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R-501CK
R-501CW

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MISCELLANEOUS

Actual wire harness may be different from illustration.

6-9

6-2

6-1

3-5

3-2-1

3-3

3-4

3-5

3-1

3-2

3-2-2

3-2-3

5-1

5-1-2

5-1-1

5-3

5-4

5-5

5-2

CONTROL PANEL PARTS

DOOR PARTS

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Summary of Contents for R-501CK

Page 1: ...ED BEFORE 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 6 TROUBLESHOOTINGGUIDE 9 TESTPROCEDURE 10 TOUCHCONTROLPANEL 18 COMPONENTREPLACEMENTANDADJUSTMENTPROCEDURE 22 PICTORIAL...

Page 2: ...tion 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 Mic...

Page 3: ... 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 capacitor 4 Reco...

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: ...t damaged D The door is not deformed or warped E There is no other visible damage with the oven Servicing and repair work must be carried out only by trained service personnel DANGER Certaininitialpartsareintentionallynotgroundedandpresenta riskofelectricalshockonlyduringservicing Servicepersonnel Do not contact the following parts while the appliance is energized High Voltage Capacitor Power Tran...

Page 6: ...ck pad Stop Clearpad START pad Oven Cavity Light Yes Safety Standard UL Listed FCC Authorized DHHS Rules CFR Title 21 Chapter 1 Subchapter J SPECIFICATION GENERAL INFORMATION GROUNDING INSTRUCTIONS This oven is equipped with a three prong grounding plug It must be plugged into a wall receptacle that is properly installed and grounded in accordance with the National Electrical Code and local codes ...

Page 7: ... open button Push to open door 2 Door latches The oven will not operate unless the door is securely closed 3 Removable turntable support 4 Removable turntable The turntable will rotate clockwise or counterclockwise 5 Oven lamp It will light when oven is operating or door is opened 6 Oven door with see through window 7 Ventilation openings Rear 8 Auto Touch control panel 9 Time display Digital disp...

Page 8: ...g results The circuits to the turntable motor the cooling fan 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 The monitor switch electrically monitors the operation of the secondary interlock switch and primary interlock relay and is mechanically associated with t...

Page 9: ...NITOR SWITCH H V RECTIFIER MAGNETRON SECONDARY INTERLOCK SWITCH TTM OL FM MONITOR FUSE 20A CAVITY TEMP FUSE MAGNETRON TEMP FUSE A1 A2 COM COM COM N O N C N O DOOR SENSING SWITCH RY 1 RY 2 CONTROL UNIT PRIMARY INTERLOCK RELAY B1 B2 GRN POWER TRANSFORMER CAPACITOR 1 0µF AC 2300V 120V AC 60 Hz OVEN LAMP TURN TABLE MOTOR FAN MOTOR MONITOR SWITCH H V RECTIFIER MAGNETRON SECONDARY INTERLOCK SWITCH TTM O...

Page 10: ... A BLOWN MONITOR FUSE TEST THE DOOR SENSING SWITCH PRIMARY INTERLOCK RELAY RY2 RELAY RY1 SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OP ERATION REFERTOCHAPTER TESTPRO CEDURE NOTE MONITOR FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY TURNTABLE MOTOR The turntable motor rotates the turntable located on the bottom of the oven cavity so that the foods on the turntable cook evenly du...

Page 11: ...S BA016 KIT as an assembly IMPORTANT Whenever troubleshooting is performed with the power supply cord disconnected It may in some cases be necessary to connect the power supply cord after the outer case has been removed in this event 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 Disconnect the leads to the prima...

Page 12: ... 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 but extremely uneven heating is pro duced in oven load food Oven does not cook properly when programmed for Cooking Power P 50 mode Operates properly on Cooking P HI HIGH mode Oven goes into COMPU DEFROST but food is not defrosted well OFF CONDITION PROBLEM CONDITION ...

Page 13: ...GHVOLTAGESAREPRESENTDURINGTHECOOKCYCLE SOEXTREMECAUTIONSHOULDBE OBSERVED Power output of the magnetron can be measured by performing a water temperature rise test This test shouldonlybeusedifabovetestsdonotindicateafaultymagnetronandthereisnodefectinthefollowing componentsorwiring siliconrectifier highvoltagecapacitorandpowertransformer Thistestwillrequire a 16 ounce 453cc measuring cup and an acc...

Page 14: ... 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 voltage ca...

Page 15: ...interlock switch 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 PRIMARY 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...

Page 16: ... Therefore unlikeconventionalmicrowaveovens propermaintenancecannotbeperformedwithonlyavoltmeterand ohmmeter In this service manual the touch control panel assembly is divided into two units Control Unit and Key Unit and also the Control Unit is divided into two units LSI Unit and Power Unit and troubleshooting by unit replacement is described according to the symptoms indicated Beforetesting 1 Di...

Page 17: ...ord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Reconnect all leads removed from components during testing 5 Re install the outer case cabinet 6 Reconnect the power supply cord after the outer case is installed 7 Run the oven and check all functions TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST J KEY UNIT TEST 1 Disconnect the power supply co...

Page 18: ...rol unit with an A C voltmeter The meter should indicate 120 volts if not check oven circuit RY1 and RY2 Relay Test These relays are operated by D C voltage Check voltage at the relay coil with a D C voltmeter during the microwave cooking operation DC voltage indicated Defective relay DC voltage not indicated Check diode which is connected to the relay coil If diode is good control unit is defecti...

Page 19: ...lled 9 Run the oven and check all functions 2 Followthetroubleshootingguidegivenbelow ifindicatordoesnotlightupafterabovecheckandrepairs are finished 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 Disconnect the leads to the primary of the power transformer 5 Ensurethattheseleadsremainisolatedfromothercomponentsa...

Page 20: ...back to the LSI through P41 P43 P44 P45 and AN0 to perform the function that was re quested Control Unit Control unit consists of LSI ACL circuit indicator circuit power source circuit relay circuit buzzer circuit synchro nizing signal circuit and back light circuit 1 ACL This circuit generates a signal which resets the LSI to the initial state when power is supplied 2 Indicator Circuit This circu...

Page 21: ... a corresponding signal will be input into P44 23 P43 IN Signal similar to P45 When either G10 line on key matrix is touched a corresponding signal will be input into P43 24 INT0 IN Signal synchronized with commercial power source frequency This is the basic timing for time processing of LSI 25 P41 IN Signal similar to P45 When either G9 line on key matrix is touched a corresponding signal will be...

Page 22: ... Signal applied to touch key section A pulse signal is input to P41 P43 P44 and P45 terminal while one of G2 line keys on key matrix is touched 40 P20 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P41 P43 P44 and P45 terminal while one of G1 line keys on key matrix is touched 41 48 P17 P10 OUT Terminal not used 49 50 P07 P06 OUT Terminal not used 51 72 SEG21 ...

Page 23: ...d controls of the touch control panel by using the dummy resistor s 3 Servicing Tools Tools required to service the touch control panel assembly 1 Soldering iron 30W Itisrecommendedtouseasolderingironwithagrounding terminal 2 Oscilloscope Singlebeam frequencyrange DC 10MHz type or more advanced model 3 Others Hand tools 4 Other Precautions 1 Before turning on the power source of the control unit r...

Page 24: ...OR WIRING 1 Disconnect the power supply cord 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 push the door open button with the other this causes the latch leads to rise it is then possible to hear a click as the door switches operate 3 Visuallycheckthedoorandcavityfaceplatefordamage dents cracks signs o...

Page 25: ...t the filament lead short one of the power transformer from the high voltage capacitor 7 Remove one 1 screw holding capacitor holder with the high voltage rectifier to the base plate 8 Disconnect rectifier terminal from capacitor High voltage rectifier assembly is now free 9 Remove capacitor holder Capacitor is now free CAUTION WHEN REPLACING HIGH VOLTAGE RECTI FIER AND HIGH VOLTAGE CAPACITOR GROU...

Page 26: ...ully so that there is no excessive force applied to the ribbon connection LSI unit 1 Disconnect the power supply cord 2 Removeturntableandturntablesupportfromovencavity 3 Lay the oven on it s backside Remove the turntable motor cover by snipping off the material in four corners 4 Where the corners have been snipped off bend corner areas flat No sharp edges must be evident after removal of the turn...

Page 27: ... of the shaft is not slanted 5 Install the fan motor to the the oven cavity back plate with the two 2 screws 6 Connect the wire leads to the fan motor referring to the pictorial diagram Side View Rear View 1 Disconnect the power supply cord and remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect wire leads from the switches 5 Remove two 2 screws hold...

Page 28: ... two 2 pins of door panel from two 2 holes of upper and lower oven hinges by lifting up 8 Now door panel with door frame is free from oven cavity Figure C 4 Door Disassembly 9 Release the door panel from twelve 12 tabs of door frame 10 Remove the door panel from the door frame 11 Now door panel with sealer film is free 12 Tear sealer film from door panel 13 Now door panel is free 14 Slide latch he...

Page 29: ... warm air movement around oven door is not abnormal and do not of themselves indicate a leakage of microwave energy from oven cavity Figure C 5 Door Replacement SEALER FILM Installation 1 Put the adhesive tape on the backing film of the sealer film as shown in Fig C 6 2 Tear the backing film by pulling the adhesive tape 3 Put the pasted side of the sealer film on the door panel Figure C 6 Sealer f...

Page 30: ...light socket POWER TRANSFORMER COM NO NOTE The neutral WHT GRY wire must be connected to the terminal with N mark on the power supply cord RED WHT BRN RED WHT WHT ORG WHT RED BLK RED BLU PNK GRN GRN to Oven cavity WHT WHT RED BLK WHT WHT BLUE MARK WHT RED WHT CAVITY TEMP FUSE MAGNETRON TEMP FUSE FAN MOTOR MONITOR FUSE HOLDER RED RED WHT 1 WHT GRY WHT ORG BLU GRN ORG ORG RY2 RY1 PRIMARY INTERLOCK R...

Page 31: ...C 3 C 5 C 9 C 4 C 6 C 8 C 1 C 7 C 2 A 2 NO NO SH A COM COM D1 S1NB10 T1 AC AC GND VR INT BUZZER MICRO BROWNER NC DOOR OVEN LAMP TURNTABLE MOTOR FAN MOTOR CN C 9PIN LEAD WIRE HARNESS OVEN LAMP TURNTABLE MOTOR FAN MOTOR MICRO DOOR SENSING SWITCH CN A RY1 RY2 a b c d J1 VRS1 SP1 PKM22EPT C1 2200µ 25v 10G471K SH B ...

Page 32: ...15k R90 15k J16 J17 4 7k J15 4 7k J13 4 7k J11 4 7k 1 25 64 41 1 24 25 40 65 80 J14 J12 J10 Q1 2SA1037AK IC1 1XA019DR Q30 DTA143EKA Q20 DTA143EKA Q22 DTA123JKA D40 MA152WA Q21 DTD143EKA Q10 DTA143EKA Q2 2SA1037AK LD1 LD2 LD3 LD4 R4 560 1 2w VR INT BUZZER OVEN LAMP TURNTABLE MOTOR FAN MOTOR NC BROWNER MICRO NOTE IF NOT SPECIFIED 1 10W 5 DOOR SEG8 VL2 VL1 AN7 AN6 AN5 AN4 AN2 AN1 AN0 P57 P56 P55 CNTR...

Page 33: ...e S 5 Printed Wiring Board of Power Unit Figure S 5 Printed Wiring Board of Power Unit Figure S 5 Printed Wiring Board of Power Unit Figure S 5 Printed Wiring Board of Power Unit 4 4 3 AC 1 7 S P OL TTM FM KPC M PP F B 0 3 4 M R D1 SP1 C1 VRS1 AC CN A T1 T1 J1 1 QKITPB034MRE0 CN C 1 1 9 2 DU OM RY1 RY2 DU OM DIP 1 2 MICRO CN B ...

Page 34: ...Diode bridge S1NB10 1 AG RY1 2 RRLY A114DRE0 J Relay DU12D1 1PR M 2 AN SP1 RALM A014DRE0 J Buzzer PKM22EPT 1 AG T1 RTRNPB013MRE0 M Transformer 1 AK T1 RTRNPA110DRE0 J Transformer Interchangeable 1 AP VRS1 RH VZB001MRE0 M Varistor 470ND 10D 1 AB VRS1 RH VZA032DRE0 J Varistor 10G471K Interchangeable 1 AE 3 2 FPNLCB332MRK0 M Control panel frame with key unit R 501CK 1 AY 3 2 FPNLCB333MRK0 M Control p...

Page 35: ...PB025MRK0 M Turntable support 1 AN 6 5 NTNT A099WRE0 M Turntable tray 1 AT 6 6 TCAUAB037MRR0 M Monitor caution label 1 AA 6 7 TCAUAB038MRR0 M DHHS Screw caution label 1 AB 6 8 TINSEB244MRR0 M Operation manual R 501CK CW 1 AD 6 9 QW QZB016MRE0 M High voltage wire A 1 AC SCREWS NUTSANDWASHERS 7 1 LX BZA041WRE0 M Special screw 1 AA 7 2 LX CZ0052WRE0 M Special screw 2 AA 7 3 XHTSD40P12RV0 M Screw 4mm ...

Page 36: ... OVEN AND CABINET PARTS 2 3 4 7 6 7 1 5 4 6 4 8 4 9 6 3 6 5 6 4 2 1 7 11 1 12 4 10 4 13 7 2 7 2 7 5 4 3 1 13 1 10 7 3 7 6 7 6 1 9 7 8 7 8 4 2 7 5 1 11 1 3 1 4 7 4 1 8 1 8 4 4 4 12 7 1 4 1 1 1 1 2 2 2 2 2 2 2 2 2 7 5 7 5 4 11 7 5 6 6 1 7 1 6 4 5 1 14 7 10 7 7 7 10 7 9 7 9 7 7 ...

Page 37: ...3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H MISCELLANEOUS Actual wire harness may be different from illustration 6 9 6 2 6 1 3 5 3 2 1 3 3 3 4 3 5 3 1 3 2 3 2 2 3 2 3 5 1 5 1 2 5 1 1 5 3 5 4 5 5 5 2 CONTROL PANEL PARTS DOOR PARTS ...

Page 38: ...1CW PACKING AND ACCESSORIES DOOR PROTECTION SHEET PLASTIC BAG PACKING CASE TOP PAD ASSEMBLY INTO THE OVEN CAVITY 6 5 TURNTABLE TRAY 6 4 TURNTABLE SUPPORT 6 8 OPERATION MANUAL TRAY PACK BOTTOM PAD ASSEMBLY TRAY HOLDER ...

Page 39: ...37 R 501CK R 501CW Notes ...

Page 40: ... 2000 BY SHARP CORPORATION ALL RIGHTS RESERVED Nopartofthispublicationmaybereproduced stored in retrieval systems or transmitted in any form or by any means electronic me chanical photocopying recording or other wise without prior written permission of the publisher ...

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