R-86STM (serv.man11). Component Replacement And Adjustment Procedure — Sharp Home Appliance Service Manual (repair manual)

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R-86STM (serv.man11)
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7
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272.44 KB
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PDF
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Service Manual
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Device
Home Appliance / Microwave Oven / Component Replacement And Adjustment Procedure
File
r-86stm-sm11.pdf
Date

View Sharp R-86STM (serv.man11) Service Manual online

R86STM
11 – 1
R86STM
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 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. 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:
Top heating element, Bottom heating element, Oven lamp, Mag-
netron, 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, Convection
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, proceed as follows.
1. Disconnect oven from power supply.
2. Open the oven door and wedge it open.
3. Remove the two (2) screws holding the back plate to the oven cav-
ity rear plate. Remove the back plate.
4. Remove the air duct assembly from the oven cavity rear plate.
5. Remove the air duct assembly 
6. Remove the eight (8) screws from rear and along the side edge of
outer case cabinet.
7. Slide the entire case back about 3 cm to free it from retaining clips
on the cavity face plate.
8. Lift the entire outer case cabinet from the oven.
9. Discharge the H.V. capacitor before carrying out any further work.
10.Do not operate the oven with the outer case cabinet removed.
NOTE: Step 1, 2 and 9 form the basis of the 3D checks.
CAUTION: DISCHARGE HIGH VOLTAGE CAPACITOR BEFORE
TOUCHING ANY OVEN COMPONENT OR WIRING.
CAUTION: CAUTION: WHEN THE OUTER CASE CABINET IS REIN-
STALLED, INSTALL IT BEFORE THE BACK PLATE IS
INSTALLED, OR THE OUTER CASE CABINET WILL BE
DEFORMED.
 
WARNING AGAINST HIGH VOLTAGE:
WARNING FOR WIRING
R86STM
11 – 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 wire A from the high voltage capacitor.
3. Remove one (1) screw holding earth side terminal of the high volt-
age rectifier assembly.
4. Remove one (1) screw holding fan duct to the oven cavity rear
plate.
5. Remove one (1) screw holding capacitor holder to the oven cavity
rear plate.
6. Release the capacitor holder from the fan duct.
7. Remove the high voltage capacitor from the capacitor holder.
8. Disconnect the high voltage rectifier assembly from the high volt-
age capacitor.
9. Disconnect the high voltage rectifier assembly from the high volt-
age capacitor.
10.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 filament leads of high voltage transformer from high
voltage capacitor and the magnetron.
3. Disconnect the high voltage transformer secondary wire from the
high voltage transformer.
4. Disconnect the main wire harness from the high voltage trans-
former.
5. Remove the two (2) screws holding the transformer to the base
plate.
6. Remove the transformer.
7. 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 chassis support to the mag-
netron.
4. Move the air intake duct to left.
5. Carefully remove four (4) screws holding the magnetron to the
waveguide. When removing the screws hold the magnetron to pre-
vent it from falling.
6. Remove the magnetron from the waveguide with care so the mag-
netron antenna is not hit by any metal object around the antenna.
CAUTION: CAUTION: WHEN REPLACING THE MAGNETRON, BE
SURE THE R.F. GASKET IS IN PLACE AND THE MAG-
NETRON MOUNTING SCREWS ARE TIGHTENED
SECURELY.
[6] FAN MOTOR REREPLACEMENT
1. REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the one (1) screw holding the noise filter to the chassis
support.
3. Release the noise filter from the tabs of the fan duct. 
4. Remove the one (1) screw holding the chassis support to the oven
cavity front flange.
5. Remove one(1) screw holding the chassis support to the magne-
tron.
6. Remove the chassis support from the oven cavity.
7. Disconnect the wire leads from the fan duct.
8. Remove the one (1) screw holding the capacitor holder to the oven
cavity back plate.
9. Release the tabs of the capacitor holder from the fan duct.
10.Remove the one (1) screw holding the fan duct to the oven cavity
back plate.
11.Remove the fan duct from the oven.
12.Remove the fan duct 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.
13.Remove the two (2) screws holding the fan motor to the fan duct.
14.Now, the fan motor is free.
2. INSTALLATION
1. Install the fan motor to the fan duct with the two (2) screws.
2. 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) 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.
R86STM
11 – 3
• Make sure that the fan blade rotates smoothly after
installation.
• Make sure that the axis of the shaft is not slanted.
3. Insert the tabs of the capacitor holder to the fan duct.
4. Install the fan duct to the oven cavity back plate with the one (1)
screw.
5. Install the capacitor holder to the oven cavity back plate with the
one (1) screw.
6. Reinstall the chassis support to the oven cavity with the one (1)
screw.
7. Refit the one(1) screw to secure the chassis support to the magne-
tron.
8. Install the noise filter to the fan duct and the chassis support with
the one (1) screw.
9. Reconnect the wire leads to the fan motor.
[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 four (4) 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
(XHTS740P08RV0) as shown in Figure C-1(b).
[8] CONVECTION FAN MOTOR REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the two (2) screws holding the back plate to oven cavity.
3. Disconnect the wire leads from the convection motor.
4. Remove the two (2) screws holding the rear heat cover to the oven
cavity from out-side.
5. Remove the four (4) screws holding the convection fan duct to the
oven cavity.
6. Now, the convection fan duct assembly is free.
7. Remove the one (1) nut holding the convection fan, washers, pipe
and the cooling fan to the convection motor shaft.
8. Remove the three (3) screws holding the rear heat cover to the
convection fan duct.
9. Remove the two (2) screws holding the convection motor to the
rear heat cover.
10.Remove the pipe, washers and the cooling fan from the convection
motor shaft.
11.Remove the ring on the convection motor shaft.
12.Now, the convection motor is free.
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
Screw;
XHTS740P08RV0
Turntable motor cover
Base plate
Tabs
Slits
Cutting pliers
Bridges
Bridges
Turntable motor
cover
Figure C-1(a) Turntable Motor Cover Removal
Figure C-1(b) Turntable Motor Cover Reinstallation
R86STM
11 – 4
[9] POSITIVE LOCK CONNECTOR REMOVAL
1. CARRY OUT 3D CHECKS.
2. Push the lever of positive lock
®
 connector.
3. Pull down on the positive lock
®
 connector.
Figure C-1. Positive lock
® connector
CAUTION: WHEN CONNECTING THE POSITIVE LOCK
®
 CON-
NECTORS TO THE TERMINALS, CONNECT THE POS-
ITIVE LOCK
®
 SO THAT THE LEVER FACES YOU.
[10] OVEN LAMP REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the wire leads as Positive lock
®
 connector removal
above.
3. Lift up the oven lamp from its retaining clips.
Now, the oven lamp is free.
[11] POWER SUPPLY CORD REPLACEMENT
1. REMOVAL
1. CARRY OUT 3D CHECKS.
2. Remove the one (1) screw holding the green/yellow wire to the cav-
ity back plate.
3. Disconnect the leads of the power supply cord from the noise filter,
referring to the Figure C-4(a).
4. Release the power supply cord from the rear cabinet.
5. Now, the power supply cord is free.
Figure C-4 (a) Power Supply Cord Replacement
2. REINSTALLATION
1. Insert the moulding cord stopper of power supply cord into the
square hole of the cavity back plate, referring to the Figure C-4(b).
2. Install the earth wire lead of power supply cord to the oven cavity
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-4(b). Power Supply Cord Replacement
[12] TOP HEATING ELEMENTS 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 two (2) screws holding the two (2) grill heater angles to
the top of the oven cavity.
4. Remove the two (2) grill heater angles 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.
Terminal
Push
Pull down
1
2
Lever
Positive lock¨
connector
Figure C-1. Positive lock, connector
Lock
Socket
Bulb
Oven lamp
Power supply cord
Green/ Yellow-
wire
Brown wire
Oven cavity back plate
Blue wire
Noise filter
Screw
L
TP
F 8 A
TL
RED
20
A
WHT
N
POWER
SUPPLY CORD
MOULDING
CORD STOPPER
OVEN CAVITY
BACK PLATE
SQUARE HOLE
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