R-67STM (serv.man11). Component Replacement And Adjustment Procedure — Sharp Home Appliance Service Manual (repair manual)

Model
R-67STM (serv.man11)
Pages
6
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339 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-67stm-sm11.pdf
Date

View Sharp R-67STM (serv.man11) Service Manual online

R67STM
11 – 1
R67STM
Service Manual
 
CHAPTER 11. 
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 fuse, 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) 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. Do not 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:
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, Turntable motor and cooling fan.
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 the oven from power supply.
2. Open the oven door and wedge it open.
3. Remove the two screws from the exhaust duct (rear).
4. Slide the exhaust duct (rear) up and pull it away from the oven cav-
ity.
5. Remove the screws from the rear(4).
6. Slide the entire case back about 3 cm to free it from retaining clips
on the cavity face plate.
7. Lift the entire case 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.
CAUTION: DISCHARGE HIGH VOLTAGE CAPACITOR BEFORE
TOUCHING ANY OVEN COMPONENT OR WIRING.
[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 all the leads and terminals of high voltage rectifier from
high voltage capacitor.
3. Remove one (1) screw holding capacitor holder from the base
plate.
4. Remove one (1) screw holding earth side terminal of the high volt-
age rectifier assembly
 
WARNING AGAINST HIGH VOLTAGE:
WARNING FOR WIRING
R67STM
11 – 2
5. Remove the capacitor from the capacitor holder.
6. Now the high voltage rectifier and capacitor should be free.
CAUTION: WHEN REPLACING HIGH VOLTAGE RECTIFIER
ASSEMBLY, ENSURE THAT THE CATHODE (EARTH)
CONNECTION IS SECURELY FIXED TO THE BASE
PLATE THROUGH THE CAPACITOR HOLDER WITH AN
EARTHING SCREW.
[4] HIGH VOLTAGE TRANSFORMER REMOVAL
To remove the components, proceed as follows.
1. CARRY OUT 3D CHECKS.
2. Disconnect the primary connections from high voltage transformer.
3. Disconnect the filament leads of the high voltage transformer from
high voltage capacitor and the magnetron.
4. Disconnect the H.V. secondary wire (white) from the high voltage
capacitor.
5. Remove the two (2) screws holding the transformer to base plate.
6. Remove the transformer from the base plate by sliding it away from
the oven cavity and lifting it.
7. Disconnect the high voltage wire from the filament lead of the high
voltage transformer.
8. Now, the high voltage transformer is free.
[5] MAGNETRON REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the H.V. wire and filament lead of the transformer from
the magnetron.
3. Remove the one (1) screw holding the air intake duct to the latch
hook.
4. Remove the one (1) screw holding the chassis support to the mag-
netron.
5. Move the air intake duct to left.
6. Carefully remove four (4) screws holding magnetron to the
waveguide.
7. 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, BE SURE THE
R.F. GASKET IS IN PLACE AND THE MAGNETRON
MOUNTING SCREWS ARE TIGHTENED SECURELY.
[6] FAN MOTOR REREPLACEMENT
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 oven cavity
back plate. The fan motor is now free.
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 any pieces do not enter the gap
between the rotor and the starter of the fan motor.
Because the rotor is easy to be shaven by pliers and
metal pieces may be produced. 
• Do not let the pliers touch the coil of the fan motor
because the coil may be cut or damaged.
• Do not distort the bracket by touching with the pliers.
ii) Remove the fan blade from the shaft of the fan motor by pulling
and rotating the fan blade with your hand.
CAUTION: • Do not use this removed fan blade again. Because the
hole (for shaft) of it may become bigger than a standard
one.
iii) Now, the fan blade is free.
2. INSTALLATION
1. Install the fan blade to the fan motor shaft according to the following
procedure.
i)
Hold the centre of the bracket which supports the shaft of the
fan motor on a flat table.
ii) 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 oven cavity back plate with the two (2)
screws.
3. Reconnect the wire leads to the fan motor, referring to the pictorial
diagram.
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
R67STM
11 – 3
[7] TURNTABLE MOTOR REPLACEMENT
1. REMOVAL
1. Disconnect the oven from the power supply.
2. Remove the turntable from the oven cavity.
3. Turn the oven over.
4. Cut the eight (8) bridges holding the turntable motor cover to the
base plate with cutting pliers as shown in Figure C-1(a).
CAUTION: DO NOT DROP THE TURNTABLE MOTOR COVER INTO
THE OVEN AFTER CUTTING THE BRIDGES. BECAUSE
IT WILL DAMAGE THE WIRE LEADS OF THE MOTOR
AND IT IS DIFFICULT TO REMOVE IT OUT OF THE
OVEN.
5. Remove the turntable motor cover from the base plate.
6. Disconnect the wire leads from the turntable motor.
7. Remove the one (1) screw holding the turntable motor to the turnta-
ble motor angle.
8. Bend the turntable motor retaining tab back to release the motor.
9. Remove the turntable motor from the turntable motor angle. 
10.Now, the turntable motor is free.
2. REINSTALLATION
1. Remove the any sharp edges on the turntable motor cover and the
base plate with the cutting pliers.
2. Reinstall turntable motor by locating shaft onto turntable motor
shaft to the turntable motor angle with the one (1) screw.
3. Bend the turntable motor retaining tab forward to secure the motor.
4. Reconnect the wire leads to the turntable motor.
5. Insert the two (2) tabs of the turntable motor cover into the slits of
the base plate as shown in Figure C-1(b).
6. Reinstall the turntable motor cover to the base plate with the screw
(XOTS740P08000) as shown in Figure C-1(b).
[8] CONTROL PANEL ASSEMBLY REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect all the wire leads and the connectors from the control
panel.
3. Straighten the tab holding the control panel to the oven cavity face.
4. Remove the one (1) screw holding the control panel frame to the
oven cavity front plate
5. Lift up the control panel assembly and pull it forward. 
Now the control panel assembly is free.
[9] GRAPHIC SHEET AND MEMBRANE SWITCH REPLACEMENT
1. REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the control panel assembly, referring to chapter of CON-
TROL PANEL ASSEMBLY REMOVAL.
3. Disconnect the ribbon cable of the membrane switch from the con-
nector (CN-G) on the control unit.
4. Tear away the graphic sheet from the control panel frame.
5. Tear away the membrane switch from the control panel frame.
 Figure C-2. Graphic Sheet and Membrane Switch Replacement
Screw;
XOTS740P08000
Turntable
motor cover
Tab
Tab
Slits
Cutting pliers
Turntable
motor cover
Figure C-1(a) Turntable Motor Cover Removal
Figure C-1(b) Turntable Motor Cover Reinstallation
Base plate
Base plate
Bridges
Graphic sheet
Ribbon
cable
Connector
(CN-G)
Small depression
Control panel frame
Slit
Control unit
Membrane
switch
Ribbon
cable
Large
depression
R67STM
11 – 4
2. REINSTALL
1. Remove remaining adhesive on the control panel frame surfaces
with a soft cloth soaked in alcohol.
2. Tear the backing paper from the new membrane switch.
3. Insert the ribbon cable of the membrane switch into the slit of the
control panel frame.
4. Adjust the upper edge and right edge of the membrane switch to
the small depression on the surface of the control panel frame. 
5. Attach the membrane switch to the control panel frame by rubbing
with a soft cloth not to scratch.
6. Tear the backing paper from the new graphic sheet.
7. Adjust the upper edge and right edge of the graphic sheet to the
large depression on the surface of the control panel frame. 
8. Attach the graphic sheet to the control panel frame by rubbing with
a soft cloth not to scratch.
9. Connect the ribbon cable of the membrane switch to the connector
(CN-G) on the control unit.
[10] BOTTOM HEATING ELEMENTS REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the turntable motor cover from the base plate, referring to
“TURNTABLE MOTOR REPLACEMENT”.
3. Disconnect the wire leads from the bottom heating element.
4. Remove the two (2) nuts holding the heater cover and heater pack-
ing to the bottom heater.
5. Remove the heater cover and the heater packing from the bottom
heating element.
6. Remove the two(2) nuts holding the bottom heating element to the
oven cavity.
7. Remove the bottom heating element from the oven cavity.
[11] OVEN LAMP REMOVAL
1. CARRY OUT 3D CHECKS.
2. Disconnect the wire lead from the oven lamp.
3. Lift up the oven lamp from the clips of the air intake duct.
4. Now, the oven lamp is free.
[12] TOP HEATING ELEMENT REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the two (2) screws holding the two (2) terminals of the
main wire harness to the top heating element.
3. Remove the one(1) screw holding the grill heater angle to the top of
the oven cavity.
4. Remove the grill heater angle from the oven cavity. 
5. Remove the top heating element from the top of the oven cavity.
6. Now the top heating element is free.
[13] POWER SUPPLY CORD REPLACEMENT
1. REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the one (1) screw holding the green/yellow wire to the
chassis support.
3. Disconnect the leads of the power supply cord from the noise filter,
referring to the Figure C-2(a).
4. Release the power supply cord from the oven cavity.
5. Now, the power supply cord is free.
Figure C-2 (a) Power Supply Cord  Replacement
2. REINSTALL
1. Insert the moulding cord stopper of power supply cord into the
square hole of the power angle, referring to the Figure C-2(b).
2. Install the earth wire lead of power supply cord to the chassis sup-
port with one (1) screw and tight the screw.
3. Connect the brown and blue wire leads of power supply cord to the
noise filter correctly, referring to the Pictorial Diagram.
Figure C-2(b). Power Supply Cord Replacement
BULB
LOCK
Oven Lamp
Power supply
cord
Oven cavity
back plate
Chassis
support
BLU
G-Y
BRN
EARTH
Noise filter
RED
N
F2
F1
TP
TL
L
WHT
RED
RED
BLK
WHT
Power Supply
Cord
Oven Cavity
Rear Plate
Moulding Cord
Stopper
Square Hple
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