Sharp Carousel R-1405, Carousel R-1406 Service Manual Download Page 32

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R-1405
R-1406

1. Disconnect the power supply cord.
2. Open the door and block it open.
3. To discharge the high voltage capacitor, wait for 60

seconds.

4. Remove the one (1) screw holding the base cover to the

oven cavity back plate.

5. Remove the three (3) screws holding the base cover to

the oven cavity front face plate.

6. Open the base cover.
7. Release the two hood lamp sockets from the base cover.
8. Remove the base cover from the oven cavity by pulling

down and moving to the left slightly.

8. Pull the wire leads from the oven lamp socket by pushing

the terminal hole of the oven lamp socket with the small
flat type screw driver.

9. Now, the oven lamp socket is free.

TURNTABLE MOTOR AND FOOD LAMP SOCKETS REMOVAL

TURNTABLE MOTOR
9. Disconnect the wire leads from the turntable motor.
10.Remove one (1) screw holding turntable motor to the

oven cavity.

11.Now the turntable motor is free.

HOOD LAMP SOCKET
9. Screw the hood lamp off from the lamp socket.
10.Disconnect the wire leads from the lamp socket by

pushing the terminal hole of the lamp socket with the
small flat type screw driver.

11. Now, the lamp socket is free.

1. Disconnect the power supply cord, remove the oven

from the wall and remove the outer case. (Refer to
procedure of "REMOVAL OF OVEN FROM WALL" and
"OUTER CASE REMOVAL".). And proceed as follows.

2. Open the door and block it open.
3. To discharge the high voltage capacitor, wait for 60

seconds.

4. Remove the three (3) screws holding the hood intake duct

R to the oven cavity top plate, the oven cavity front flange
and the fan duct. And remove the hood intake duct R.

5. Turn the lamp socket and release it from the magnetron

duct.

6. Screw the oven lamp off from the lamp socket.
7. Now, the oven lamp is free.

OVEN LAMP AND LAMP SOCKET REMOVAL

POSITIVE LOCK

CONNECTOR (NO-CASE TYPE) REMOVAL

1. Disconnect the power supply cord and remove the oven

from wall and remove outer case. (Refer to procedure of
"Removal of Oven from Wall" and "Outer case Removal")

2. Open the door and block it open.
3. To discharge the high voltage capacitor, wait for 60

seconds.

4. Push the lever of positive lock

connector.

5. Pull down on the positive lock

connector.

CAUTION: WHEN CONNECTING THE POSITIVE LOCK

CONNECTORS TO THE TERMINALS, IN-
STALL THE POSITIVE LOCK

SO THAT THE

LEVER FACES YOU.

Positive lock

connector

Oven lamp

socket

Terminal

Wire lead

Terminal hole

Flat type small

screw driver

1. Disconnect the power supply cord.
2. Open the door and block it open.
3. To discharge the high voltage capacitor, wait for 60

seconds.

4. Remove three (3) screws holding the hood exhaust

louver to oven cavity front face plate.

5. Remove the hood exhaust louver from the oven by

pushing the right and left tabs of the hood exhaust louver.
(Refer to procedure of "HOOD EXHAUST LOUVER
REMOVAL")

CONTROL PANEL ASSEMBLY, CONTROL UNIT AND KEY UNIT REMOVAL

6. Remove one (1) screw holding the control panel to the

oven cavity front face plate.

7. Release the control panel from the oven cavity front face

plate by lifting it up.

8. Disconnect the wire leads from the relays RY1 and RY2.
9. Disconnect the connectors CN-A, CN-B and CN-E from

the control unit.

10. Remove the control panel assembly from the oven.
11.Now, the control panel assembly is free.
12.Disconnect the connector CN-G from the control unit.

Terminal

Push

Pull down

Lever

Positive lock¨

connector

Summary of Contents for Carousel R-1405, Carousel R-1406

Page 1: ... AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY INSIDE FRONT COVER BEFORESERVICING INSIDE FRONT COVER WARNING TO SERVICE PERSONNEL 1 MICROWAVEMEASUREMENTPROCEDURE 2 FOREWORDANDWARNING 3 PRODUCTSPECIFICATIONS 4 GENERAL INFORMATION 4 OPERATION 7 TROUBLESHOOTINGGUIDE 11 TESTPROCEDURE 13 TOUCH CONTROL PANEL ASSEMBLY 22 COMPONENTREPLACEMENTANDADJUSTMENTPROCEDURE 26 PICTOR...

Page 2: ...and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner e A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner BEFORE SERVICING Before servicing an operative unit perform a microwave emission check as per the Microwav...

Page 3: ...capacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that these leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord When the testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Rec...

Page 4: ...f the oven cavity The water container shall be a low form of 600 ml 20 oz beaker with an inside diameter of approx 8 5 cm 3 1 2 in and made of an electrically nonconductive material such as glass or plastic The placing of this standard load in the oven is important not only to protect the oven but also to insure that any leakage is measured accurately 4 Set the cooking control on Full Power Cookin...

Page 5: ...The door packing is not damaged D The door is not deformed or warped E There is not any other visible damage with the oven Servicing and repair work must be carried out only by trained service personnel DANGER Certaininitialpartsareintentionallynotgroundedandpresent a risk of electrical shock only during servicing Service personnel Do not contact the following parts while the appliance is energize...

Page 6: ...rox 30 of Full Power P 20 approx 20 of Full Power P 10 approx 10 of Full Power P 0 No power throughout the cooking time KEEP WARM pad POPCORN pad HOT WATER pad REHEAT CENTER pads COOK CENTER pads DEFROST CENTER pads Number selection pads POWER LEVEL pad TIMER CLOCK pad LIGHT button FAN button STOP CLEAR button START MINUTE PLUS button Oven Cavity Light 20W x 1 Incandescent light bulb Safety Standa...

Page 7: ...ndow 2 Doorhinges 3 Waveguidecover 4 Turntable motor shaft 5 Oven lamp Itwilllightwhenovenisoperatingordoorisopen 6 Door latches The oven will not operate unless the door is securely closed 7 One touch door open button 8 Auto Touch control panel 9 Time display Digital display 99 minutes 99 seconds 10 Ventilationopenings 11 LightCover 12 Grease filters 13 Removableturntable The turntable will rotat...

Page 8: ...one touch cooking features such as MINUTE PLUS are disabled after three minutes when the oven is not used These features are automatically enabled when the door is opened and closed or STOP CLEAR button is pressed CONTROL PANEL ...

Page 9: ...ble motor and the high voltage components are de energized the oven lamp remains on and the digital read out displays the time still remaining in the cook cycle when the door was opened 7 Themonitorswitchiselectricallymonitoringtheoperation of the primary interlock switch and secondary interlock relay RY2 andismechanicallyassociatedwiththedoor so that it will function in the following sequence 1 W...

Page 10: ...VERTICAL VENTING except that the final air discharge is directed horizontally out from the top rear of the oven into the customer s vent system 3 RE CIRCULATION INSIDEVENTING The air handing is the same as VERTICAL VENTING except that the final air discharge is directed horizontally through theupperfrontoftheovenintothekitchen INthis case the accessory charcoal filter RK 240 must be provided to fi...

Page 11: ...CH PRIMARY INTERLOCK SWITCH RED BLU POWER TRANSFORMER MAGNETRON HIGH VOLTAGE CAPACITOR xx uF HOOD CAPACITOR ORG BRN WHT SECONDARY INTERLOCK RELAY OVEN LAMP RELAY ORG BLK ORG RED RED BLK RED RED ORG PPL BLU WHT RY5 GRY BLK BLK WHT WHT WHT GRY GND BRN WHT F1 F2 F3 AH SENSOR BRN FUSE 20A CAVITY THERMAL CUTOUT 120VAC 60Hz HOOD FAN THERMAL CUT OUT RED PPL COM RED RED ORG BLK WHT WHT WHT GRY BRN WHT WHT...

Page 12: ...er direction The turntable motor can be turned off by touching TURNTABLEON OFFpad COOLING FAN MOTOR The cooling fan motor drives a blade which draws external cool air This cool air is directed through the air vanes surroundingthemagnetronandcoolsthemagnetron Thisair is channelled through the oven cavity to remove steam and DOOR OPEN MECHANISM Thedoorisopenedbypushingtheopenbuttononthecontrol panel...

Page 13: ... voltage capacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that the leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord When the testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacito...

Page 14: ... does light when door is opened Fan motor does not operate Oven lamp and turntable motor operate Turntable motor does not operate Oven lamp lights and fan motor operate Oven does not go into cook cycle when START button is touched Oven seems to be operating but little or no heat is produced in oven load Food incompletely cooked or not cooked at all at end of cook cycle Oven goes into a cook cycle ...

Page 15: ...rorthermocouplethroughthe water until the temperature stabilizes Record the temperature of the water 2 Placethecupofwaterintheoven OperateovenatPOWER10 HIGH selectingmorethan60seconds cooktime Allowthewatertoheatfor60seconds measuringwithastopwatch secondhandofawatch or the digital read out countdown 3 Removethecupfromtheovenandagainmeasurethetemperature makingsuretostirthethermometer or thermocou...

Page 16: ...oven cavity especially the cooling fan and air guide 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions MAGNETRON TEMPERATURE FUSE TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high...

Page 17: ...sting 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions F PRIMARY INTERLOCK SWITCH TEST H MONITOR SWITCH TEST G SECONDARY INTERLOCK SYSTEM TEST DOORSENSINGSWITCH 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Isolatetheswi...

Page 18: ...tingthemonitorswitch reconnectthewireleadtothemonitorswitch COM terminal and check the continuity of the monitor circuit 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions J HOOD THERMAL CUT OUT TEST 1 Disconnect the power supply cord and then remo...

Page 19: ...D 5 AND BLK 2 102Ω YLW 4 AND RED 5 162Ω 6 PIN CONNECTOR OF HOOD FAN MOTOR 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions BLU BLK YLW RED 1 2 4 5 60 Ω 102 Ω HOOD FAN CAPACITOR YLW RED BLU BLK 1 2 4 5 SUB 60 Hz 120 v MAIN ...

Page 20: ... after the outer case is installed 6 Run the oven and check all functions The following symptoms indicate a defective key unit a When touching the pads a certain pad produces no signal at all b When touching a number pad two figures or more are displayed c When touching the pads sometimes a pad produces no signal If the key unit is defective 1 Disconnect the power supply cord and then remove outer...

Page 21: ...od disconnect the flat ribbon cable that connects the key unit to the control unit and make sure the door sensing switch is closed either close the door or short the door sensing switch connecter Use the Key unit matrix indicated on the control panel schematic and place a jumper wire between the pins that correspond to the STOP CLEAR pad making momentary contact If the control unitrespondsbycleari...

Page 22: ...nts during testing 13 Re install the hood intake duct R 14 Re install the outer case cabinet 15 Reconnect the power supply cord after the outer case is installed 16 Run the oven and check all functions O DEFROST CENTER TEST 1 Open the door 2 Place one cup of water in the center of the turntable tray in the oven cavity 3 Close the door 4 Touch the DEFROST pad once 5 Touch the number pad 2 6 Touch t...

Page 23: ...TER CASE REMOVAL 2 Open the door and block it open 3 To discharge high voltage capacitor wait for 60 seconds 4 Remove the hood intake duct R 5 Disconnect the leads to the primary of the power transformer 6 Ensure that these leads remain isolated from other components and oven chassis by using insulation tape 7 After that procedure re connect the power supply cord 8 Follow the troubleshooting guide...

Page 24: ... motor hood motor and light the oven lamp and hood lamp 8 Indicator Circuit This circuit consists of 22 segments and 3 common electrodes using a Light Crystal Display 9 Back Light Circuit A circuit to drive the back light Light emitting diodes LD1 LD4 The touch control section consists of the following units as shown in the touch control panel circuit 1 Key Unit 2 Control Unit The Control unit con...

Page 25: ... signal is held at H level 21 P45 IN Signal similar to P46 When either G11 line on key matrix is touched a corresponding signal will be input into P45 22 P44 IN Signal similar to P46 When either G10 line on key matrix is touched a corresponding signal will be input into P44 23 P43 IN Signal similar to P46 When either G9 line on key matrix is touched a corresponding signal will be input into P43 24...

Page 26: ...d lamp OFF 43 P15 OUT Terminal not used 44 P14 OUT Hood motor driving signal To turn on and off relay RY4 L level During Hood motor ON H level During Hood motor OFF 45 47 P13 P11 OUT Terminal not used 48 50 SEG24 SEG22 OUT Terminal not used 51 72 SEG21 SEG0 OUT Segment data signal Connected to LCD The relation between signals are as follows LSI signal Pin No LCD Pin No LSI signal Pin No LCD Pin No...

Page 27: ... panel and the oven itself is so short that the two can t be separated For those models check and repairallthecontrols sensor relatedonesincluded ofthe touch control panel while keeping it connected to the oven B On some models the power supply cord between the touch control panel and the oven proper is long enough that they may be separated from each other For those models it is possible to check...

Page 28: ...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 transmission assembly 7 There is visible damage to the oven Do not operate the oven 1 Without the RF gasket Magnetr...

Page 29: ...CAUTION 1 DISCONNECT OVEN FROM POWER SUPPLY BEFORE REMOVING OUTER CASE 2 DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING POWER TRANSFORMER REMOVAL 1 Disconnect the power supply cord remove the oven from wall and remove outer case Refer to procedure of REMOVAL OF OVEN FROM WALL AND OUTER CASE REMOVAL And proceed as follows 2 Open the door and block it open 3 To di...

Page 30: ...en cavity top plate the oven cavity front flange and the fan duct And remove the hood intake duct R 5 Disconnect the high voltage wire lead with high voltage rectifier from the magnetron 6 Disconnect filament lead of the transformer from high voltage capacitor 7 Disconnect high voltage wire A from capacitor HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR REMOVAL 8 Remove the fan duct assembly fr...

Page 31: ... capacitor wait for 60 seconds 4 Remove the fan duct assembly from the oven cavity referring to the procedure of COOLING FAN MOTOR REMOVAL 5 Disconnect the wire leads from the temperature fuse Magnetron 6 Remove the one 1 screw holding the temperature fuse Magnetron to the fan duct 7 Now the temperature fuse Magnetron is free COOLING FAN MOTOR REMOVAL 15 Remove the fan blade from the shaft of the ...

Page 32: ...ove the hood intake duct R 5 Turn the lamp socket and release it from the magnetron duct 6 Screw the oven lamp off from the lamp socket 7 Now the oven lamp is free OVEN LAMP AND LAMP SOCKET REMOVAL POSITIVE LOCK CONNECTOR NO CASE TYPE REMOVAL 1 Disconnect the power supply cord and remove the oven from wall and remove outer case Refer to procedure of RemovalofOvenfromWall and OutercaseRemoval 2 Ope...

Page 33: ...NSING SWITCH PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH REMOVAL 9 Remove each switch from the latch hook by pushing the one 1 stopper tab holding each switch 10 Now each switch is free Re install 1 Re install each switch in its place The primary interlock switch is in the lower position door sensing switch is in the upper position and the monitor switch is in the middle position 2 Re connect wire...

Page 34: ... contacts of interlock switches 4 Make sure upper and lower oven hinges are inserted into the upper an lower door hinge pins 5 Make sure the door is parallel with oven face lines left and upper side lines and door latch heads pass through latch holes correctly 6 Re install the door stopper to the door assembly 7 Re install the hood exhaust louver to the oven cavity front face plate with the three ...

Page 35: ...over and door stopper and between the choke cover and the door frame as shown Figure C 3 to free engaging parts 9 Pry the choke cover by inserting a putty knife in order shown in Figure C 3 10 Now choke cover is free from door panel and door frame NOTE When carrying out any repair to the door do not bend or warp the slit choke tabs on the door panel assembly to prevent microwave leakage DOOR DISAS...

Page 36: ...VEN LAMP SOCKET HOOD LAMP SOCKET HOOD LAMP SOCKET CN E GRY WHT WHT WHT WHT RED PRIMARY INTERLOCK SWITCH N O N C COM COM MONITOR SWITCH FUSE HOLDER N O N O GRN RED GRN GRN GRN N O COM DOOR SENSING SWITCH CN B CN C CN G CN C CN A CN E 1 9 1 1 2 1 14 5 SECONDARY INTERLOCK RELAY RY1 RY2 RY4 C100 T1 HOOD FAN MOTOR 1 2 3 4 5 6 RED YLW BLU BLK RED YLW BLU BLK 1 2 RED GRN 1 2 3 4 5 YLW RED PPL CN A TURNTA...

Page 37: ...A D20 1SS270A C1 0 1µ 50v C2 1000µ 35v 3 8 D3 D1 D2 R1 390 2w SP1 PKM22EPT Q21 KRC243M C21 10µ 35v D1 D4 1N4002 C100 7µ 230v R2 750 1w AC N OVEN LAMP TURNTABLE MOTOR FAN MOTOR OVEN LAMP TURNTABLE MOTOR FAN MOTOR CN C 14pin WIRE HARNESS BUZZER MICRO N C N C GND VC VA INT HOOD THERMAL CUT OUT AC H MICRO CN B CN A CN E HOOD MOTOR COM HOOD MOTOR COM HOOD LAMP Q22 DOOR SENSING SWITCH DOOR SENSING SWITC...

Page 38: ...6 P25 P24 P23 P22 P21 P20 COM0 COM0 COM1 COM2 NC SEG0 SEG1 SEG2 SEG3 SEG4 SEG5 SEG6 SEG7 SEG8 SEG9 SEG10 SEG11 SEG12 SEG13 SEG14 SEG15 SEG16 SEG17 SEG18 SEG19 SEG20 SEG21 COM1 COM2 COM3 COM0 LCD COM1 LCD COM2 LCD COM0 LCD COM1 LCD COM2 LCD AVSS VREF VCC SEG0 SEG1 SEG2 SEG3 SEG4 SEG5 SEG6 SEG7 VL1 AN7 AN6 AN5 AN4 AN3 AN2 AN1 AN0 P57 P56 P55 CNTR0 P53 P52 P51 P50 P47 P46 P45 P44 P43 INT0 SEG14 SEG9 ...

Page 39: ... S 4 Printed Wiring Board 0 F C S M 2 7 A 9 4 V 0 M B M R 3 5 0 R BFB DIP LOT NO QKITPB035MRE0 RY1 VRS1 R30 T1 S 8 5 1 3 P C100 D26 D24 D23 D22 C21 CN E CN C D21 D40 D20 2 1 R2 Q21 Q1 B B ZD1 E E R1 R3 C2 D1 D3 D4 D2 D25 1 1 9 5 RY5 CN B CN A C1 C3 1 1 2 14 SP1 J1 RY2 RY3 RY4 RY6 ...

Page 40: ... 2 7 FANGKB010MRY0 M Hood lamp glass assembly R 1406 1 AM 2 7 1 LANGQB016MRP0 M Hood lamp glass angle R 1405 1 AG 2 7 1 LANGQB020MRP0 M Hood lamp glass angle R 1406 1 AG 2 7 2 PGLSPB004MRE0 M Hood lamp glass 1 AH 2 8 PCOVPB096MRT0 M Base cover R 1405 1 AV 2 8 PCOVPB097MRT0 M Base cover R 1406 1 AV CONTROLPANELPARTS 3 1 CPWBFB069MRU0 M Control unit 1 BE 3 1A QCNCMA017JDZZ M 3 pin connector CN A 1 A...

Page 41: ...C 4 22 PCUSGB043MRP0 M Transformer cushion 1 AC DOORPARTS 5 CDORFB321MRK0 M Door assembly R 1405 1 BB 5 CDORFB322MRK0 M Door assembly R 1406 1 BB 5 1 FDORFB070MRT0 M Door panel assembly 1 AW 5 2 FCOV B225MRK0 M Door frame assembly R 1405 1 AY 5 2 FCOV B226MRK0 M Door frame assembly R 1406 1 AY 5 2 1 LSTPPB023MRF0 M Latch head 1 AC 5 2 2 MSPRTA046WRE0 M Latch spring 1 AB 5 3 GCOVHB044MRF0 M Choke c...

Page 42: ...R DOOR PAD SPADFA020WRE0 Non replaceable items DOOR PROTECTOR GREASE FILTER x 2 6 10 INSTALL MATERIAL ASSEMBLY 6 1 6 2 OPERATION MANUAL 6 3 TOP WALL TEMPLATE EXHAUST DAMPER ASSEMBLY 6 11 SCREWS NUTSANDWASHERS 7 1 LX CZB004MRE0 M Special screw R 1405 3 AA 7 1 LX CZB016MRE0 M Special screw R 1406 3 AA 7 2 XOTSE40P12000 M Screw 4mm x 12mm R 1405 5 AA 7 2 XOTSF40P12000 M Screw 4mm x 12mm R 1406 5 AB 7...

Page 43: ...2 6 6 7 1 1 14 7 5 7 5 7 5 7 5 7 3 7 3 4 13 2 4 4 7 4 15 4 8 7 9 6 10 2 8 1 13 7 2 1 16 7 3 7 2 1 4 1 11 2 7 6 10 1 10 4 21 7 7 1 11 1 9 4 13 4 14 7 8 4 16 4 16 4 20 4 5 1 7 4 22 1 6 7 3 7 3 7 3 7 3 2 3 4 9 7 4 1 8 1 16 1 13 4 6 4 3 4 2 4 11 7 7 7 3 7 3 7 3 2 5 4 19 6 11 2 1 7 3 7 3 4 12 1 12 7 3 1 3 1 15 1 2 1 1 4 4 7 8 2 7 1 2 7 2 1 5 6 8 ...

Page 44: ... F G H 3 2 1 3 2 2 3 2 3 3 1 1 3 2 4 3 2 3 3 3 3 3 1 3 1 2 3 3 7 3 Actual wire harness may be different from illustration 6 9 6 5 6 4 5 2 5 2 2 5 2 1 5 4 5 3 5 1 5 5 6 5 5 6 1 6 1 1 6 1 2 6 1 3 6 1 7 6 1 8 6 1 5 6 1 6 6 1 4 MISCELLANEOUS DOOR PARTS CONTROL PANEL PARTS ...

Page 45: ...43 R 1405 R 1406 NOTES ...

Page 46: ...44 R 1405 R 1406 NOTES ...

Page 47: ...45 R 1405 R 1406 NOTES ...

Page 48: ...SERVED No part of this publication may be reproduced stored in retrieval systems or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without prior written permis sion of the publisher 02SHARPCORP 9S2 420E PrintedinU S A ...

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