SHARP KB3425L, KB-3425JK, KB-3425JW, KB-4425JS, KB-442, KB4425L Service Manual
SERVICE MANUAL
FREE STANDING/SLIDE-IN RANGE
WITH MICROWAVE DRAWER
MODELS
KB-3425LS/K/W
KB-4425LS/K/W
S66R264KB442L
KB-3425LS
KB-3425LK
KB-3425LW
KB-4425LW pictured
WARNING TO SERVICE PERSONNEL:
This service manual is intended for use by persons having electrical and mechanical training and a level of
knowledge of these subjects generally considered acceptable in the appliance repair trade. Sharp Electronics
Corporation cannot be responsible, nor assume any liability, for injury or damage of any kind arising from the
use of this manual.
Microwave ovens contain circuitry capable of producing very high voltage and current. Contact with the
following parts may result in a severe, possibly fatal, electrical shock. (High Voltage Capacitor, High Voltage
Power Transformer, High Voltage Rectifier and Heat sink etc., and Magnetron, High Voltage Harness etc..)
TABLE OF CONTENTS
Page
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO
AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY ..................... INSIDE FRONT COVER
BEFORE SERVICING ....................................................................................................... INSIDE FRONT COVER
WARNING TO SERVICE PERSONNEL ................................................................................................................. 3
POWER CONNECTION ....................................................................................................................................... 10
CONTROL LAYOUT ............................................................................................................................................. 13
TEST PROCEDURES .......................................................................................................................................... 18
TOUCH CONTROL PANEL ASSEMBLY .............................................................................................................. 29
PARTS LIST ......................................................................................................................................................... 63
PACKING AND ACCESSORIES .......................................................................................................................... 74
KB-4425LS
KB-4425LK
KB-4425LW
SHARP ELECTRONICS CORPORATION
This document has been published to be used for after sales service only. The contents are subject to change without notice.
1
KB-3425LS/K/W
KB-4425LS/K/W
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO
EXCESSIVE MICROWAVE ENERGY
(a) Do not operate or allow the oven to be operated with the door open.
(b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave
source, and make repairs as necessary: (1) interlock operation, (2) proper door closing, (3) seal and sealing
surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and latches, (5) evidence of
dropping or abuse.
(c) Before turning on microwave power for any service test or inspection within the microwave generating compart-
ments, check the magnetron, wave guide or transmission line, and cavity for proper alignment, integrity, and
connections.
(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave generation 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 Microwave Measurement Procedure outlined in this service manual.
If microwave emissions level is in excess of the specified limit, contact SHARP ELECTRONICS CORPORATION immediately @1-800-237-4277.
If the unit operates with the door open, service person should 1) tell the user not to operate the oven
and 2) contact SHARP ELECTRONICS CORPORATION and Food and Drug Administration's Center for
Devices and Radiological Health immediately.
Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found with
emissions in excess of 4mW/cm2. The owner of the unit should be instructed not to use the unit until the
oven has been brought into compliance.
2
WARNING TO SERVICE PERSONNEL
Range units contain circuitry capable of producing very high voltage and current, contact
with following parts
(Example)
High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier
Assembly, High Voltage Harness, Heating Elements, etc..
Read the Service Manual carefully and follow all instructions.
Before Servicing
1. Disconnect the power supply cord , a n d t hen
remove cabinet.
2. Open the drawer and keep it open.
3. Discharge high voltage capacitor.
WARNING: RISK OF ELECTRIC SHOCK.
DISCHARGE THE HIGH-VOLTAGE
CAPACITOR BEFORESERVICING.
may result in a severe, possibly fatal, electrical shock.
KB-3425LS/K/W
KB-4425LS/K/W
When the testing is completed,
1. Disconnect the power supply cord, and then remove
covers.
2. Open the drawer and keep it open.
3. Discharge high voltage capacitor.
4. Reconnect the leads to the primary of the power
transformer.
5. Reinstall the covers.
6. Reconnect the power supply cord.
7. Run the unit and check all functions.
The high-voltage capacitor remains charged about 60
seconds after the oven has been switched off. Wait for
60 seconds and then short-circuit the connection of the
high-voltage capacitor (that is the connecting lead of the
high-voltage rectifier) against the chassis with the use of
an insulated screwdriver.
Whenever troubleshooting is performed the power supply
must be disconnected. It may, in some cases, be necessary
to connect the power supply after the outer case has been
removed, in this event:
1. Disconnect the power supply cord, and then remove
neccessary covers.
2. Open the drawer and keep it open.
3. Discharge high 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.
After repairing
1. Reconnect all leads removed from components during
testing.
2. Reinstall the covers.
3. Reconnect the power supply cord.
4. Run the oven and check all functions.
Microwave ovens should not be operated empty. To test for
the presence of microwave energy within a cavity, place a
cup of cold water on the oven tray, close the drawer and set
the power to HIGH and set the microwave timer for two (2)
minutes. When the two minutes has elapsed (timer at zero)
carefully check that the water is now hot. If the water remains
cold carry out Before Servicing procedure and re-examine
the connections to the component being tested.
When all service work is completed and the oven is fully
assembled, the microwave power output should be checked
and a microwave leakage test should be carried out.
3
KB-3425LS/K/W
ATTENTION!!!
Thisservicemanual is intendedfor useby persons having electricalandmechanical training
anda level of knowledgeof these subjects generallyconsidered acceptablein the appliance
repair trade. Sharp Electronics Corporation cannot be responsible, nor assume any liability,
for injury or damage of any kind arising from the use of this manual.
SAFE SERVICING PRACTICES
To avoid personal injury and/or property damage, it is important that Safe Servicing
Practices be observed. The following are some limited examples of safe practices:
1. DO NOT attempt a product repair if you have any doubts as to your ability to
complete it in a safe and satisfactory manner.
2. Before servicing or moving an appliance:
•Remove the power cord from the electrical outlet, trip the circuit breaker to the
OFF position, or remove the fuse.
3. Never interfere with the proper operation of any safety device.
4. USE ONLY REPLACEMENT PARTS CATALOGED FOR THIS APPLIANCE.
SUBSTITUTIONS MAY DE F E A T COMPL I A N C E WITH SAFETY
STANDARDS SET FOR HOME APPLIANCES.
5. GROUNDING : The standard color coding for safety ground wires is GREEN, or
GREEN with YELLOW STRIPES . Ground leads are not to be used as current
carrying conductors. It is EXTREMELY important that the service technician
reestablish all safety grounds prior to completion of service. Failure to do so will
create a hazard.
6. Prior to returning the product to service, ensure that:
•All electrical connections are correct and secure
•All electrical leads areproperly dressed and secured away from sharp edges,
•All safety grounds (both internal and external) are correctly and securely
connected
•All panels are properly and securely reassembled
KB-4425LS/K/W
4
KB-3425LS/K/W
KB-4425LS/K/W
MICROWAVE MEASUREMENT PROCEDURE
A. Requirements:
1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave
oven should not exceed 1mW/cm2 at any point 5cm or more from the external surface of the oven, measured prior to
acquisition by a purchaser, and thereafter (through the useful life of the oven), 5 mW/cm2 at any point 5cm or more
from the external surface of the oven.
2) Safety interlock switches:
Primary interlock relay switch shall prevent microwave radiation emission in excess of the requirement as above
mentioned. Secondary interlock relay and door sensing switch shall prevent microwave radiation emission in excess
of
5 mW/cm2 at any point 5cm or more from the external surface of the oven.
B. Preparation for testing:
Before beginning the actual measurement of leakage, proceed as follows:
1) Make sure that the actual instrument is operating normally as specified in its instruction booklet.
Important:
Survey instruments that comply with the requirement for instrumentation as prescribed by the performance standard for
microwave ovens, 21 CFR 1030.10(c)(3)(i), must be used for testing.
2) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5
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.
3) Set the cooking control on Full Power Cooking Mode.
4) Close the drawer and select a cook cycle of several minutes. If the water begins to boil before the survey is completed,
replace it with 275 ml of cool water.
O
C (68OF) in the center of the oven cavity.
C. Leakage test:
Closed-drawer leakage test (microwave measurement):
1) Grasp the probe of the survey instrument and hold it perpendicular to the gap between the drawer and the body of the
oven.
2) Move the probe slowly, not faster than 1 in./sec. (2.5 cm/sec.) along the gap, watching for the maximum indication on
the meter.
3) Check for leakage at the drawer screen, sheet metal seams and other accessible positions where the continuity of the
metal has been breached (eg., around the switches, indicator, and vents).
While testing for leakage around the drawer, pull the drawer away from the front of the oven as far as is permitted by
the closed latch assembly.
4) Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW/cm2,
and that the primary interlock switch/secondary interlock relay does turn the oven OFF before any door movement.
This Manual has been prepared to provide Sharp Electronics Corp.
Service Personnel with Operation and Service Information for the
SHARP FREE STANDING and SLIDE-IN RANGE WITH MICROWAVE
DRAWER, KB-3425LS/JK/JW and KB-4425LS/JK/JW
It is recommended that service personnel carefully study the entire
text of this manual so that they will be qualified to render satisfactory
customer service.
Check the interlock switches and the door seal carefully. Special
attention should be given to avoid electrical shock and microwave
radiation hazard.
WARNING
Never operate the oven until the following points are ensured.
(A) The door is tightly closed.
(B) The door brackets and hinges are not defective.
(C) 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.
PRODUCT DESCRIPTION
POWER CONNECTION
ANTI-TIP DEVICE
SCHEMATICS
TEST PROCEDURE
TOUCH CONTROL PANEL
COMPONENT REPLACEMENT
AND ADJUSTMENT PROCEDURE
WIRING DIAGRAM
Servicing and repair work must be carried out only by trained service
personnel.
DANGER
Certain initial parts are intentionally not grounded and present
a risk of electrical shock only during servicing. Service
personnel - Do not contact the following parts while the appliance is energized;
High Voltage Capacitor, Power Transformer, Magnetron, High
Voltage Rectifier Assembly, High Voltage Harness;
If provided, Vent Hood, Fan assembly, Cooling Fan Motor.
All the parts marked “*” on parts list are used at voltages more
than 250V.
Removal of the outer wrap gives access to voltage above 250V.
All the parts marked “ ” on parts list may cause undue microwave
∆
exposure, by themselves, or when they are damaged, loosened
or removed.
SHARP ELECTRONICS CORPORATION
PARTS LIST
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
7
KB-3425LS/K/W
KB-4425LS/K/W
OVEN SPECIFICATION
ITEM DESCRIPTION
Power Requirements 120 /208 - 120/240Volts / 46/50 Amperes
60 Hertz
Single phase, 3 wire grounded
DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J
9
KB-3425LS/K/W
208/240 VOLT CONNECTION INSTRUCTIONS
The rangecan be set for 208V or 240V. The voltage settingfor your
range is pre-set at 240V from the factory. Follow these steps to
change the voltage setting.
1 Locate the voltage switch on the lower back side of the
range.
2 Removethe screwandrotate theswitchplate180 as indicated
in the Figure 3.
3 Reinsert the switch plate and replace screw as indicated
in Figure 4. The voltage setting is indicated by the visible
marking.
POWER CORD CONNECTIONS
4-WIRE CONNECTION INSTRUCTIONS-FIGURE 8
Beforewiringtherange,reviewthe suggested powersourcelocation.
Ifconnecting to a 4-wireelectrical system for a
new branch-
circuit or mobile home use a 4-wire connection.
1 Follow the power supply kit manufacturer s Installation
Instructions supplied with the strain relief clamp and install.
See Figure 7.
2 Insert the end connectors for line 1, line 2 and neutral and
tighten securely to the terminal block.
IMPORTANT
DO NOT LOOSEN the factory installed nut
connections which secure the range wiring to the terminal
block. Electrical failure or loss of electrical connection may
occur if these 3 nuts are loosened or removed.
3 You must disconnect the ground strap. Remove the factory
installed ground screw and plate to release the copper ground
strap from the frame of the range. Cut and discard the copper
ground strap and plate. KEEP the ground screw.
4 Connectthegreengroundwireleadwith the eyeletto the frame
of the range with the ground screw using the same hole in the
frame where the ground screw was originally installed. See
Figure 8.
5 Make sure all screws are tightened securely and replace the
rear access cover. See Figure 6.
3-WIRE CONNECTION INSTRUCTIONS
For existing installations ONLY,refer to Figure 9.
1 Follow the power supply kit manufacturer s Installation
Instructions supplied with the strain relief clamp and install.
See Figure 7.
2 Insert the end connectors for line 1, line 2 and neutral and
tighten securely to the terminal block. See Figure 7.
IMPORTANT
DO NOT LOOSEN the factory installed nut
connections which secure the range wiring to the terminal
block. Electrical failure or loss of electrical connection may
occur if these 3 nuts are loosened or removed.
ACCESS TO TERMINAL BLOCK
Loosen screw on rear access cover and pull down as illustrated in
Figure6toaccessterminal blockwiring connection.Toclose,return
to original location and secure screw.
Figure 5A illustrates 4-wire receptacle required for new and
remodeled installations.
Figure 5B illustrates 3-wire receptacle that is allowed for existing
installations.
Figure 5A
4-wire wall receptacle (14-50R)
Figure 5B
3-wire wall receptacle (10-50R)
strain-relief clamp
Figure 7
240V
180
screw
208V
screw
KB-4425LS/K/W
POWER CONNECTION
10
KB-3425LS/K/W
3 Make sure all connections are tightened securely and replace
the rear access cover.See Figure 7.
GROUNDING IN STRUCTIONS - ONLY 3 -WIRE CONNECTION S:
A ground strap is installed on this range which connects the center
terminal of the neutral terminal block to the range chassis. The
ground strap is connected to the range by the center, lowestscrew
SeeFigure9. Theground strapmustnotbe removedunlessNational
State or Local Codes do not permit use of a ground strap.
Note: If the ground strap is removed forany reason, a separate
ground wire must be connected to the separate ground screw
attached to the range chassis and to an adequate ground source
Note: Install strain-relief
clamp. Center or white
wire must always be
attached to the center
terminal on block.
Figure 8
4-WIRE CONNECTION
3-WIRE CONNECTION
Figure 10
ground
screw
ground
wire lead
ground
plate
proper ground for
4-wire permanent
connection
Figure 11
4-WIRE PERMANENT CONNECTION ONLY
FOR 3 & 4-WIRE PERMANENT CONNECTIONS
connections.Tightenall 3 or 4-wire leads to the terminal block.
Followwire locations shown in Figure 10.
IMPORTANT
DO NOT LOOSEN the factory installed nut
connections which secure the range wiring to the terminal
block. Electrical failure or loss of electrical connection may
occur if these 3 nuts are loosened or removed.
Note: For 3-wirepermanentconnection skipsteps 3 and4 and
continue with step 5.
3 Disconnect the ground strap. Remove the factory installed
ground screw and plate to release the factory installed copper
ground strap from frame of the range. Cut and discard the
copperstrap fromthe terminalblock.KEEP theground screw,
ground plate and go to step 4.
4 Connect the green ground wire lead to the frame of the range
usingthe groundscrewand plateas showninFigure11. Be sure
to install using the same hole in the frame where the ground
screw was originally installed.
5 Make sure all connections are tightened securely and replace
the rear access cover.See Figure 7.
Note:Non-terminated fieldwirecompressionconnectionsmust
be set at approximately 90 in./lbs.
terminal
block
ground
screw
ground plate
ground strap
line 2
neutral
line 1
KB-4425LS/K/W
11
KB-3425LS/K/W
2 DRILL PILOT HOLES AND FASTEN BRACKET
Drill a1/8-inch pilot hole where screws are to be located. If bracket
is to be mounted to the wall, drill pilot hole at an approximate 20
degree downward angle. If bracket is to be mounted to masonry or
ceramic floors, drill a5/32-inch pilot hole 13/4-inches deep. The
screws provided may be used in wood or concrete material. Use a
5
/16-inch nut-driver or flat head screwdriver to secure the bracket
in place.
FASTEN BRACKET (WALL OR FLOOR MOUNTING)
FASTEN BRACKET (FLOOR MOUNTING ONLY)
Floor Mount
Floor Mount
Anti-Tip Bracket
Anti-Tip Bracket
Wall
Wall Mount
Wall Plate
More Than
11/4"
Max 11/4"
Leveling Leg
Leveling Leg
3 LEVEL AND POSITION RANGE
Level range by adjusting the (4) leveling legs with a wrench. Note:
A minimum clearance of1/8-inch is required between the bottom
of the range and the leveling leg to allow room for the bracket. Use
a levelto check your adjustments. Plug range into properlyprepared
electrical receptacle or if hard wired, check that it was completed
properly. Check door condition for evenness and stability. Slide
range back into position.
Visuallycheck that rear levelinglegisinserted into and fully secured
by the Anti-Tip bracket by looking underneath the range with a
flashlight and carefully attempt to tilt it forward.
To reduce the risk of tipping of the range, the range must be secured
to the floorby properly installed Anti-Tip bracket and screwspacked
with the range. Failure to install the Anti-Tip bracket will allow the
range to tip over if excessive weight is placed on an open door or if
a child climbs upon it. Serious injury might result from spilled hot
liquids or from the range itself.
If range is ever moved to a different location, the Anti-Tip bracket
must also be moved and installed with the range. Instructions are
provided forinstallationinwoodor cementfastenedto eitherthefloor
orwall.Wheninstalledtothewall,makesurethatscrewscompletely
penetratedry wall and are securedin woodormetal.When fastening
to the floor or wall, be sure that screws do not penetrate electrical
wiring or plumbing.
1 LOCATE THE BR ACKET - USING THE TE MPLATE
The bracket may be located on either the left or right side of the
range. Use the information below to locate the bracket if template
is not available.
Mark the floor or wall where left or right side of the range will be
located. If rear of range is against the wall or no further than 11/4inchesfromwallwheninstalled, youmay use the wall or floormount
method. If molding is installed and does not allow the bracket to fit
push against the wall, removemoldingor mount bracket to the floor.
For wall mount, locate the bracket by placing the back edge of the
template against the rear wall and the side edge of template on the
mark made referencing the side of the range. Place bracket on top
of template and mark location of the screw holes in wall. If rear of
rangeis further than 11/4-inchesfrom the wall wheninstalled, attach
bracket to the floor. For floor mount, locate the bracket by placing
backedgeofthe templatewheretherear of the range will be located.
Mark the location of the screw holes, shown in template.
Figure 18
Figure 15
Figure 16
Figure 17
Range Slide
15/8" to edge
of bracket
KB-4425LS/K/W
KB-3425L Shown
12
KB-3425LS/K/W
KB-4425LS/K/W
KB-3425LS
13
KB-3425LS/K/W
COOK TOP
NOTES:
1. Circuits / wire colors are subject to change without notice.
2. Terminal that is located on the right side on lamp sockets back view
must be connected to neutral wire.
SM
OL
FM
B1
B3
RY1
R
Y2
RY5
HUMIDITY
SENSOR
NOISE SUPRESSION COIL
RESISTOR 470 kohm 1/2W
LINE CROSS CAPACITOR 1.0uF 250V
LINE BYPASS CAPACITOR
0.0033uF 250V
LINE BYPASS CAPACITOR
0.0033uF 250V
FUSE
20A
FAN MOTOR
FM
CLOSS FLOW
FAN MOTOR
OV
EN LAMP
OL
OVEN LAMP
CONV. HEATER
TOP HEATER
MONITOR SWITCH
PRIMARY INTERLOCK
RELAY
RECTIFIERMAGNETRON
POWER TRANSFORMER
CAPACITOR
1.00uF
AC 2300V
STIRRER MOTOR
LM
DOOR LOCK
MOTOR
L
L
N.O.
N.O.
N.O.
COM.
COM.
COM.
N.O.
COM.
C1
E2
E1
RY7
RY4
RY10
RY3
RY8
RY11
CONTROL UNIT
M12
DOOR LOCK
MOTOR
SWITCH
THERMISTOR
M11
M10
M9
M8
M6
N1
N2
N3
N4
N5
M7
M4
DOOR
SWITCH
M5
CONTROL UNIT
OVEN
MICROWAVE DRAWER
SWITCHING POWER SUPPLY UNIT
L1
L2
N
N
L1
L2
2
INSIDE
OUTSIDE
CONTROL
RIGHT FRONT
SURFACE
ELEMENT
44aS2S1
P2
P1
H2 /
2
2a
1a
2
P1 /
4
CONTROL
H1 /
4
P
L1 /
P2
L2 /
P1
H2 /
2
PROTECTOR
CONTROL
INDICATOR LIGHT
INDICATOR LIGHT
HOT SURFACE LIGHT
HOT SURFACE
LIGHT
SWITCHES
H1 /
4
P
L1 /
P2
L2 /
P1
H2 /
2
CONTROL
LEFT REAR
SURFACE
ELEMENT
H1 /
4
P
L1 /
P2
L2 /
P1
1b /
H
RR
LR
RF
LF
2b /
S
1b /
H
2b /
S
1b /
H
2b /
S
1b /
H
2b /
S
OVEN
THERMAL
CUT-OUT
MG
THERMAL
CUT-OUT
CM
RY9
CONV. MOTOR
D1
D5
D3
C3C7
C5
E6E5
E3
RY6
SECONDARY INTELOCK SWITCH
VOLTAGE SWITCH
DM
MICROWAVE DRAWER
DOOR OPEN-CLOSE
MOTOR
DOOR
POSITION
SWITCH
FRONT
M14
M13
DOOR
POSITION
SWITCH
REAR
BOTTOM HEATER
OVEN THERMAL
CUT-OUT (THERMAL OVEN)
A2
A4
A6
A1
M1
DOOR
SENSING
SWITCH
M3
F3
F2
F1
2a
2a
2a
2a
1a
2
P1 /
4
PROTECTOR
LEFT FRONT
SURFACE
ELEMENT
1a
2
P1 /
4
PROTECTOR
RIGHT REAR
SURFACE
ELEMENT
1a
PROTECTOR
1a
2
P1 /
4
PROTECTOR
RY-BRY-C
WARMER
SURFACE
ELEMENT
L2
L1
LOW VOLTAGE
TRANSFORMER
BLK
YLW
BLK
YLW
WHT
BLK
ORG
RED
YLW
RED
RED
BLK
WHT
WHT
RED
BRN
RED
YLW
RED
RED
YLW
ORG
YLW
YLW
WHT
YLW
RED
YLW
RED
RED
RED
BLK
BLK
BLK
RED
RED
RED
YLW
YLW
YLW
YLW
YLW
WHT
YLW
BLU
BLK
YLW
YLW
YLW
YLW
BRN
YLW
WHT
RED
BRN
BLU
BLK
YLW
WHT
WHT
BLK
BLK
BLU
BLU
BLU
BLK
BLU
BLK
BLK
YLW
RED
WHT
YLW
RED
BLK
YLW
YLW
YLW
WHT
BLK
RED
RED
BLK
RED
YLW
RED
BLK
ORG
ORG
BRN
BRN
BLK
WHT
WHT
YLW
WHT
WHT
ORG
RED
BLU
WHT
YLW
WHT
BRN
RED
BLK
GRY
BLK
WHT
WHT
BLU
BLK
REDRED
BLK
RED
WHT
WHT
BLK
BLK
BLK
BLK
BLK
BLU
BLK
BLK
BRN
GRY
YLW
ORG
YLW
BLK
RED
BLU
WHT
WHT
ORG
ORG
RED
BLK
RED
RED
RED
RED
BRN
RED
RED
WHT
GRN
BLK
RED
BLK
BRNBLK
BLK
RED
BLK
BLK
WHT
WHT
ORG
ORG
RED
WHT
BRN
BRN
ORG
WHT
WHT
ORG
RED
RED
BLK
WHT
1
3
3
1
BRN
WHT
WHT
WHT
BLK
RED
ORG
P1B /
4
P1A /
4A
KB-4425LS/K/W
Schematic-Off Condition
14
COOK TOP SCHEMATIC (DETAIL)
COOK TOP
L2
N
N
L1
L2
2
INSIDE
OUTSIDE
CONTROL
RIGHT FRONT
SURFACE
ELEMENT
4
4a
S2S1
P2
P1
H2 /
2
2a
1a
2
P1 /
4
CONTROL
H1 /
4
P
L1 /
P2
L2 /
P1
H2 /
2
PROTECTOR
CONTROL
INDICATOR LIGHT
INDICATOR LIGHT
HOT SURFACE LIGHT
HOT SURFACE
LIGHT
SWITCHES
H1 /
4
P
L1 /
P2
L2 /
P1
H2 /
2
CONTROL
LEFT REAR
SURFACE
ELEMENT
H1 /
4
P
L1 /
P2
L2 /
P1
1b /
H
RR
LR
RF
LF
2b /
S
1b /
H
2b /
S
1b /
H
2b /
S
1b /
H
2b /
S
2a
2a
2a
2a
1a
2
P1 /
4
PROTECTOR
LEFT FRONT
SURFACE
ELEMENT
1a
2
P1 /
4
PROTECTOR
RIGHT REAR
SURFACE
ELEMENT
1a
PROTECTOR
1a
2
P1 /
4
PROTECTOR
WARMER
SURFACE
ELEMENT
L2
BLK
YLW
BLK
YLW
WHT
BLK
ORG
RED
YLW
RED
RED
BLK
WHT
WHT
RED
BRN
RED
YLW
RED
RED
YLW
ORG
YLW
YLW
WHT
YLW
RED
YLW
RED
RED
RED
BLK
BLK
BLK
RED
RED
RED
YLW
YLW
YLW
YLW
YLW
WHT
YLW
BLU
BLK
YLW
YLW
YLW
YLW
BRN
YLW
WHT
RED
BRN
BLU
BLK
YLW
WHT
WHT
BLK
BLK
BLU
BLU
BLU
BLK
BLU
BLK
BLK
YLW
RED
WHT
YLW
RED
BLK
YLW
YLW
YLW
WHT
BRN
WHT
WHT
P1B /
4
P1A /
4A
KB-3425LS/K/W
KB-4425LS/K/W
15
KB-3425LS/K/W
SM
OL
FM
B1
B3
RY1
R
Y2
RY5
HUMIDITY
SENSOR
NOISE SUPRESSIONCOIL
RESISTOR 470kohm 1/2W
LINE CROSSCAPACITOR 1.0uF 250V
LINE BYPASSCAPACITOR
0.0033uF 250V
LINE BYPASSCAPACITOR
0.0033uF 250V
FUSE
20A
FAN MOTOR
OV
EN LAMP
MONITOR SWITCH
PRIMARY INTERLOCK
RELAY
RECTIFIERMAGNETRON
POWER TRANSFORMER
CAPACITOR
1.00uF
AC 2300V
STIRRER MOTOR
L
L
N.O.
COM.
N.O.
COM.
C1
E2
E1
RY11
CONTROL UNIT
M6
N1
N2
N3
N4
N5
M7
MICROWAVE DRAWER
SWITCHING POWER SUPPLY UNIT
N
OVEN
THERMAL
CUT-OUT
MG
THERMAL
CUT-OUT
SECONDARY INTELOCK SWITCH
VOLTAGE SWITCH
DM
MICROWAVE DRAWER
DOOR OPEN-CLOSE
MOTOR
DOOR
POSITION
SWITCH
FRONT
M14
M13
DOOR
POSITION
SWITCH
REAR
B
A2
A4
A6
A1
M1
DOOR
SENSING
SWITCH
M3
F3
F2
F1
RY-BRY-C
L2
L1
LOW VOLTAGE
TRANSFORMER
RED
RED
BLK
BLU
BLK
BLK
BRN
GRY
YLW
ORG
YLW
BLK
RED
BLU
WHT
WHT
ORG
ORG
RED
BLK
RED
RED
RED
RED
BRN
RED
RED
WHT
GRN
BLK
RED
BLK
BRNBLK
BLK
RED
BLK
BLK
WHT
WHT
ORG
ORG
RED
WHT
BRN
BRN
ORG
WHT
WHT
ORG
RED
RED
BLK
WHT
1
3
3
1
WHT
WHT
ORG
KB-4425LS/K/W
MICROWAVE DRAWER SCHEMATIC (DETAIL)
16
KB-3425LS/K/W
FM
CLOSS FLOW
FAN MOTOR
OL
OVEN LAMP
CONV. HEATER
TOP HEATER
LM
DOOR LOCK
MOTOR
N.O.
N.O.
COM.
COM.
RY7
RY4
RY10
RY3
RY8
M12
DOOR LOCK
MOTOR
SWITCH
THERMISTOR
M11
M10
M9
M8
M4
DOOR
SWITCH
M5
CONTROL UNIT
OVEN
L1
N
CM
RY9
CONV. MOTOR
D1
D5
D3
C3C7
C5
E6E5
E3
RY6
BOTTOM HEATER
OVEN THERMAL
CUT-OUT (THERMAL OVEN)
RY-BRY-C
BLK
RED
RED
BLK
RED
YLW
RED
BLK
ORG
ORG
BRN
BRN
BLK
WHT
WHT
YLW
WHT
WHT
ORG
RED
BLU
WHT
YLW
WHT
BRN
RED
BLK
GRY
BLK
WHT
WHT
BLU
BLK
REDRED
BLK
RED
WHT
WHT
BLK
BLK
BLK
BLK
WHT
BLK
RED
ORG
KB-4425LS/K/W
RANGE SCHEMATIC (DETAIL)
17
KB-3425LS/K/W
KB-4425LS/K/W
PROCEDURE
LETTER
A TOUCH CONTROL PANEL ASSEMBLY TEST
The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore,
TEST PROCEDURES
unlike conventional microwave ovens, proper maintenance cannot be performed with only a voltmeter
and ohmmeter.
In this service manual, the touch control panel assembly is divided into three units, Control Unit and
Keyboard Unit and Power Unit, and troubleshooting by unit replacement is described according to the
symptoms indicated.
Before testing,
1) Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
2) Open the drawer and block it open.
3) Discharge high voltage 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.
1. Keyboard Unit.
NOTE ;
1) Check Keyboard unit connection before replacement.
2) Reconnect all leads removed from components during testing.
3) Re-install the outer case (cabinet).
4) Reconnect the power supply cord after the outer case is installed.
5) Run the oven and check all functions.
The following symptoms indicate a defective keyboard 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 Keyboard unit is defective.
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) Replace the Keyboard unit.
5) Reconnect all leads removed from components during testing.
6) Re-install the covers.
7) Reconnect the power supply cord after the outer case is installed.
8) Run the oven and check all functions.
2. Control Unit
The following symptoms indicate a defective control unit. Before replacing the control unit, perform
the Keyboard unit test (Procedure J) to determine if control unit is faulty.
2-1 In connection with indicators
a) At a certain digit, all or some segments do not light up.
b) At a certain digit, brightness is low.
c) Only one indicator does not light.
d) The corresponding segments of all digits do not light up; or they continue to light up.
e) Wrong figure appears.
f) A certain group of indicators do not light up.
g) The figure of all digits flicker.
2-2 Other possible problems caused by defective control unit.
a) Buzzer does not sound or continues to sound.
b) Clock does not operate properly.
c) Cooking is not possible.
3. Power Unit or Touch Control Transformer
a) Fan motor, stirrer motor, oven lamp or electrical parts do not turn on or do not turn off.
b) Digital display on the control unit does not show anything.
When testing is completed,
1) Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
2) Open the drawer and block it open.
3) Discharge high voltage capacitor.
COMPONENT TEST
18
KB-3425LS/K/W
KB-4425LS/K/W
TEST PROCEDURES
PROCEDURE
LETTER
4) Reconnect all leads removed from components during testing.
5) Re-install the covers.
6) Reconnect the power supply cord after the outer case is installed.
7) Run the oven and check all functions.
B KEYBOARD UNIT TEST
1. Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
2. Open the drawer and block it open.
3. Discharge high voltage capacitor.
4. If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the wire harness
and connectors are making good contact between the control unit and the keyboard, verify that the
door sensing switch operates properly; that is the contacts are closed when the door is closed and
open when the door is open.
5. Remove the old keyboard unit and install the new keyboed unit (as the normal keyboard unit).
6. Reconnect the wire harness to the keyboard unit.
7. If the control unit responds by clearing with a beep when the stop/clear pad is touched, the old
keyboard unit is faulty and must be replaced. If the control unit does not respond, it is faulty and
must be replaced. If a specific pad does not respond, the above method may be used (after clearing
the control unit) to determine if the control unit or keyboed unit is at fault.
8. Reconnect all leads removed from components during testing.
9. Re-install the covers.
10. Reconnect the power supply cord after the outer case is installed.
11. Run the oven and check all functions.
COMPONENT TEST
C RELAY TEST
1. Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
2. Open the drawer and block it open.
3. Discharge high voltage 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, re-connect the power supply cord.
7. Remove the covers and check voltage between Pin Nos. 1 and 3 of the 2 pin connector (CN-B) on
the power unit with an A.C. voltmeter.
The meter should indicate 116 or 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 defective.
RELAY SYMBOL OPERATIONAL VOLTAGE CONNECTED COMPONENTS
RY1 Approx. 18V D.C. Oven lamp / Stirrer motor
RY2 Approx. 18V D.C. Power transformer
RY3 Approx. 18V D.C. Oven common relay
RY4 Approx. 18V D.C. Top heater
RY5 Approx. 24V D.C. Fan motor (Microwave)
RY6 Approx. 24V D.C. Fan motor (Oven)
RY7 Approx. 24V D.C. Oven lamp (Oven)
RY8 Approx. 24V D.C. Door lock motor (Oven)
RY9 Approx. 24V D.C. Convection motor
RY10 Approx. 24V D.C. Warmer (Cook top)
RY11 Approx. 24V D.C. Switching power supply
RY-B Approx. 24V D.C. Bottom heater
RY-C Approx. 24V D.C. Convection heater
19
KB-3425LS/K/W
KB-4425LS/K/W
PROCEDURE
LETTER
8. Reconnect all leads removed from components during testing.
9. Re-install the covers.
10. Reconnect the power supply cord after the cabinets are installed.
11. Run the drawer and check all function.
D DEFROST TEST
WARNING : The unit should be fully assembled before following procedure.
(1) Place one cup of water in the center of the turntable tray in the oven cavity.
(2) Close the door, touch the Stop/Clear (M) pad and touch the Defrost pad on the LCD. Then touch
the Steaks/Chops pad on the LCD. And touch the number pad 5 on the LCD. (Now, weight 0.5lb is
set.) And then touch the start pad on the LCD.
(3) The oven is in Defrost cooking condition.
(4) The oven will operate as follows
(5) If improper operation is indicated, the control unit is probably defective and should be checked.
TEST PROCEDURES
COMPONENT TEST
WEIGHT 1ST STAGE 2ND STAGE 3RD. STAGE
LEVEL TIME LEVEL TIME LEVEL TIME
0.5lb 60% 20sec. 40% 20sec. 30% 45sec.
E PROCEDURES TO BE TAKEN WHEN THE FUSE ON THE PRINTED WIRING BOARD (PWB) IS OPEN.
To protect the electronic circuits, this model is provided with a fuse added to the primary on the PWB.
1. Fuse check and repairs.
1) Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
2) Open the drawer and block it open.
3) Discharge high voltage capacitor.
4) If the Fuse is blown, replace power unit.
5) Make a visual inspection of the varistor. Check for burned damage. If the varistor has been
burned, replace the power unit.
6) Examine the touch control transformer with a tester for the presence of layer short-circuit (check
the primary coil resistance which is approximately 60Ω ± 10%). If any abnormal condition is
detected, replace the touch control transformer.
7) Reconnect all leads removed from components during testing.
8) Re-install the covers.
9) Reconnect the power supply cord after the outer case is installed.
10) Run the oven and check all functions.
2. Follow the troubleshooting guide given below, if indicator does not light up after above check and
repairs are finished.
1) Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
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) Ensure that these leads remain isolated from other components and oven chassis by using
insulation tape.
6) After that procedure, re-connect the power supply cord.
7) Follow the troubleshooting guide given below for repair.
20
TEST PROCEDURES
PROCEDURE
LETTER
STEPS OCCURRENCE CAUSE OR CORRECTION
1 The rated AC voltage is not present between Check supply voltage and oven power cord.
Pin Nos. 1and 3 of the 2-pin connecter (CN-B).
2 The rated AC voltage is present at primary Touch control transformer or secondary circuit defective.
side of touch control transformer. Check and replace touch control transformer or power
unit .
8) Reconnect all leads removed from components during testing.
9) Re-install the covers.
10) Reconnect the power supply cord after the cabinets are installed.
11) Run the oven and check all functions.
F AH SENSOR TEST
Checking the initial sensor cooking condition
WARNING : The oven should be fully assembled before following procedure.
(1) The oven should be plugged in at least two minutes before sensor cooking.
(2) Room temperature should not exceed 95
(3) The unit should not be installed in any area where heat and steam are generated. The unit should not be
installed, for example, next to a conventional surface unit. Refer to the “INSTALLATION INSTRUCTIONS”
of the operation manual.
(4) Exhaust vents are provided on the back of the unit for proper cooling and air flow in the cavity. To permit
adequate ventilation, be sure to install so as not to block these vents. There should be some space for
air circulation.
(5) Be sure the exterior of the cooking container and the interior of the oven are dry. Wipe off any moisture
with a dry cloth or paper towel.
(6) The Sensor works with food at normal storage temperature. For example, chicken pieces would be at
refrigerator temperature and canned soup at room temperature.
(7) Avoid using aerosol sprays or cleaning solvents near the oven while using Sensor settings. The sensor
will detect the vapor given of by the spray and turn off before food is properly cooked.
(8) If the sensor has not detected the vapor of the food, ERROR will appear and the oven will shut off.
COMPONENT TEST
o
F (35oC).
KB-3425LS/K/W
KB-4425LS/K/W
Water load cooking test
WARNING : The oven should be fully assembled before following procedure.
Make sure the oven has been plugged in at least two minutes before checking sensor cook operation. The
cabinet should be installed and screws tightened.
(1) Fill approximately 200 milliliters (7.2 oz) of tap water in a 1000 milliliter measuring cup.
(2) Place the container on the center of tray in the oven cavity.
(3) Close the door.
(4) Touch the UPER MICROWAVE OVEN pad, pad, pad, START MINUTE PLUS pad and the
SENSOR LOAD pad on the LCD. And touch the number pad 4 once. Now, the oven is in the sensor
cooking condition, and "20BIT" and "MICRO" will appear in the display.
(5) The oven will operate for the first 16 seconds, without generating microwave energy.
NOTE: ERROR will appear if the door is opened or STOP/CLEAR pad is touched during first stage of sensor
cooking.
(6) After approximately 16 seconds, microwave energy is produced.
If ERROR is displayed or the oven does not turn off, replace the AH sensor or check the control unit, refer
to explanation below.
<
<
TESTING METHOD FOR AH SENSOR AND/OR CONTROL UNIT
To determine if the sensor is defective, the simplest method is to replace it with a new replacement
sensor.
1) Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE
DRAWER DISASSEMBLY" page 40.
2) Open the drawer and block it open.
3) Discharge high voltage capacitor.
4) Remove the AH sensor.
21
KB-3425LS/K/W
Plunger
NC
NO
COM
COM
NO
NC
R3R4
R1
R2
1
2
3
F-1
F-2
F-3
To connector (F)
on Control Unit.
CONNECTOR
KB-4425LS/K/W
PROCEDURE
LETTER
TEST PROCEDURES
COMPONENT TEST
(5) Install the new AH sensor.
(6) Reconnect all leads removed from components during testing.
(7) Re-install the outer case (cabinet).
(8) Reconnect the power supply cord after the cabinets are installed.
(9) Reconnect the oven to the power supply and check the sensor cook operation as follows:
9-1. Fill approximately 200 milliliters (7.2 oz) of tap water in a 1000 milliliter measuring cup.
9-2. Place the container on the center of tray in the oven cavity.
9-3. Close the door.
9-4. Touch the UPER MICROWAVE OVEN pad, pad, pad, START MINUTE PLUS pad and the
<
SENSOR LOAD pad on the LCD. And touch the number pad 4 once.
9-5. The control panel is in automatic Sensor operation.
9-6. The oven turns off automatically, and the time for detecting moisture will be displayed.
If new sensor dose not operate properly, the problem is with the control unit, and refer to explanation below.
CHECKING CONTROL UNIT
(1) Disconnect the power supply cord, and then disassemble as per "OVEN/MICROWAVE DRAWER
DISASSEMBLY" page 40.
(2) Open the drawer and block it open.
(3) Discharge high voltage capacitor.
(4) Disconnect the sensor connector that is mounted to control panel.
(5) Then connect the dummy resistor circuit (see fig.) to the sensor connector of control panel.
(6) Disconnect the leads to the primary of the power transformer.
(7) Ensure that these leads remain isolated from other components and oven chassis by using insulation
tape.
(8) After that procedure, re-connect the power supply cord.
(9) Check the sensor cook operation proceed as follows:
9-1. Close the door.
9-2. Touch the UPER MICROWAVE OVEN pad, pad, pad, START MINUTE PLUS pad and the
<
SENSOR LOAD pad on the LCD. And touch the number pad 4 once.
9-3. The control panel is in the sensor cooking operation.
9-4. After approximately 25 seconds, push plunger of select switch for more than 3 seconds. This condition
is same as judgement by AH sensor.
9-5. After approximately 3 seconds, the display shows “ X X . X X “ which is the time for detecting
moisture.
If the above is not the case, the control unit is probably defective.
If the above is proper, the AH sensor is probably defective.
(10) Disconnect the power supply cord, and the covers.
(11) Open the door and block it open.
(12) Discharge high voltage capacitor.
(13) Disconnect the dummy resistor circuit from the sensor connector of control panel.
(14) Carry out necessary repair.
(15) Reconnect all leads removed from components during testing and repairing.
(16) Re-install the covers.
(17) Reconnect the power supply cord after the cabinets are installed. Run the oven and check all
functions.
(18) Carry out "Water load cooking test" again and ensure that the oven works properly.
Checking the system with a Voltmeter, if the element
does not heat up.
1.Remove the back of the control panel to
expose the switch terminals.
2.With a Voltmeter set for AC on a scale higher
than 240 Volts measure the voltage drop
between terminals P2 and P1. If the meter
reads zero the wiring between the main
terminal block on the range and the switch is
open. If the meter reads line to line voltage
(around 240 VAC) go to step 3.
3.With the switch turned to the high position
measure the voltage drop between terminals
4 and 2. If the meter reads zero the switch
is defective. If the meter reads line to line
voltage the switch is good. If the range has
standard elements go to step 4. If the range
has a glass smooth go to step 5.
4.Remove the element and measure the
voltage drop between terminals of the terminal
block. If the meter reads zero the terminal
block or the wiring between the switch and the
terminal block is open. If the meter reads line
to line voltage the element is defective.
NOTE: Always inspect the terminal block for
burnt spots that can cause poor connection.
5.Raise the top and locate the two terminals on
the element that the wires from 4 and 2 are
on. Measure the voltage drop between the two
terminals. If the meter reads zero the wires
ELEMENT
CONTROL SYSTEMS
Two types of surface elements control systems are
covered in this manual.
1.Standard infinite switch.
2.Dual infinite switch.
Standard infinite switch:
The surface elements and standard infinite switches provide an infinite choice of heat settings for cooking. Controls are safety type and must be pushed in before turning. All surface controls are marked on the control panel
for their respective heating element. Power is supplied
to the surface elements through the infinite switch contacts P2-4 and P1-2. During actual surface element
operation, if the control is set to the high position contacts P1-2 are lock closed providing continuous power
to the element. In all other setting contacts L2-H2 will
cycle to maintain the correct heat setting. Contacts L1P provide power to the surface element indicator light.
Troubleshooting:
There are four ways a surface control system with a
standard infinite switch can fail.
1.The element does not heat.
2.The switch does not cycle the element off and
on when set to a position other than high.
3.The element operates correctly, but the
indicator light does not glow.
4.Indicator light glows with all infinite switches
in the off position.
NOTE: If the indicator light glows very dimly
with all the switches in the off position. This
problem is caused by a capacitive feed over in
the wiring and can be corrected by connecting
a 100,000 Ohm 1/4 watt resistor in parallel with
the light.
Continuity tests can be performed on the infinite switch
contacts. All tests should be performed with power to
the range disconnected, and wiring removed from the
switch. Set an ohmmeter on R X 1K scale and check
the contacts in the following chart and switch terminal
diagram.
Contacts
Di a l P os it ion
OFFLO-MEDHI
P2 - POXX
P2 - 4OXX
P1 - 2OX - CX
SURFACE
OX
- open- closed
P1
4
PILOT
P2
2
PROCEDURE
LETTER
G
TEST PROCEDURES
COMPONENT TEST
KB-3425LS/K/W
KB-4425LS/K/W
23
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