oven from power supply.
2. Open the oven door and wedge the door open.
3. Remove the four (4) screws holding the exhaust cover
2. Open the oven door and wedge the door open.
3. Remove the four (4) screws holding the exhaust cover
to the back plate and the outer case cabinet.
4. Remove the three (3) screws holding the outer case
cabinet to the back plate.
5. Remove the four (4) screws holding the right and left
sides of the outer case cabinet to the bottom plate.
6. Slide the entire outer case cabinet back out about 1
inch (3cm) to free it from retaining clips on the oven
cavity front plate.
cavity front plate.
OUTER CASE REMOVAL
7. Lift entire outer case cabinet from the unit.
8. Discharge the H.V. capacitor before carrying out any
8. Discharge the H.V. capacitor before carrying out any
further work.
9. Do not operate the oven with the outer case removed.
N.B.; Step 1, 2 and 8 form the basis of the 3D checks.
CAUTION
1. DISCONNECT THE OVEN FROM THE POWER
N.B.; Step 1, 2 and 8 form the basis of the 3D checks.
CAUTION
1. DISCONNECT THE OVEN FROM THE POWER
SUPPLY BEFORE REMOVING THE OUTER CASE
CABINET.
CABINET.
2. DISCHARGE THE HIGH VOLTAGE CAPACITOR
BEFORE TOUCHING ANY OVEN COMPONENTS
OR WIRING.
OR WIRING.
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R-90GCK
Flat type
screw driver
screw driver
Terminal
insulator
insulator
Receptacle
Covers
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.
3. Now, the terminal insulator is free.
TERMINAL INSULATOR REPLACEMENT
Installation
1. Insert the receptacle into terminal insulator.
2. Close covers of the terminal insulator, as shown
1. Insert the receptacle into terminal insulator.
2. Close covers of the terminal insulator, as shown
illustrated below
Removal
1. CARRY OUT 3D CHECKS.
2. Remove the one (1) screw holding the green/ yellow
1. CARRY OUT 3D CHECKS.
2. Remove the one (1) screw holding the green/ yellow
wire of the power supply cord to the bottom plate.
3. Disconnect the blue and brown wire leads of the power
supply cord from the noise filter.
4. Nip the cord bushing with bushing pliers and release it
from the hole of the back plate.
5. Remove the cord bushing from the power supply cord,
and the power supply cord from the back plate.
6. Now, the power supply cord is free.
Reinstall
1. Reinstall the cord bushing to the power supply cord.
2. Insert the power supply cord with the cord bushing into
1. Reinstall the cord bushing to the power supply cord.
2. Insert the power supply cord with the cord bushing into
the hole of the back plate.
3. Hold the green/ yellow wire of the power supply cord to
the bottom plate with the one (1) screw.
4. Reconnect the blue and brown wire leads of the power
supply cord to noise filter, referring to the pictorial
diagram.
diagram.
POWER SUPPLY CORD REPLACEMENT
5. Not to be caught by the outer case cabinet, pass the
green/ yellow wire of the power supply cord under the
high voltage capacitor.
high voltage capacitor.
6. Reinstall the outer case cabinet and check that the
oven is operating properly.
Figure C-1. Power supply cord replacement
1. CARRY OUT 3D CHECKS.
2. Remove the one (1) screw holding the green/ yellow
2. Remove the one (1) screw holding the green/ yellow
wire of the power supply cord to the bottom plate.
3. Disconnect the blue and brown wire leads wire of the
power supply cord from the noise filter.
4. Remove the three (3) screws holding the back plate to
BACK PLATE REMOVAL
the bottom plate.
5. Remove the two (2) screws holding the right and left
chassis supports to the back plate.
6. Release the tabs of the chassis supports from the back
plate.
7. Now, the back plate with the back plate is free.
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Disconnect the main wire harness from the high voltage
transformer.
4. Disconnect the filament leads of the high voltage
transformer from the high voltage capacitor and the
magnetron.
magnetron.
HIGH VOLTAGE TRANSFORMER REMOVAL
5. Disconnect the high voltage fuse from the high voltage
transformer.
6. Remove the four (4) screws holding the transformer
mounting angle to the bottom plate from under the
bottom plate.
bottom plate.
7. Remove the four (4) screws holding the high voltage
transformer to the transformer mounting angle.
8. Now, the high voltage transformer is free.
N
L
Back plate
Bottom plate
Power supply cord
Blue wire
Cord bushing
High voltage
capacitor
capacitor
Brown wire
Green/ Yellow
wire
wire
Noise filter
Screw
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Disconnect the high voltage wire of the high voltage
rectifier assembly from the magnetron.
4. Disconnect the filament wire of the high voltage
transformer from the magnetron.
5. Remove the two (2) screws holding the magnetron
MAGNETRON REMOVAL
guide to the magnetron and remove it.
6. Disconnect the wire leads and the connector from the
solid-state relay.
7. Release the main wire harness from the hole of the
magnetron separator and the hook of the fan motor.
8. Remove the three (3) screws holding the magnetron
separator to the bottom plate and the thermal cover back.
9. Remove the magnetron separator from the oven.
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R-90GCK
10.Carefully remove the four (4) screws holding the
magnetron to the waveguide. When removing the
screws, hold the magnetron to prevent it from falling.
screws, hold the magnetron to prevent it from falling.
11.Remove the magnetron from the unit with care so the
magnetron tube should not be hit by any metal object
around the tube.
around the tube.
CAUTION: WHEN REPLACING THE MAGNETRON, BE
SURE THE R.F. GASKET IS IN PLACE AND
THE MAGNETRON MOUNTING SCREWS
ARE TIGHTENED SECURELY.
THE MAGNETRON MOUNTING SCREWS
ARE TIGHTENED SECURELY.
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Disconnect the high voltage wire of the high voltage
rectifier assembly from the magnetron.
4. Disconnect the filament lead of the high voltage
transformer from the high voltage capacitor.
5. Disconnect the high voltage fuse from the high voltage
transformer.
6. Remove the one (1) screw holding the capacitor holder
to the fan motor mounting angle.
HIGH VOLTAGE CAPACITOR, HIGH VOLTAGE FUSE AND HIGH VOLTAGE RECTIFIER
ASSEMBLY REMOVAL
HIGH VOLTAGE TRANSFORMER SIDE
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Remove the one (1) screw holding the capacitor holder
to the fan motor mounting angle. And remove the
capacitor holder from the fan motor mounting angle.
capacitor holder from the fan motor mounting angle.
4. Disconnect the wire leads from the fan motor.
5. Remove the four (4) screws holding the fan motor
5. Remove the four (4) screws holding the fan motor
mounting angle to the bottom plate and the thermal
cover back.
cover back.
6. Remove the three (3) screws holding the fan motor to
the fan motor mounting angle.
7. Now, the fan motor is free.
7. Remove the one (1) screw holding the high voltage
rectifier assembly to the capacitor holder.
8. Disconnect the high voltage rectifier assembly and
high voltage fuse from the high voltage capacitor.
11.Now, the high voltage rectifier assembly, high voltage
fuse, and also the high voltage capacitor are free.
CAUTION: WHEN REPLACING HIGH VOLTAGE REC-
TIFIER ASSEMBLY, ENSURE THAT THE
CATHODE (EARTH) CONNECTION IS SE-
CURELY FIXED TO THE CAPACITOR
HOLDER WITH AN EARTHING SCREW.
CATHODE (EARTH) CONNECTION IS SE-
CURELY FIXED TO THE CAPACITOR
HOLDER WITH AN EARTHING SCREW.
FAN MOTOR REMOVAL
MAGNETRON SIDE ONE REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Disconnect the wire leads from the fan motor.
4. Disconnect the connector of the main wire harness
4. Disconnect the connector of the main wire harness
from the connector of the thermistor.
5. Release the main wire harness from the hole of the
magnetron separator and the hook of the fan motor.
6. Remove the three (3) screws holding the magnetron
separator to the bottom plate and the thermal cover back.
7. Remove the magnetron separator from the oven.
8. Remove the one (1) screw holding the fan motor to the
8. Remove the one (1) screw holding the fan motor to the
bottom plate.
9. Now, the fan motor is free.
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Disconnect the wire leads and the connector from the
solid-state relay.
4. Release the main wire harness from the hole of the
magnetron separator.
5. Remove the three (3) screws holding the magnetron
separator to the bottom plate and the thermal cover
back.
back.
6. Remove the magnetron separator form the oven.
SOLID-STATE RELAY (MAGNETRON SIDE) REMOVAL
7. Remove the two (2) screws holding the solid-sate relay
to the magnetron separator.
8. Now, the solid-sate relay is free.
CAUTION : WHEN THE SOLID-STATE RELAY (MAGN-
CAUTION : WHEN THE SOLID-STATE RELAY (MAGN-
ETRON SIDE ONE OR HEATER DUCT LEFT
SIDE ONE) IS REINSTALLED, APPLY THE
SILICON GREASE ( SHINETSU SILICON
GREASE G746 OF SHINETSU CHEMICAL
CO.,LTD.) TO THE BACK SIDE OF THE
SOLID-STATE RELAY IN A THICKNESS OF
0.3 MM. THIS IS TO PREVENT THE OVER
HEATING OF THE SOLID-STATE RELAY.
SIDE ONE) IS REINSTALLED, APPLY THE
SILICON GREASE ( SHINETSU SILICON
GREASE G746 OF SHINETSU CHEMICAL
CO.,LTD.) TO THE BACK SIDE OF THE
SOLID-STATE RELAY IN A THICKNESS OF
0.3 MM. THIS IS TO PREVENT THE OVER
HEATING OF THE SOLID-STATE RELAY.
DAMPER MOTOR AND DAMPER SWITCH REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Remove the one (1) screw holding the right chassis
support to the oven cavity front plate.
4. Disconnect the wire leads from the damper motor.
5. Remove the two (2) screws holding the damper motor
5. Remove the two (2) screws holding the damper motor
to the motor mounting angle.
6. Now, the damper motor is free.
7. Disconnect the wire leads from the damper switch.
8. Remove the two (2) screws holding the motor mounting
7. Disconnect the wire leads from the damper switch.
8. Remove the two (2) screws holding the motor mounting
angle to the damper duct assembly.
9. Remove the one (1) screw holding the damper switch
to the motor mounting angle.
10.Now, the damper switch is free.
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R-90GCK
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Remove the door assembly from the oven, referring to
“DOOR REPLACEMENT”, and remove the door
springs, the door cam right and the door cam left.
springs, the door cam right and the door cam left.
4. Remove the high voltage transformer, magnetron,
magnetron separator, high voltage capacitor assembly,
fan motor (high voltage transformer side) with fan
mounting angle, and fan motor (magnetron side),
referring to their removal procedures.
fan motor (high voltage transformer side) with fan
mounting angle, and fan motor (magnetron side),
referring to their removal procedures.
5. Disconnect the wire leads from all electrical parts
except for the turntable motor, monitor switch,
secondary interlock switch, door sensing switch and
3rd. latch switch.
secondary interlock switch, door sensing switch and
3rd. latch switch.
6. Remove the two (2) screws holding the latch hook right
and latch hook left from the oven cavity front plate.
7. Remove the two (2) screws holding the right and left
chassis supports to the oven cavity front plate.
8. Remove the two (2) screws holding the exhaust duct to
the oven cavity. And remove it.
9. Remove the one (1) screw holding the damper duct assembly
to the oven cavity from inside of the oven cavity.
10.Remove the two (2) screws holding the damper duct
assembly to the thermal cover upper and the waveguide.
11.Remove the damper duct assembly from the oven.
12.Remove the two (2) screws holding the separator left
12.Remove the two (2) screws holding the separator left
to the thermal cover upper. And remove it.
13.Disconnect the connector of the touch control
transformer from the power unit.
14.Remove the one (1) screw holding the touch control
transformer to the bottom plate. And remove it.
15.Remove the two (2) screws holding the PWB mounting
angle to the bottom plate.
HEATER DUCT LEFT ASSEMBLY, HEATER DUCT UPPER ASSEMBLY AND CONVECTION
DUCT ASSEMBLY REMOVAL
16.Remove the PWB mounting angle with the power unit
from the bottom plate.
17.Remove the three (3) screws holding the thermal cover
left to the heater duct left.
18.Remove the one (1) screw holding the thermal cover
left to the thermal cover upper.
19.Straighten the three (3) tabs holding the thermal cover
left to the oven cavity, and remove the thermal cover
left and the thermal insulation left from the oven cavity.
left and the thermal insulation left from the oven cavity.
20.Remove the two (2) screws holding the thermal cover
upper to the heater duct upper.
21.Straighten the four (4) tabs holding the thermal cover
upper to the oven cavity, and remove the thermal cover
upper and the thermal insulation upper from the oven
cavity.
upper and the thermal insulation upper from the oven
cavity.
22.Straighten the two (2) tabs holding the thermal insulation
upper, and remove it.
23.Remove the fourteen (14) screws holding the heater
duct left to the oven cavity and the convection duct.
24.Remove the heater duct left assembly from the oven
cavity.
25.Now, the heater duct left assembly is free.
26.Remove the two (2) screws holding the convection
26.Remove the two (2) screws holding the convection
motor mounting angle to the bottom plate from under
the bottom plate.
the bottom plate.
27.Remove the thirteen (13) screws holding the convection
duct to the oven cavity and the heater duct upper.
28.Remove the convection duct assembly from the oven
cavity.
29.Now, the convection duct assembly is free.
30.Remove the nine (9) screws holding the heater duct
30.Remove the nine (9) screws holding the heater duct
upper to the oven cavity.
31.Remove the heater duct upper from the oven cavity.
32.Now, the heater duct upper assembly is free.
32.Now, the heater duct upper assembly is free.
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Remove the heater duct left assembly from the oven
cavity, referring to “HEATER DUCT LEFT ASSEMBLY,
H E A T E R D U C T U P P E R A S S E M B L Y A N D
H E A T E R D U C T U P P E R A S S E M B L Y A N D
SIDE HEATING ELEMENT REMOVAL
CONVECTION DUCT ASSEMBLY REMOVAL
4. Remove the one (1) screw holding the heater mounting
angle B to the heater duct left.
5. Remove the two (2) nuts holding the side heating
element to the heater duct left.
6. Now, the side heating element is free.
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Remove the convection duct assembly from the oven
cavity, referring to “HEATER DUCT LEFT ASSEMBLY,
H E A T E R D U C T U P P E R A S S E M B L Y A N D
CONVECTION DUCT ASSEMBLY REMOVAL
H E A T E R D U C T U P P E R A S S E M B L Y A N D
CONVECTION DUCT ASSEMBLY REMOVAL
4. Loosen the one (1) screw holding the convection fan
assembly to the convection fan motor shaft with a
CONVECTION MOTOR REMOVAL
hexagon key wrench, and remove the convection fan.
5. Remove the four (4) screws holding the convection
motor mounting angle to the convection duct.
6. Remove the six (6) screws holding the convection
motor to the convection motor mounting angle.
7. Remove the convection motor from the convection
motor mounting angle.
8. Now, the convection motor is free.
TOP HEATING ELEMENT REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the back plate from the oven, referring to
2. Remove the back plate from the oven, referring to
“BACK PLATE REMOVAL”.
3. Remove the heater duct left assembly from the oven
cavity, referring to “HEATER DUCT LEFT ASSEMBLY,
H E A T E R D U C T U P P E R A S S E M B L Y A N D
CONVECTION DUCT ASSEMBLY REMOVAL
H E A T E R D U C T U P P E R A S S E M B L Y A N D
CONVECTION DUCT ASSEMBLY REMOVAL
4. Remove the one (1) screw holding the heater mounting
