Sharp R-21JCA-F User Manual

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SERVICE MANUAL

S0514R21JCPAF

LIGHT DUTY

COMMERCIAL

MICROWAVE OVENS

R-21JCA-F

1000W/ R-21JCA

MODEL

TIME GUIDE F

OR ONE SERVIN

15 - 30 sec.

30 - 60 sec.

Bagel, Roll

Hot Dog

Muffin, Pastry

Pizza Slice

Pie Slice

Small Sandwic

1 - 2 min.

2 - 3 min.

Beverage, Soup

Casserole, S

tew

Large Sandwich

Chili, Chowd

Popcorn, 1.5 oz.

Popcorn, 3.5 oz.

1.5

2.5

ith the d the desired tim ope

o shut o to "0".

INSTRUCT

IONS

oor closed

,turn the

tim

er to

e. O

n w

ill b

egin

rating

ediate

ly.

ven off m

nua

lly,return tim

In the interest of user-safety the oven should be restored to its original condition and only parts identical to those specified should be used.

WARNING TO SERVICE PERSONNEL: Microwave ovens contain circuitry capable of producing very high voltage and current,

R-21JCA-F

contact with following parts may result in a severe, possibly fatal, electrical shock. (High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, 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 ................................................................................................................ 1

MICROWAVE MEASUREMENT PROCEDURE ................................................................................................... 2

FOREWORD AND WARNING ............................................................................................................................... 3

PRODUCT SPECIFICATIONS .............................................................................................................................. 4

GENERAL INFORMATION ................................................................................................................................... 4

OPERATION .......................................................................................................................................................... 6

TROUBLESHOOTING GUIDE .............................................................................................................................. 9

TEST PROCEDURE ............................................................................................................................................ 10

TOUCH CONTROL PANEL ................................................................................................................................. 16

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE ................................................................ 20

PICTORIAL DIAGRAM ........................................................................................................................................ 27

CONTROL PANEL CIRCUIT .............................................................................................................................. 28

PRINTED WIRING BOARD ................................................................................................................................. 29

PARTS LIST ........................................................................................................................................................ 30

PACKING AND ACCESSORIES ......................................................................................................................... 34

SHARP CORPORATION

This document has been published to be used for after sales service only. The contents are subject to change without notice.

R-21JCA-F

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.

compartments, 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 oven 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 the 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.

WARNING TO SERVICE PERSONNEL

Don't Touch ! Danger High Voltage

Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts fatal, electrical shock.

(Example) High Voltage Capacitor, High Voltage Power Trans-

former, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..

Read the Service Manual carefully and follow all instructions.

may result in a severe, possibly

R-21JCA-F

Before Servicing

1. Disconnect the power supply cord , and then remove outer case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

WARNING:RISK OF ELECTRIC SHOCK.

DISCHARGE THE HIGH-VOLTAGE CAPACITOR BEFORE SERVICING.

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 highvoltage capacitor (that is the connecting lead of the highvoltage 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 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. 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.

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. Reconnect the leads to the primary of the power transformer.

5. Reinstall the outer case (cabinet).

6. Reconnect the power supply cord after the outer case is installed.

7. Run the oven and check all functions.

After repairing

1. Reconnect all leads removed from components during testing.

2. Reinstall the outer case (cabinet).

3. Reconnect the power supply cord after the outer case is installed.

4. Run the oven and check all functions.

Microwave ovens should not be run empty. To test for the presence of microwave energy within a cavity, place a cup of cold water on the oven turntable, close the door 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 microwave leakage test should be carried out.

When the testing is completed,

R-21JCA-F

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 and door sensing switch shall prevent microwave radiation emission in excess of the requirement as above mentioned, secondary interlock 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 oven tray in the oven cavity.

3) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5˚C (68˚F) in the center of 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 Cooking Mode

5) Close the door 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.

C. Leakage test:

Closed-door leakage test (microwave measurement)

1) Grasp the probe of the survey instrument and hold it perpendicular to the gap between the door 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 door 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 door pull the door 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/cm

, and that

the secondary interlock switch does turn the oven OFF before any door movement.

NOTE: After servicing, record data on service invoice and microwave leakage report.

SERVICE MANUAL

R-21JCA-F

LIGHT DUTY

COMMERCIAL

MICROWAVE OVEN

R-21JCA-F

FOREWORD

This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVENS, R-21JCA-F.

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 no other visible damage with the oven.

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.

PRODUCT DESCRIPTION

GENERAL INFORMATION

OPERATION

TROUBLESHOOTING GUIDE AND TEST PROCEDURE

TOUCH CONTROL PANEL

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE

WIRING DIAGRAM

PARTS LIST

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

SHARP PLAZA, MAHWAH,

NEW JERSEY 07430-2135

R-21JCA-F

3-Pronged Plug

Grounded Receptacle Box

Grounding Pin

3-Pronged Receptacle

SPECIFICATION

ITEM DESCRIPTION

Power Requirements 120 Volts

14 Amperes 60 Hertz / Single phase, 3 wire grounded

Power Output 1000 watts (IEC 705 Test Procedure)

Operating frequency of 2450MHz

Case Dimensions Width 20-1/2" (520mm)

Height 12-1/8" (309mm) Depth 16" (406mm)

Cooking Cavity Dimensions Width 13-7/8" (353mm) (1.0 Cubic Feet ) Height 8-1/8" (207mm)

Depth 14-5/8"(370mm)

Control Complement Light Up Dial (6 minutes)

No cooking control

Oven Cavity Light Yes

Safety Standard UL Listed FCC Authorized

DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J, NSF Certified

NOTE: Internal capacity is calculated by measuring

maximum width, depth and height. Actual capacity for holding food is less.

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 and ordinances. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

WARNING: Improper use of the grounding plug can result in a risk of electric shock.

Electrical Requirements The electrical requirements are a 120 volt 60 Hz, AC only, 15 amp. or more protected electrical supply. It is recommended that a separate circuit serving only this appliance be provided. When installing this appliance, observe all applicable codes and ordinances. A short power-supply cord is provided to reduce risks of becoming entangled in or tripping over a longer cord. Where a two-pronged wall-receptacle is encountered, it is the personal responsibility and obligation of the customer to contact a qualified electrician and have it replaced with a properly grounded three-pronged wall receptacle or have a grounding adapter properly grounded and polarized. If the extension cord must be used, it should be a 3-wire, 15 amp. or higher rated cord. Do not drape over a countertop or table where it can be pulled on by children or tripped over accidentally.

CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE ROUND GROUNDING PRONG FROM THIS

PLUG.

1. Back splash cover

2. Side splash cover

3. Oven light

4. Ceramic shelf

5. Control panel

6. Cavity face plate

7. Door latch openings

8. Door latches

9. Door hinges

10.Door seals and sealing surfaces

11.Door handle

12.Oven door with see-through window

13.Air ventilation cover and openings

14.Power supply cord

15.Air intake openings

16.Outer case cabinet

OVEN DIAGRAM

912

CONTROL PANEL

3 2

R-21JCA-F

TIME GUIDE FOR ONE SERVING

15 - 30 sec. Bagel, Roll Muffin, Pastry Pie Slice

1 - 2 min. Beverage, Soup Large Sandwich Popcorn, 1.5 oz.

INSTRUCTIONS

With the door closed,turn the timer to the desired time. Oven will begin operating immediately.

To shut oven off manually,return timer to "0".

30 - 60 sec. Hot Dog Pizza Slice Small Sandwich

2 - 3 min. Casserole, Stew Chili, Chowder Popcorn, 3.5 oz.

1.5

2.5

Light Up Dial for setting cooking time.

R-21JCA-F

OPERATION

DESCRIPTION OF OPERATING SEQUENCE

The following is a description of component functions during oven operation.

OFF CONDITION

Closing the door activates door sensing switch and secondary interlock switch. (In this condition, the monitor switch contacts are opened.) When oven is plugged in, 120 volts A.C. is supplied to the noise filter and the control unit (Figure O-1).

COOKING CONDITION

When the Light Up Dial is turned, the following operations occur:

1. The contacts of relays are closed and components connected to the relays are turned on as follows. (For details, refer to Figure O-2)

RELAY CONNECTED COMPONENTS RY-1 Oven lamp/ Antenna motor/ Fan motor RY-2 Power transformer

2. 120 volts A.C. is supplied to the primary winding of the power transformer and is converted to about 3.2 volts A.C. output on the filament winding, and approximately 2150 volts A.C. on the high voltage winding.

3. The filament winding voltage heats the magnetron filament and the H.V. winding voltage is sent to a voltage doubler circuit.

4. The microwave energy produced by the magnetron is channelled through the waveguide into the cavity feed-box, and then into the cavity where the food is placed to be cooked.

5. Upon completion of the cooking time, the power transformer, oven lamp, etc. are turned off, and the generation of microwave energy is stopped. The oven will revert to the OFF condition.

6. When the door is opened during a cook cycle, monitor switch, door sensing switch, secondary interlock switch, relay (RY2) and primary interlock relay(RY1) are activated with the following results. The circuits to the antenna motor, the cooling fan motor, the oven lamp and the high voltage components are de-energized, and the cooking program will be canceled when the door was opened.

7. The monitor switch electrically monitors the operation of the secondary interlock switch and primary interlock relay(RY1) and is mechanically associated with the door so that it will function in the following sequence. When the door opens from the closed position, the primary

(1)

interlock relay(RY1) and secondary interlock switch open their contacts. Then the monitor switch contacts close.

(2) When the door is closed from the open position, the monitor

switch contacts open first. Then the contacts of the secondary interlock switch and door sensing switch close.

If the secondary interlock switch and primary interlock relay (RY1) fail with the contacts closed when the door is opened, the closing of the monitor switch contacts will form a short circuit through the monitor fuse, secondary interlock switch, and primary interlock relay(RY1), causing the monitor fuse to blow.

R-21JCA-F

SCHEMATIC

NOTE: CONDITION OF OVEN

1. LIGHT UP DIAL OFF.

2. DOOR CLOSED.

FUSE

AC120V 60 Hz

NOISE FILTER

20A

NOISE SUPPRESSION COIL

LINE CROSS CAPACITOR 0.22 F AC250V

CAPACITOR

LINE BYPASS

0.003300 F / AC 125V

CAPACITOR

LINE BYPASS

0.003300 F / AC 125V

NOTE: Indicates components with potential above 250 V.

THERMAL CUT-OUT 125˚C (OVEN)

THERMAL CUT-OUT 145˚C (MAG.)

A3 A1

DOOR SENSING SWITCH

SECONDARY INTERLOCK SWITCH

RY1

CONTROL UNIT

OVEN LAMP

RY2

PRIMARY

INTERLOCK

RELAY

COOK

RELAY

OL FM AM

FAN MOTOR

ANTENNA MOTOR

Figure O-1 Oven Schematic-OFF Condition

POWER TRANSFORMER

MONITOR SWITCH

CAPACITOR

0.94 µF 2400V

MAGNETRON

RECTIFIER

SCHEMATIC

NOTE: CONDITION OF OVEN

1. DOOR CLOSED.

2. LIGHT UP DIAL ON.

FUSE

AC120V 60 Hz

NOISE FILTER

20A

NOISE SUPPRESSION COIL

LINE CROSS CAPACITOR 0.22 F AC250V

CAPACITOR

LINE BYPASS

0.003300 F / AC 125V

THERMAL CUT-OUT 125˚C (OVEN)

THERMAL CUT-OUT 145˚C (MAG.)

RY1

PRIMARY

INTERLOCK

RELAY

RY2

COOK

RELAY

CONTROL UNIT

MONITOR SWITCH

CAPACITOR

LINE BYPASS

0.003300 F / AC 125V

A3 A1

DOOR SENSING SWITCH

SECONDARY INTERLOCK SWITCH

OL FM AM

OVEN LAMP

FAN MOTOR

ANTENNA MOTOR

Figure O-2 Oven Schematic-Microwave cooking Condition

POWER TRANSFORMER

CAPACITOR

0.94 µF 2400V

MAGNETRON

RECTIFIER

R-21JCA-F

DESCRIPTION AND FUNCTION OF COMPONENTS

DOOR OPEN MECHANISM

The door is opened by grasping the door handle, refer to Figure D-1. When the door handle is grasped, the handle lever is pulled. And then the upper and lower latch heads are moved upward by the handle lever, and they are released from the latch hook. Now the door will open.

Handle Lever

Door Handle

Latch Lever

Latch Head

Latch Switch Lever C

Latch Head

Latch Hook

Latch Switch Lever A

Secondary Interlock Switch

Latch Switch Lever B

Monitor Switch

Door Sensing Switch

Figure D-1. Door Open Mechanism

DOOR SENSING AND SECONDARY INTERLOCK SWITCHES

The secondary interlock switch is mounted in the upper position of the latch hook and the door sensing switch in the primary interlock system is mounted in the lower position of the latch hook. The secondary interlock switch is activated by the latch switch lever A. The latch switch lever A is activated by the upper latch head. The door sensing switch is activated by the latch switch lever C. The latch switch lever C is activated by the lower latch head. When the door is opened, the switches interrupt the power to all high voltage components. A cook cycle cannot take place until the door is firmly closed thereby activating both interlock switches. The primary interlock system consists of the door sensing switch and primary interlock relay located on the control circuit board.

MONITOR SWITCH

The monitor switch is activated (the contacts opened) by the latch switch lever B on the latch hook while the door is closed. The latch switch lever B is activated by the lower latch head. The switch is intended to render the oven inoperative, by means of blowing the monitor fuse, when the contacts of the primary interlock relay (RY1) and secondary interlock switch fail to open when the door is opened.

Functions:

1. When the door is opened, the monitor switch contacts close (to the ON condition) due to their being normally closed. At this time the primary interlock relay (RY1) and secondary interlock switch are in the OFF condition (contacts open) due to their being normally open contact switches.

2. As the door goes to a closed position, the monitor switch contacts are first opened and then the door sensing switch and the secondary interlock switch contacts close. (On opening the door, each of these switches operate inversely.)

3. If the door is opened, and the primary interlock relay (RY1)

and secondary interlock switch contacts fail to open, the monitor fuse blows simultaneously with closing of the monitor switch contacts.

CAUTION: BEFORE REPLACING A BLOWN MONITOR

FUSE TEST THE DOOR SENSING SWITCH, PRIMARY INTERLOCK RELAY (RY1), SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERATION. (REFER TO CHAPTER “TEST PROCEDURE”).

NOTE: MONITOR FUSE AND MONITOR SWITCH ARE

REPLACED AS AN ASSEMBLY.

ANTENNA MOTOR

The antenna motor rotates the stirrer antenna located on the bottom of the oven cavity, so that the food on the ceramic shelf is cooked evenly during cooking. The antenna motor may turn in either direction.

COOLING FAN MOTOR

The cooling fan motor drives a blade which draws external cool air. This cool air is directed through the air vanes surrounding the magnetron and cools the magnetron. This air is channelled through the oven cavity to remove steam and vapors given off from the heating food. It is then exhausted through the exhausting air vents at the oven cavity.

MONITOR FUSE

1. The monitor fuse blows when the contacts (COM-NO) of the primary interlock relay (RY2) and secondary interlock switch remain closed with the oven door open and when the monitor switch closes.

2. If the wire harness or electrical components are shortcircuited, this monitor fuse blows to prevent an electric shock or fire hazard.

THERMAL CUT-OUT 145˚C (MAGNETRON)

This thermal cut-out protects the magnetron against overheating. If the temperature goes up higher than 293˚F (145˚C) because the fan motor is interrupted or the ventilation openings are blocked, the thermal cut-out will open and line voltages to the high voltage transformer will be cut off and the operation of the magnetron will be stopped. The thermal cutout will not resume.

THERMAL CUT-OUT 125˚C (OVEN)

The thermal cut-out located on the top of the oven cavity is designed to prevent damage to the oven if the food in the oven catches fire due to over heating produced by improper setting of the cooking time or failure of control unit. Under normal operation, the oven thermal cut-out remains closed. However, when abnormally high temperatures are reached within the oven cavity, the oven thermal cut-out will open at 257˚F(125˚C) causing the oven to shut down. The thermal cut-out will not resume.

NOISE FILTER

The noise filter prevents the radio frequency interference that might flow back in the power circuit.

R-21JCA-F

TROUBLESHOOTING GUIDE

Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected.

When troubleshooting the microwave oven, it is helpful to follow the Sequence of Operation in performing the checks. Many of the possible causes of trouble will require that a specific test be performed. These tests are given a procedure letter which will be found in the "Test Procedure "section.

IMPORTANT: If the oven becomes inoperative because of a blown monitor fuse, check the monitor switch, primary interlock relay

(RY1), door sensing switch and secondary interlock switch before replacing the monitor fuse. If monitor fuse is replaced, the monitor switch must also be replaced. Use part FFS-BA015WRK0 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 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. Reconnect the leads to the primary of the power transformer.

5. Reinstall the outer case (cabinet).

6. Reconnect the power supply cord after the outer case is installed.

7. Run the oven and check all functions.

CONDITION

OFF CONDITION

COOKING CONDITION

TEST PROCEDURE

POSSIBLE CASE

AND

DEFECTIVE PARTS

PROBLEM

Home fuse or circuit breaker blows when power cord is plugged into wall outlet.

Monitor fuse blows when power cord is

plugged into wall outlet.

Oven lamp does not light, and fan motor

and antenna motor do not operate.

Oven does not go into cook cycle when

Light Up Dial turned.

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 but extremely uneven heating is produced in oven load (food).

ABCDEFFGHI JKL

MAGNETRON

POWER TRANSFORMER

H.V. RECTIFIER ASSEMBLY

HIGH VOLTAGE CAPACITOR

THERMAL CUT-OUT

SECONDARY INTERLOCK SWITCH

PRIMARY INTERLOCK SYSTEM

MONITOR SWITCH

MONITOR FUSE

NOISE FILTER

CONTROL PANEL

RELAY (RY2)

FOIL PATTURN ON P.W.B.

RE RE RE RE RE

OVEN LAMP OR SOCKET

COOLING FAN MOTOR

ANTENNA MOTOR

CK CK CK

WRONG OPERATION

SHORTED IN POWER CORD

SHORT OR OPENED WIRING

LOW VOLTAGE

DIRTY OVEN CAVITY

R-21JCA-F

PROCEDURE

LETTER

TEST PROCEDURES

COMPONENT TEST

A MAGNETRON ASSEMBLY TEST

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. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across the magnetron filament leads should indicate less than 1 ohm.

5. To test for a shorted magnetron, connect the ohmmeter leads between the magnetron filament leads and chassis ground. This test should indicate an infinite resistance. If there is little or no resistance the magnetron is grounded and must be replaced.

6. Reconnect all leads removed from components during testing.

7. Reinstall the outer case (cabinet).

8. Reconnect the power supply cord after the outer case is installed.

9. Run the oven and check all functions.

MICROWAVE OUTPUT POWER

The following test procedure should be carried out with the microwave oven in a fully assembled condition (outer case fitted).

HIGH VOLTAGES ARE PRESENT DURING THE COOK CYCLE, SO EXTREME CAUTION SHOULD BE OBSERVED.

Power output of the magnetron can be measured by performing a water temperature rise test. This test should only be used if above tests do not indicate a faulty magnetron and there is no defect in the following components or wiring: silicon rectifier, high voltage capacitor and power transformer. This test will require a 16 ounce (453cc) measuring cup and an accurate mercury thermometer or thermocouple type temperature tester. For accurate results, the following procedure must be followed carefully:

1. Fill the measuring cup with 16 oz. (453cc) of tap water and measure the temperature of the water with a thermometer or thermocouple temperature tester. Stir the thermometer or thermocouple through the water until the temperature stabilizes. Record the temperature of the water.

2. Place the cup of water in the oven. Operate oven at POWER 10(HIGH) selecting more than 60 seconds cook time. Allow the water to heat for 60 seconds, measuring with a stop watch, second hand of a watch or the digital read-out countdown.

3. Remove the cup from the oven and again measure the temperature, making sure to stir the thermometer or thermocouple through the water until the maximum temperature is recorded.

4. Subtract the cold water temperature from the hot water temperature. The normal result should be 34.7 to

64.6˚F(19.3 to 35.9˚C) rise in temperature. If the water temperatures are accurately measured and tested for the required time period the test results will indicate if the magnetron tube has low power output (low rise in water temperature) which would extend cooking time or high power output (high rise in water temperature) which would reduce cooking time. Because cooking time can be adjusted to compensate for power output, the magnetron tube assembly should be replaced only if the water temperature rise test indicates a power output well beyond the normal limits. The test is only accurate if the power supply line voltage is 120 volts and the oven cavity is clean.

B POWER TRANSFORMER TEST

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 primary input terminals and measure the resistance of the transformer with an ohmmeter. Check for continuity of the coils with an ohmmeter. On the R x 1 scale, the resistance of the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be approximately 85 ohms; the resistance of the filament coil should be less than 1 ohm.

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.

(HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH VOLTAGE.)

PROCEDURE

LETTER

C HIGH VOLTAGE RECTIFIER TEST

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. Isolate the rectifier from the circuit. Using the highest ohm scale of the meter, read the resistance across the terminals and observe, reverse the leads to the rectifier terminals and observe meter reading. If a short is indicated in both directions, or if an infinite resistance is read in both directions, the rectifier is probably defective and should be replaced.

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.

NOTE: Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6.3 volts.

D HIGH VOLTAGE CAPACITOR TEST

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. If the capacitor is open, no high voltage will be available to the magnetron. Disconnect input leads and check for a short or open between the terminals using an ohmmeter. Checking with a high ohm scale, if the high voltage capacitor is normal, the meter will indicate continuity for a short time and should indicate an open circuit once the capacitor is charged. If the above is not the case, check the capacitor with an ohmmeter to see if it is shorted between either of the terminals and case. If it is shorted, replace the capacitor.

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.

R-21JCA-F

TEST PROCEDURES

COMPONENT TEST

E THERMAL CUT-OUT TEST 125˚C (OVEN)

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. A continuity check across the thermal cut-out terminals should indicate a closed circuit unless the temperature of the thermal cut-out reaches approximately 257˚F(125˚C). An open thermal cut-out indicates overheating of the oven, exchange the thermal cut-out and check inside of oven cavity and for improper setting of cooking time or operation of control unit. Check for restricted air flow through the vent holes of the 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.

THERMAL CUT-OUT TEST 145˚C (MAGNETRON)

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. A continuity check across the thermal cut-out terminals should indicate a closed circuit. If the temperature of the magnetron reaches approximately 293˚F(145˚C), the thermal cut-out opens. An open thermal cutout indicates overheating of the magnetron. Check for restricted air flow to the magnetron, especially the cooling fan 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.

CAUTION: IF THE THERMAL CUT-OUT INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE,

REPLACE THERMAL CUT-OUT.

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SCREW DRIVER

MONITOR SWITCH

OHMMETER

WHT/ WHT

PROCEDURE

LETTER

TEST PROCEDURES

COMPONENT TEST

F SECONDARY INTERLOCK SWITCH TEST

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. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal of the switch. The meter should indicate an open circuit with the door open and a closed circuit with the door closed. If improper operation is indicated, replace the secondary 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

DOOR SENSING SWITCH

1. Disconnect the power supply cord, and then remove outer case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

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.

NOTE: If the door sensing switch contacts fail in the open position and the door is closed, the cooling

fan, antenna and oven light will be activated by RY1.

PRIMARY INTERLOCK RELAY (RY1)

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 two (2) wire leads from the male tab terminals of the Primary Interlock Relay. Check the state of the relay contacts using a ohmmeter. The relay contacts should be open. If the relay contacts are closed, replace the circuit board entirely or the relay itself.

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.

G MONITOR SWITCH TEST

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. Before performing this test, make sure that the secondary interlock switch and the primary interlock relay are operating properly, according to the above Switch Test Procedure. Disconnect the wire lead from the monitor switch (COM) terminal. Check the monitor switch operation by using the ohmmeter as follows. When the door is open, the meter should indicate a closed circuit. When the monitor switch actuator is pushed by a screw driver through the lower latch hole on the front plate of the oven cavity with the door opened (in this condition the plunger of the monitor switch is pushed in), the meter should indicate an open circuit. If improper operation is indicated, the switch may be defective. After testing the monitor switch, reconnect the wire lead to the monitor switch (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.

PROCEDURE

LETTER

H BLOWN MONITOR 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 capacitor.

4. If the monitor fuse is blown when the door is opened, check the primary interlock relay, secondary interlock switch and monitor switch according to the "TEST PROCEDURE" for those switches before replacing the blown monitor fuse.

CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE, TEST THE PRIMARY INTERLOCK

RELAY, SECONDARY INTERLOCK SWITCH, DOOR SENSING SWITCH AND MONITOR

SWITCH FOR PROPER OPERATION. If the monitor fuse is blown by improper switch operation, the monitor fuse and monitor switch must be replaced with "monitor fuse and monitor switch assembly" part number FFS-BA015WRK0, even if the monitor switch operates normally. The monitor fuse and monitor switch assembly is comprised of a 20 ampere fuse and 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.

R-21JCA-F

TEST PROCEDURES

COMPONENT TEST

I NOISE FILTER TEST

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 lead wires from the terminal the noise filter. Using an ohmmeter, check between the terminals as described in the following table. If incorrect reading are obtained, replace the noise filter.

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.

MEASURING POINT INDICATION OF OHMMETER

Between N and L Open circuit

Between terminal N and WHITE Short circuit

Between terminal L and RED Short circuit

J CONTROL PANEL ASSEMBLY TEST

WARNING : To prevent an electric shock do not touch the electrical parts and the printed wiring

board. Because the control unit is "TRANSLESS CIRCUIT" and many electrical parts are used at A.C. line voltage.

LINE CROSS CAPACITOR 0.22 F AC250V

NOISE SUPPRESSION COIL

LINE BYPASS

CAPACITOR

0.003300 F / AC 125V

WHITE RED

LINE BYPASS

CAPACITOR

0.003300 F / AC 125V

FUSE 20A

NOISE FILTER

The control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore, unlike conventional microwave ovens, proper maintenance cannot be performed with only a voltmeter and ohmmeter. In this service manual troubleshooting by unit replacement is described according to the symptoms indicated.

Before testing,

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) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.

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PROCEDURE

LETTER

TEST PROCEDURES

COMPONENT TEST

6) After that procedure, re-connect the power supply cord.

1. Control Panel The following symptoms indicate a defective control unit.

1-1 In connection with LEDs

a) At a certain LED, all or some LEDs do not light up. b) At a certain LED, brightness is low.

c) Only one LED does not light up. d) All or some LEDs continue to light up. e) A certain group of LEDs do not light up.

f) The LEDs flicker.

1-2 Other possible troubles caused by defective control unit.

a) Buzzer does not sound or continues to sound. b) Clock is not possible.

c) Cooking time can not be set.

When 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) 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.

K RELAY TEST

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. 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 outer case and check voltage between Pin No. 5 of the 3 pin connector (A) and the common terminal of the relay RY1 on the control 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

RELAY SYMBOL OPERATIONAL VOLTAGE CONNECTED COMPONENTS

8. Disconnect the power supply cord and then remove outer case.

9. Open the door and block it open.

10.Discharge high voltage capacitor.

11.Reconnect all leads removed from components during testing.

12.Re-install the outer case (cabinet).

13.Reconnect the power supply cord after the outer case is installed.

14.Run the oven and check all functions.

good, control unit is defective.

RY1 Approx. 19.2V D.C. Oven lamp / Antenna motor / Cooling fan motor

RY2 Approx. 19.9V D.C. Power transformer

The voltage under the condition when all LEDs light up.

TEST PROCEDURES

PROCEDURE

LETTER

COMPONENT TEST

L FOIL PATTERN ON THE PRINTED WIRING BOARD TEST

To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse.

1. Foil pattern check and repairs.

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) Follow the troubleshooting guide given below for repair.

STEPS OCCURRENCE CAUSE OR CORRECTION

1 Only pattern at "a" is broken. *Insert jumper wire J1 and solder. 2 Pattern at "a" and "b" are broken. *Insert the coil RCILF2003YAZZ between "c" and "d".

5) Make a visual inspection of the varistor. Check for burned damage.

R-21JCA-F

VRS1

CNA

RY1

RY2

6) Reconnect all leads removed from components during testing.

7) Re-install the outer case (cabinet).

8) Reconnect the power supply cord after the outer case is installed.

9) Run the oven and check all function.

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 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) 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.

STEPS OCCURRENCE CAUSE OR CORRECTION

The rated AC voltage is not present between

1 Pin No. 5 of the 3-pin connector (A) and the Check supply voltage and oven power cord.

common terminal of the relay RY1.

8) Disconnect the power supply cord and then remove outer case.

9) Open the door and block it open.

10) Discharge high voltage capacitor.

11) Reconnect all leads removed from components during testing.

12) Re-install the outer case (cabinet).

13) Reconnect the power supply cord after the outer case is installed.

14) Run the oven and check all functions.

R-21JCA-F

TOUCH CONTROL PANEL ASSEMBLY

OUTLINE OF TOUCH CONTROL PANEL

Control Unit

Control unit consists of LSI, power source circuit, synchronizing signal circuit, reset circuit, buzzer circuit, encoder circuit and indicator circuit.

1) LSI

This LSI controls the encoder signal, relay driving signal for oven function, buzzer signal and LED signal.

2) Power Source Circuit

This circuit generates voltage necessary in the control unit.

Symbol Voltage Application

VC +5V (*) LSI(I-1)

VR +20V (*) RELAY(RY1, RY2)

(*) The voltage under the condition when all LEDs light up.

The voltage VR will vary according to the quantity of the LEDs which light up.

3) Synchronizing Signal Circuit

The power source synchronizing signal is available in order to compose a basic standard time in the clock circuit. It accompanies a very small error because it works on commercial frequency.

4) Reset Circuit

A circuit to generate a signals which resets the LSI to the initial state when power is supplied.

5) Buzzer Circuit

The buzzer is responsive to signals from the LSI to emit audible sounds (completion sound).

6) Door Sensing Switch

A switch to “tell” the LSI if the door is open or closed.

7) Relay Circuit

To drive the magnetron, fan motor, antenna motor and light the oven lamp.

8) Encoder

The encoder generates the pulse signal, and the pulse signal is sent to the LSI.

9) Indicator Circuit

Indicator elements are the Light-emitting diodes (LD1LD20). This circuit consists of 4-digits and 5 segments.

DESCRIPTION OF LSI

LSI

The I/O signal of the LSI is detailed in the following table.

Pin No. Signal I/O Description

1D3OUT Segment data signal.

Signal is input to the cathodes of the light-emitting diodes (LD1, LD6, LD11 and LD16).

2D4OUT Digit selection signal.

Signal is input to the anodes of the light-emitting diodes (LD16 - LD20).

3D5OUT Digit selection signal.

Signal is input to the anodes of the light-emitting diodes (LD11 - LD15).

4D6OUT Digit selection signal.

Signal is input to the anodes of the light-emitting diodes (LD6 - LD10).

5D7OUT Digit selection signal.

Signal is input to the anodes of the light-emitting diodes (LD1 - LD5). 6 P20 IN Connected to VDD terminal.

7 P21 IN Connected to VSS terminal. 8 P22 IN Signal coming from encoder.

When the encoder is turned, the contacts of encoder make pulse signals. And pulse

signals are input into P22.

Pin No. Signal I/O Description

R-21JCA-F

RESET

IN Auto clear terminal.

Signal is input to reset the LSI to the initial state when power is applied. Temporarily set to "L" level the moment power is applied, at this time the LSI is reset. Thereafter set at "H" level.

10 CNVSS IN Power source voltage.

The power source voltage to drive the LSI is input to CNVSS terminal.

11 XOUT OUT Internal clock oscillation frequency control output.

Output to control oscillation input of XIN.

12 XIN IN Internal clock oscillation frequency input setting.

The internal clock frequency is set by inserting the ceramic filter oscillation circuit with respect to XOUT terminal.

13 VSS IN Power source voltage: 0V.

The power source voltage to drive the LSI is input to VSS terminal. Connected to VC.

14 VDD IN Power source voltage: +5V.

The power source voltage to drive the LSI is input to VDD terminal.

15 N.F IN Connected to VSS terminal. 16 INT0 IN Signal coming from encoder.

Signal similar to P22. Pulse signals are input into INT0.

17 INT1 IN Signal to synchronize LSI with commercial power source frequency.

This is basic timing for all real time processing of LSI.

16.7 msec

H : +5V

L: 0V

18 AIN0 IN Input signal which communicates the door open/close information to LSI.

Door closed; "L" level signal. Door opened; "H" level signal.

19-21

AIN1-AIN3

IN Terminal to change functions according to the model.

Signal in accordance with the model in operation is applied to set up its function.

22 P00 OUT Terminal not used. 23 P01 OUT Magnetron high-voltage circuit driving signal.

To turn on and off the cook relay (RY2). In 100% power operation, the signals hold "H" level during microwave cooking and "L" level while not cooking.

24 P02 OUT Oven lamp, turntable motor and fan motor driving signal(Square Waveform :

60Hz).

16.7 msec

To turn on and off shut-off relay (RY1). The square waveform voltage is delivered to the relay (RY1) driving circuit and relay(RY2) control circuit.

25 P03 OUT Signal to sound buzzer.

Completion sound.

During cooking

2.0 sec H: +5V

L: 0V

26 P10 OUT Terminal not used.

27-29 P11-P13 OUT Segment data signal.

Signal is input to the cathodes of the light-emitting diodes (LD5, LD10, LD15 and LD20).

30 D0 OUT Segment data signal.

Signal is input to the cathodes of the light-emitting diodes (LD4, LD9, LD14 and LD19).

31 D1 OUT Segment data signal.

Signal is input to the cathodes of the light-emitting diodes (LD3, LD8, LD13 and LD18).

32 D2 OUT Segment data signal.

Signal is input to the cathodes of the light-emitting diodes (LD2, LD7, LD12 and LD17).

R-21JCA-F

TOUCH CONTROL PANEL SERVICING

1. Precautions for Handling Electronic Components

This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following precautions should be strictly followed. CMOS LSI have extremely high impedance at its input and output terminals. For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc., and sometimes it is not fully protected by the built-in protection circuit. In order to protect CMOS LSI.

1) When storing and transporting, thoroughly wrap them in aluminium foil. Also wrap PW boards containing them in aluminium foil.

2) When soldering, ground the technician as shown in the figure and use grounded soldering iron and work table.

approx. 1M ohm

2. Servicing of Touch Control Panel

We describe the procedures to permit servicing of the touch control panel of the microwave oven and the precautions you must take when doing so. To perform the servicing, power to the touch control panel is available either from the power line of the oven itself or from an external power source.

(1) Servicing the touch control panel with power supply of

the oven : CAUTION:

THE HIGH VOLTAGE TRANSFORMER OF THE MICROWAVE OVEN IS STILL LIVE DURING SERVICING AND PRESENTS A HAZARD .

Therefore, before checking the performance of the touch control panel,

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) 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. After checking the performance of the touch control panel,

1) Disconnect the power supply cord.

2) Open the door and block it open.

3) Re-connect the leads to the primary of the power

transformer.

4) Re-install the outer case (cabinet).

5) Re-connect the power supply cord after the outer

case is installed.

6) Run the oven and check all functions.

A. On some models, the power supply cord between the touch

control panel and the oven itself is so short that the two can't be separated. For those models, check and repair all the controls (sensor-related ones included) of the 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 so long enough that they may be separated from each other. For those models, therefore, it is possible to check and repair the controls of the touch control panel while keeping it apart from the oven proper; in this case you must short both ends of the door sensing switch (on PWB) of the touch control panel with a jumper, which brings about an operational state that is equivalent to the oven door being closed. As for the sensorrelated controls of the touch control panel, checking them is possible if the dummy resistor(s) with resistance equal to that of the controls are used.

(2) Servicing the touch control panel with power supply

from an external power source:

Disconnect the touch control panel completely from the oven proper, and short both ends of the door sensing switch (on PWB) of the touch control panel, which brings about an operational state that is equivalent to the oven door being closed. Connect an external power source to the power input terminal of the touch control panel, then it is possible to check and repair the controls of the touch control panel; it is also possible to check the sensor-related 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: 60W (It is recommended to use a soldering iron with a grounding terminal.)

2) Oscilloscope: Single beam, frequency range: 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, remove the aluminium foil applied for preventing static electricity.

2) Connect the connector of the key unit to the control unit being sure that the lead wires are not twisted.

3) After aluminium foil is removed, be careful that abnormal voltage due to static electricity etc. is not applied to the input or output terminals.

4) Attach connectors, electrolytic capacitors, etc. to PWB, making sure that all connections are tight.

5) Be sure to use specified components where high precision is required.

PRECAUTIONS FOR USING LEAD-FREE SOLDER

1. Employing lead-free solder

The "Main PWB" of this model employs lead-free solder. This is indicated by the "LF" symbol printed on the PWB and in the service manual. The suffix letter indicates the alloy type of the solder. Example:

Sn-Ag-Cu

Indicates lead-free solder of tin, silver and copper.

2. Using lead-free wire solder

When repairing a PWB with the "LF" symbol, only lead-free solder should be used. (Using normal tin/lead alloy solder may result in cold soldered joints and damage to printed patterns.) As the melting point of lead-free solder is approximately 40˚C higher than tin/lead alloy solder, it is recommend that a dedicated bit is used, and that the iron temperature is adjusted accordingly.

3. Soldering

As the melting point of lead-free solder (Sn-Ag-Cu) is higher and has poorer wettability, (flow), to prevent damage to the land of the PWB, extreme care should be taken not to leave the bit in contact with the PWB for an extended period of time. Remove the bit as soon as a good flow is achieved. The high content of tin in lead free solder will cause premature corrosion of the bit. To reduce wear on the bit, reduce the temperature or turn off the iron when it is not required. Leaving different types of solder on the bit will cause contamination of the different alloys, which will alter their characteristics, making good soldering more difficult. It will be necessary to clean and replace bits more often when using lead-free solder. To reduce bit wear, care should be taken to clean the bit thoroughly after each use.

R-21JCA-F

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE

WARNING AGAINST HIGH VOLTAGE:

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, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..

WARNING:

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.

Avoid possible exposure to microwave energy. Please follow the instructions below before operating the oven.

WARNING FOR WIRING

To prevent an electric shock, take the following precautions.

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 followiong parts;

1) High voltage parts: Magnetron, High voltage transformer, High voltage capacitor and High voltage rectifier assembly.

2) Hot parts: Oven lamp, Magnetron, High voltage transformer, and Oven cavity.

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 (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.

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, Switch lever and antenna motor.

3. Do not catch the wire leads in the outer case cabinet.

4. Insert the positive lock connector until its pin is locked and make sure that the wire leads do not come off even if the wire leads are pulled.

5. To prevent an error function, connect the wire leads correctly, referring to the Pictorial Diagram.

Please refer to ‘OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS’, when carrying out any of the following removal procedures:

OUTER CASE REMOVAL

To remove the outer case, proceed as follows.

1. Disconnect the power supply cord.

2. Open the oven door and block it open.

3. Remove the five (5) screws from rear and along the side edge of case.

4. Slide the entire case back about 3cm to free it from retaining clips on the cavity face plate.

5. Lift the entire case from the oven.

6. Discharge the H.V. capacitor before carrying out any further work.

7. Do not operate the oven with the outer case removed.

CAUTION: 1. DISCONNECT OVEN FROM POWER SUP

PLY 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 and then remove outer case.

2. Open the oven door and block it open.

3. Discharge high voltage capacitor.

4. Disconnect the filament leads of power transformer from high voltage capacitor and the magnetron.

5. Disconnect the H.V. wire from the power transformer.

6. Disconnect the main wire harness from the power transformer.

7. Remove the two (2) screws and two (2) VCP caps holding the transformer to base plate.

8. Remove the transformer.

9. Now the power transformer is free.

HIGH VOLTAGE RECTIFIER ASSEMBLY AND HIGH VOLTAGE CAPACITOR REMOVAL

Oven lamp socket

Terminal

Wire lead

Terminal hole

Flate type small screw driver

R-21JCA-F

To remove the components, proceed as follows.

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 H.V. wire of the high voltage rectifier assembly from the magnetron and the power transformer.

5. Disconnect the filament lead of the power transformer from the high voltage capacitor.

6. Remove one (1) screw holding earth side terminal of the high voltage rectifier assembly.

7. Disconnect all the leads and terminals of high voltage rectifier assembly from the high voltage capacitor.

Now, the high voltage rectifier assembly should be free.

MAGNETRON REMOVAL

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 high voltage wire of the high voltage rectifier assembly and filament lead of the transformer from the magnetron.

5. Remove the one (1) screw holding the airguide to the magnetron and remove the airguide.

6. Remove the one (1) screw holding the insertion plate A to the magnetron and remove the insertion plate A.

7. Remove the one (1) screw holding the chassis support to the magnetron.

9. Remove one (1) screw holding the capacitor holder to the oven cavity rear plate.

10.Remove one (1) screw holding the fan duct to the oven cavity rear plate.

11.Release the capacitor holder from the fan duct.

12.Remove the capacitor from the capacitor holder.

13.Now, the capacitor should be free.

CAUTION: WHEN REPLACING HIGH VOLTAGE RECTI-

FIER AND HIGH VOLTAGE CAPACITOR, GROUND SIDE TERMINAL OF THE HIGH VOLTAGE RECTIFIER MUST BE SECURED FIRMLY WITH A GROUNDING SCREW.

8. Release the tabs of air intake duct from the chassis support and the oven cavity.

9. Move the air intake duct to the left.

10.Carefully remove four (4) screws holding magnetron to waveguide, when removing the screws hold the magnetron to prevent it from falling.

11.Remove the magnetron from the waveguide with care so the magnetron antenna is not hit by any metal object around the antenna.

CAUTION: WHEN REPLACING THE MAGNETRON, BE

SURE THE R.F. GASKET IS IN PLACE AND THE MAGNETRON MOUNTING SCREWS ARE TIGHTENED SECURELY.

CONTROL PANEL ASSEMBLY REMOVAL

CONTROL PANEL ASSEMBLY

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 main wire harness from the control unit.

5. Remove the one (1) screw holding the control panel assembly to the oven cavity front plate.

6. Lift up the control panel assembly.

7. Now, the control panel assembly is free.

CONTROL UNIT

8. Remove the five (5) screws holding the control unit to the control panel frame.

9. Remove the control unit from the control panel frame.

10.Now, the control unit is free.

OVEN LAMP AND LAMP SOCKET REMOVAL

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. Lift up the oven lamp socket from air intake duct.

5. 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.

6. Now, the oven lamp socket is free.

TIMER KNOB

11.After removing the control unit, release the tab of the timer knob from the hole of the control panel.

12.Now, the timer knob is free.

NOTE: 1. Before attaching a new timer sheet, wipe off

remaining adhesive on the control panel frame surfaces completely with a soft cloth soaked in alcohol.

2. When attaching the timer sheet to the control panel frame, adjust the upper edge and right edge of the timer sheet to the correct position of control panel frame.

3. Stick the timer sheet firmly to the control panel frame by rubbing with a soft cloth so not to cause scratches.

Figure C-1. Oven lamp socket

R-21JCA-F

Shaft

Table

Center of bracket

POSITIVE LOCK® CONNECTOR (NO-CASE TYPE) REMOVAL

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. 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, INSTALL THE POSITIVE LOCK® CONNECTOR SO THAT THE LEVER FACES YOU.

ANTENNA MOTOR REMOVAL

Terminal

Positive lock® connector

Lever

Push

Pull down

Figure C-2. Positive lock® connector

1. Disconnect the power supply cord.

2. Remove the one (1) screw holding the base plate cover to the base plate and remove the base plate cover.

3. Disconnect the wire leads from the antenna motor and

COOLING FAN MOTOR REMOVAL

REMOVAL

Disconnect the power supply cord and

2. Open the door and block it open.

3. Discharge high voltage capacitor.

4. Disconnect the wire leads from the fan motor.

5. Remove the one (1) screw holding the capacitor holder to the oven cavity rear plate.

6. Remove the one (1) screw holding the fan duct to the oven cavity rear plate.

7. Release the tabs of the capacitor holder from fan duct.

8. Remove the fan duct from the oven.

9. Remove the fan blade from the fan motor shaft according to the following procedure.

10.Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers.

CAUTION: * Make sure that no metal pieces enter the gap between

the rotor and the stator of the fan motor because the rotor is easily shaven by pliers and metal pieces may be produced.

* Do not touch the pliers to the coil of the fan motor

because the coil may be cut or injured.

* Do not disfigure the bracket by touching with the pliers.

11.Remove the fan blade from the shaft of the fan motor by pulling and rotating the fan blade with your hand.

12. Now, the fan blade will be free.

then

remove outer case.

remove the one (1) screw holding the antenna motor.

4. Remove the antenna motor shaft from the antenna motor.

5. Now, the antenna motor is free.

CAUTION: * Do not reuse the removed fan blade because the hole

(for shaft) may be larger than normal.

13.Remove the two (2) screws holding the fan motor to the fan duct.

14.Now, the fan motor is free.

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.

3. Hold the center of the bracket which supports the shaft of the fan motor on the flat table.

4. 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 hard when installing because

the bracket may be disfigured.

* Make sure that the fan blade rotates smooth after

installation.

* Make sure that the axis of the shaft is not slanted.

5. Install the fan duct to the oven cavity rear plate with the one (1) screw.

6. Insert the tabs of the capacitor holder to the fan duct.

7. Install the capacitor holder to the oven cavity rear plate with the one (1) screw.

8. Re-connect the wire leads to the fan motor.

Coil

Stator

Gap Bracket

Rear View

Rotor

Groove joint pliers

Side View

Axis

Shaft

Stator

Rotor

These are the positions that should be pinched with pliers

POWER SUPPLY CORD REPLACEMENT

R-21JCA-F

Removal

Disconnect the power supply cord and

then

remove outer case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

4. Remove the one (1) screw holding the green wire to the cavity rear plate.

5. Disconnect the wire leads of the power supply cord from the noisew filter.

6. Release the power supply cord from the oven cavity rear

7. Now, the power supply cord is free.

Re-install

1. Insert the moulding cord stopper of power supply cord into the square hole of the oven cavity rear plate, referring to the Figure C-3b.

2. Install the earth wire lead of power supply cord to the cavity rear plate with one (1) screw and tighten the screw.

3. Connect the wire leads of power supply cord to the noise filter, referring to the Pictorial Diagram.

plate.

Oven Cavity Rear Plate

Power Supply Cord

Moulding

Screw

Green Wire

Black Wire

White Wire

Noise Filter

Chassis

RED

WHT

Support

Cord Stopper

Power Supply Cord

Oven Cavity Rear Plate

Square Hole

Figure C-3a. Power Supply Cord Replacement

Figure C-3b. Power Supply Cord Replacement

DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH REMOVAL

1. Disconnect the power supply cord and then remove outer case.

2. Open the door and block it open.

4. Make sure that the monitor switch is operating properly and check continuity of the monitor circuit. Refer to chapter "Test Procedure" and Adjustment procedure.

3. Discharge high voltage capacitor.

4. Remove the control panel assembly referring to "CONTROL

Latch Hoo

PANEL ASSEMBLY REMOVAL".

5. Disconnect the leads from all switches.

6. Remove the two (2) screws holding the latch hook to the oven cavity.

7. Remove the latch hook.

8. Push the retaining tab outward slightly and remove the switch.

Re-install

1. Re-install each switch in its place. The door sensing switch and monitor switch are in the lower position and the secondary interlock switch is in the upper position.

2. Re-connect wire leads to each switch. Refer to pictorial diagram.

3. Secure latch hook (with two (2) mounting screws) to oven flange.

Tab

Figure C-4. Switches

Tabs

Secondary Interlock Switch

Tab

Monitor Switch

Tab

Door Sensing Switch

DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT

1. Disconnect the power supply cord and then remove outer case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

If the door sensing switch, secondary interlock switch and monitor switch do not operate properly due to a misadjustment, the following adjustment should be made.

4. Loosen the two (2) screws holding the latch hook to the oven cavity front flange.

5. With door closed, adjust latch hook by moving it back and forth, and up and down. In and out play of the door allowed

by the upper and lower position of the latch hook should be less than 0.5mm. The vertical position of the latch hook should be adjusted so that the door sensing switch and secondary interlock switch are activated with the door closed. The horizontal position of the latch hook should be adjusted so that the plunger of the monitor switch is pressed with the door closed.

6. Secure the screws with washers firmly.

7. Check the operation of all switches. If each switch has not activated with the door closed, loosen screw and adjust the latch hook position.

R-21JCA-F

After adjustment, check the following.

1. In and out play of door remains less than 0.5mm when in the latched position. First check upper position of latch hook, pushing and pulling upper portion of door toward the oven face. Then check lower portion of the latch hook, pushing and pulling lower portion of the door toward the oven face. Both results (play in the door) should be less than 0.5mm.

2. The door sensing switch and secondary interlock switch interrupt the circuit before the door can be opened.

3. Monitor switch contacts close when door is opened.

4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)

Handle Lever

Door Handle

Latch Lever

Latch Head

Latch Hook

Latch Switch Lever A

Secondary Interlock Switch

Latch Switch Lever B

Monitor Switch

DOOR PARTS REMOVAL

CHOKE COVER

1. Disconnect the power supply cord.

2. Open the door slightly.

3. Insert a putty knife (thickness of about 0.5mm) into the gap between the choke cover and door frame as shown in Figure C-6 to free engaging parts.

4. Pry the choke cover by inserting a putty knife as shown in Figure C-6.

5. Release choke cover from door panel.

6. Now choke cover is free.

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.

Choke Cover

Putty Knif

Door Frame

Figure C-6. Door Disassembly

7. Release two (2) pins of door panel from two (2) holes of upper and lower oven hinges by lifting up.

8. Now, door sub assembly is free from oven cavity.

DOOR PANEL REMOVAL

9. Remove the four (4) screws holding the door panel to the door frame.

10.Release door panel from seven (7) tabs of door frame by sliding door panel downward.

11.Now, the door panel is free.

DOOR HANDLE REMOVAL

12.Release the latch spring from the tab of the latch angle assembly.

Latch Switch Lever C

Door Sensing Switch

Figure C-5. Latch Switch Adjustments

13.Remove the two (2) screws holding the door handle and the latch angle assembly through the door frame.

14.Now, door handle is free.

LATCH HEADS REMOVAL

15.Remove the one (1) screw holding the latch angle assembly to the door frame.

16.Remove the latch angle assembly together with the latch lever, latch spring and the upper and lower latch heads from the door frame.

17.Release the latch lever together with the latch spring and the latch heads from the latch angle assembly.

18.Release the two (2) latch heads from the latch lever.

19.Now, the upper and lower latch heads are free.

FRONT DOOR GLASS OR SEALER PLATE REMOVAL

(After DOOR PANEL REMOVAL)

12.Remove the four (4) screws holding the glass stopper U to the door frame and remove the glass stopper U.

13.Remove the two (2) screws holding the glass stopper R to the door frame and remove the glass stopper R.

14.Slide the front door glass and the sealer plate left at first and then slide upwards to release them from the tabs holding it.

17.Now, the front door glass or the sealer plate free.

DOOR CASE REMOVAL

(After DOOR PANEL REMOVAL)

12.Straighten all tabs of the door case holding the door case to the door frame.

13.Release door case from the door frame.

17.Now, the door case is free

NOTE: At this moment, the door badge is attached on the

door case.

RE-INSTALL OF THE DOOR

1. Re-install all door parts except the choke cover.

2. Catch two (2) pins of door panel on two (2) holes of upper and lower oven hinges.

3. Re-install choke cover to door panel by pushing.

NOTE: After any service to the door; (A) Make sure that door sensing switch and secondary

interlock switch are operating properly. (Refer to chapter "Test Procedures".).

R-21JCA-F

(B) An approved microwave survey meter should be used

to assure compliance with proper microwave radiation emission limitation standards. (Refer to Microwave Measurement Procedure.)

After any service, make sure of the following :

1. Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of latch hole.

2. Deviation of door alignment from horizontal line of cavity face plate is to be less than 1.0mm.

3. Door is positioned with its face pressed toward cavity face plate.

4. Check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)

Note: The door on a microwave oven is designed to act as

an electronic seal preventing the leakage of microwave energy from oven cavity during cook cycle. This function does not require that the door be air-tight, moisture (condensation)-tight or light-tight. Therefore, occasional appearance of moisture, light or sensing of gentle warm air movement around oven door is not abnormal and do not in themselves indicate a leakage of microwave energy from oven cavity.

Upper

Oven Hinge

Upper Oven Hinge

Lower

Choke Cover

Lower Oven Hinge

Oven Hinge

Door Panel

Slit Chok

Figure C-7. Door Replacement

ANTENNA MOTOR SHAFT REPLACEMENT

REMOVAL

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 antenna motor from the oven cavity bottom plate, referring to "ANTENNA MOTOR REMOVAL" .

5. Remove the ceramic shelf from the oven cavity bottom plate.

6. Remove the one (1) screw and the one (1) washer holding the antenna holder of the stirrer antenna assembly to the oven cavity bottom plate through the square hole of the stirrer antenna. Refer to Figure C-8.

7. Release the antenna holder from the one (1) tab of the oven cavity bottom plate.

8. Remove the stirrer antenna assembly from the oven cavity bottom plate.

9. Remove the antenna motor shaft from the hole of the oven cavity bottom plate.

10.Now, the antenna motor shaft is free.

Washer

Square hole

Screw

Antenna holder

Tab

Stirrer antenna

Antenna motor shaft

Oven cavity bottom plate

INSTALLATION

1. Install the antenna motor shaft into the hole of the oven cavity bottom plate, and turn the flat faces of antenna motor shaft to the left and right side walls of oven cavity (to fit the stirrer antenna holder). Refer to Figure C-9.

2. Set the direction of the stirrer antenna and antenna holder so that the hole of the antenna holder fit to the centre of the stirrer antenna's big blade. Refer to Figure C-9.

3. Hook the hole of the antenna holder on the tab of the oven cavity bottom plate. Refer to Figure C-10.

4. Insert the antenna holder into the hole of the oven cavity bottom plate and fit the hole of the antenna holder with an antenna motor shaft. Refer to Figure C-10.

5. Install the antenna holder to the oven cavity bottom plate with the one (1) screw and the one (1) washer. Refer to Figure C-8.

6. Install the antenna motor to the oven cavity bottom plate with one (1) screw. Refer to Figure C-8.

7. Connect the wire leads to the antenna motor, referring to the pictorial diagram.

8. Install the base plate cover to the base plate with one (1) screw.

9. Install the ceramic shelf to the oven cavity bottom plate. Refer to "INSTALLATION OF CERAMIC SHELF" .

Antenna motor

Screw

Figure C-8. Antenna Motor Shaft Removal

R-21JCA-F

Antenna holder

Stirrer antenna

To left wall of oven cavity

Flat face

Hole

Antenna motor shaft

To right wall of oven cavity

Flat face

Centre

Stirrer antenna's big blade

Figure C-9. Derection of Antenna Motor Shaft and

Stirrer Antenna Assembly

Antenna holder

Stirrer antenna

Stirrer antenna assembly

Antenna holder

Tab

Antenna motor shaf

Oven cavity bottom plate

Stirrer antenna

Tab

Antenna motor shaft

Figure C-10. Stirrer Antenna Assembly Installation

INSTALLATION OF CERAMIC SHELF

1. Disconnect the power supply cord.

2. Open the door and block it open.

3. Make sure that the smooth surface of the ceramic shelf face up.

4. Make sure that the rubber packing without a fin of the ceramic shelf faces the front of the oven.

NOTE: The three (3) rubber packings with the fins and the

one (1) rubber packing without a fin are attached to the four (4) edges of the ceramic shelf. The one (1) rubber packing without a fin is the front edge of the ceramic shelf.

5. Put the front edge of the ceramic shelf into the front edge of the oven cavity bottom plate.

6. Push down the rear edge of the ceramic shelf into the oven cavity bottom plate.

7. Now, the ceramic shelf is installed.

Antenna motor shaft

Oven cavity bottom plate

Tab

WARNING

Make sure that the rubber packing is not caught between the oven door and the oven cavity front plate, to avoid possible exposure to excessive microwave energy.

Oven Cavity

Rear Edge

Push

Ceramic

Front Edge

Shelf

R-21JCA-F

FUSE

RED

BLK

WHT

RED

WHT

ORG

GRY

THERMAL

CUT-OUT

125˚C(OVEN)

OVEN LAMP

& SOCKET

THERMAL

CUT-OUT

145°C(MAG.)

FAN MOTOR

WHT

ORG

WHT

RED

WHT

HIGH VOLTAGE COMPONENTS

MAGNETRON

H.V.

CAPACITOR

H.V.

RECTIFIER

POWER TRANSFORMER

GRN

POWER SUPPLY

CORD

COM

WHT

ORG

WHT

N.C.

N.O.

COM.

CONNECTOR

ORG

WHT

BLU

BRN

ANTENNA

MOTOR

MONMITOR

SWITCH

PRIMARY

INTERLOCK

RELAY

WHT

BLU

RED

ORG

RED

ORG

YLW

PNK

BLU

CN-A

RY2

RY1

NEUTRAL

HOT

EARTH

PNK

YLW

N.O.

COM.

DOOR SENSING SWITCH

SECONDARY

INTERLOCK

SWITCH

NOTE:

Hot (ORG) wire must be

connected to the terminal

with blue mark on the

oven light socket.

BLUE MARK

RED

BRN

RED

NOISE

FILTER

Figure S-1. Pictorial Diagram

R-21JCA-F

INT0

N.F

VDD

VSS

XIN

XOUT

CNVSS

RESET

P20

P21

P22

ICP1

R1 R2

R5 1K

POWER

TRANSFORMER

D70D71D72D73

DOOR

SENSING

SWITCH

0.1µ/50 V

1000µ/35V

0.1µ/50 V

C31

P03

P10

P11

P12

P13

932

17 18 19 20 21 22 23 24

P02

P01

P00

AIN3

AIN2

AIN1

AIN0

INT1

D1 D2

C61

0.1µ/50V

Model Chg.

(J1)

9321

144

67810

: IF NOT SPECIFIED 1/10W 5%

: IF NOT SPECIFIED 0.01µ/50V

: IF NOT SPECIFIED 1SS270A

CN-A3

Pin5mm

Pitch

COM

120V/60Hz

N.O

OVEN LAMP

ANTENNA

MOTOR

FAN MOTOR

N.O

RY2

Q22

KRC105S

RY1

D22

D20

D30

4.7K

47K

R31

R30

C30

D21

R21

4.7K

Q20

KRC101S

4.7K

R22

C21

10µ

/35V

0.1µ

/50V

C20

R20 4.7K

Q21

KRA101S

HZ11A3 x 3

ZD3

ZD2

ZD1

1W 510 x 2

1W 1K

KTC3198A

HZ6C3 x 2

ZD5

ZD4

KTA1504

4.7K

HZ4C1

ZD6

4.7K

R10

D11

D100.1µ/50V

27K

Q40

KRC101S

SP1

R41

1.5K

R42

3.3K

27K27K

R40

4.7K

220µ/16V

(J3)

(J5) 6.2K

(J7)

(J6) 4.7K

(J4) 4.7K

(J2) 4.7K

(JF)

4.7K

C60

4MHz

CF1

D82

D83

D84D85

R70

R71R72

R73

R74

100

150

240

330

430

LD1

LD20 LTL-1CHE-011A x 20

LD1

(20S)

LD2

(40S)

LD3

(1M)

LD4

( . )

LD5

(2M)

Q70

KRA101S

Q71

KRA101S

Q72

KRA101S

Q73

KRA101S

LD16

LD17

LD18

LD19

LD20

(15M)

D81

( . )

D80

( . )

D79

( . )

D78

( . )

LD11

D74 (6M)

LD12

D75 (7M)

LD13

D76 (8M)

LD14

D77 (9M)

LD15

(10M)

LD10

(5M)

LD9

(4M)

LD8

( . )

LD7

(3M)

LD6

( . )

I-1

IXA167DR

R63 4.7K

R62 4.7K

SW1

R61

10K

R60

10K

R50

10K

1N4005E x 4

2.2µ/160VAC

R12

1/2W 100K

2W 100

R11

10G471K

VRS1

Figure S-2. Control Panel Circuit

R-21JCA-F

LD4

JP32

JP35

LD20

D72

JP34

JP31

JP27

LD3

LD2

LD1

D81

D77

D73

JP29

D84

D85

JP25

JP24

D83

LD5

LD19

D71

JP26

LD6

JP39

JP36

SW1

D82

LD18

JP28

LD7

LD8

D76

D80

D79

D75

JP33

JP30

D70

LD16

LD17

12345

D74

LD9

D78

LD15

JP23

JP38

LD10

LD14

JP37

LD11

LD12

LD13

JP19

CNC

JP8

D20

JP13

C21

RY1

JP14

ZD5

ZD4

D10

D11

JP1

JP12

JP18

JP17

JP3

JP2

VRS1

8 9

CF1

JP6

R12

R11

CNA

JP11

JP10

JP9

JP7

ZD1

ZD2 ZD3

D21

RY2

JP20

JP21

SP1

JP4

D22

ZD6

JP16

JP15

JP5

D30

JP22

ICP1

WHA

SW2

Figure S-3. Printed Wiring Board

R-21JCA-F

PARTS LIST

Note: The parts marked “∆” may cause undue microwave exposure.

The parts marked “*” are used in voltage more than 250V.

REF. NO. PART NO. DESCRIPTION Q'TY CODE

ELECTRIC PARTS

1- 1 FFS-BA015WRK0 1- 2 QSW-MA051WRE0 Door sensing switch 1 AF 1- 3 QSW-MA135WRE0 Secondary interlock switch 1 AH 1- 4 FACCDA116WREZ Power supply cord 1 AV 1- 5 FH-DZA084WRK0 High voltage rectifier assembly 1 AV

1- 6 RC-QZA242WRE0 High voltage capacitor 1 AV

1- 7 RMOTEA376WRE0 Fan motor 1 AU 1- 8 FPWBFA389WRKZ Noise filter 1 AW 1- 9 QSOCLA021WRE0 Oven lamp socket 1 AG 1-10 RLMPTA086WRZZ Oven lamp 1 AL 1-10 RLMPTA072WRE0 Oven lamp (Interchangeable) 1 AY 1-11 RMOTDA233WRE0 Antenna motor 1 AQ 1-12 RTHM-A080WRE0 Thermal cut-out 145 deg. (MAG) 1 AP 1-13 RTHM-A096WRE0 Thermal cut-out 125 deg. (OVEN) 1 AK 1-14 RTRN-A570WRE0 Power transformer 1 BM

1-15 RV-MZA197WRE0 Magnetron 1 BN

∆

2- 1 GCABUA674WRP0 Outer case cabinet 1 AX 2- 2 GDAI-A311WRW0 Base plate 1 AS 2- 3 GCOVHA406WRW0 Base plate cover 1 AQ 2- 4 GLEGPA074WRE0 Foot 2 AC 2- 5 GLEGPA076WRF0 Leg 1 AF

3- 1 DPWBFC288WRUZ Control unit assembly 1 BF 3- 2 FPNLCB434WRK0 Panel sub assembly 1 BA 3- 2-1 HPNLTA137WRE0 Timer sheet 1 AH 3- 2-2 GCOVAA260WRP0 C/P case 1 BA 3- 3 TCAUAA076WRR0 User caution label 1 AB 3- 4 JKNBKA606WRM0 Timer knob 1 AL 3- 5 XEPS730P08XS0 Screw; 3mm X 8mm 5 AB

4- 1 FGLSPA062WRE0 Ceramic shelf 1 BL 4- 2 ************* Oven cavity (Not a replaceable part) 1 —

∆

4- 3 MLEVPA227WRF0 Latch switch lever A 1 AF 4- 4 MLEVPA228WRF0 Latch switch lever B 1 AF 4- 5 MLEVPA229WRF0 Latch switch lever C 1 AF 4- 6 MSPRCA108WRE0 Latch lever spring 3 AC 4- 7 MSPRTA191WRE0 Switch lever B spring 1 AC 4- 8 PHOK-A121WRFZ Latch hook 1 AG

∆

4- 9 FDUC-A341WRY0 Steam duct sub assembly 1 BL 4-10 PSKR-A351WRP0 Steam guide 1 AY 4-11 LBNDKA136WRP0 HV capacitor holder 1 AQ 4-12 NFANJA029WRE0 Fan blade 1 AK 4-13 PDUC-A697WRF0 Fan duct 1 AM 4-14 FPLT-A007WRY0 Stirrer antenna assembly 1 BB 4-15 PCUSGA504WRP0 Insertion cushion 2 AB 4-16 PSKR-A348WRW0 Insertion plate A 1 AN 4-17 GCOVHA404WRE0 VCP cap 2 AG 4-18 LANGFA199WRWZ Chassis support 1 AH 4-19 NSFTPA035WRFZ Antenna motor shaft 1 AQ 4-20 PCLICA032WRE0 Hand clip 4 5 AD 4-21 PCLICA033WRE0 Hand clip 5 4 AD 4-22 PCOVPA344WRF0 Side splash cover 1 AF 4-23 PCOVPA345WRF0 Back splash cover 1 AF 4-24 PCUSGA249WRP0 Cushion 3 AA 4-25 PCUSUA511WRP0 Cushion 1 AC 4-26 PCUSUA194WRP0 Cushion 2 AC 4-27 PCUSUA514WRP0 Cushion 1 AB 4-28 PDUC-A722WRF0 Air intake duct 1 AF 4-29 PFILWA060WRP0 Lamp filter 1 AD 4-30 PSHEPA644WRE0 Insertion sheet 1 AD 4-31 PSKR-A347WRW0 Insertion plate B 1 AL 4-32 PSKR-A349WRP0 Steam duct barrier 1 AF 4-33 PSKR-A359WRW0 Air guide 1 AM

Monitor fuse(20A) and monitor switch(V-5220D-070) assembly

CABINET PARTS

CONTROL PANEL PARTS

OVEN PARTS

1AK

REF. NO. PART NO. DESCRIPTION Q'TY CODE

4-34 PSPA-A112WRE0 Mica washer 1 AC 4-35 PCUSGA378WRP0 Cushion 1 AL 4-36 PCUSUA507WRP0 Cushion 1 AC 4-37 PCUSUA517WRP0 Cushion 1 AE 4-38 PSHEPA674WRE0 Cover 1 AL 4-39 PPACGA171WRE0 Cushion 1 AK 4-40 PSHEPA673WRE0 S/Film 1 AD 4-41 PCUSUA518WRP0 Cushion 1 AC

DOOR PARTS

∆

5- 1 CDORFA804WRK0 Door assembly 1 BP

∆

5-1-1 FDORFA322WRT0 Door panel assembly 1 AZ 5-1-2 PSHEPA649WRE0 Sealer film 1 AB 5-1-3 FANGKA206WRY0 Latch angle assembly 1 AW

∆

5-1-4 FCOV-A002WRK0 Door case assembly 1 BQ

∆

5-1-4-1 LSTPPA180WRF0 Glass stopper R 1 AK 5-1-4-2 LSTPPA182WRF0 Glass stopper U 1 AN 5-1-4-3 PGLSPA516WRE0 Front door glass 1 AU 5-1-4-4 PSLDMA198WREZ Sealer plate 1 BB 5-1-4-5 XCPS740P08000 Screw : 4mm x 8mm 6 AB 5-1-5 GWAKPA580WRM0 Door handle 1 AQ 5-1-6 JHNDMA040WRW0 Handle lever 1 AN 5-1-7 LANGKA874WRW0 Latch lever 1 AR

∆

5-1-8 LSTPPA181WRF0 Latch head 2 AL

∆

5-1-9 MSPRTA190WRE0 Latch spring 1 AD 5-1-10 PCUSUA506WRP0 Cushion 1 AC 5-1-11 XEPS740P06000 Screw : 4mm x 6mm 1 AA 5-1-12 PSHEPA686WRE0 Panel sheet 2 AK 5-1-13 PSHEPA687WRE0 Panel sheet 1 AK 5-1-14 PCUSGA514WRP0 Cushion 1 AK 5-1-15 PCUSUA505WRP0 Cushion 1 AC 5-1-16 XEBS738P08000 Screw : 3.8mm x 8mm 4 AB 5-1-17 XEPS740P25K00 Screw : 4mm x 25mm 2 AC 5-1-18 PCUSUA508WRP0 Cushion 1 AC 5- 2 GCOVHA407WRF0 Choke cover 1 AM

∆

5- 3 HBDGCA107WREZ Door badge 1 AL

MISCELLANEOUS

6- 1 TINSEA954WRRZ Instruction book 1 AM 6- 1 FW-VZC073WREZ Main wire harness 1 AX 6- 3 TCAUAA166WRR0 DHHS caution label 1 AB 6- 4 TCAUAA295WRRZ Monitor caution 1 AH 6- 5 TCAUAA243WRR0 Earth caution 1 AC 6- 6 TCAUAA245WRR0 Cover caution 1 AC 6- 7 TLABMA572WRR0 Menu sticker 1 AE 6- 8 TMAPCA776WRRZ Schematic diagram 1 AH 6- 9 LHLDWA013WRE0 Purse lock LL 1 AC 6-10 TCAUAA249WRR0 Caution label 1 AE

SCREWS,NUTS AND WASHERS

7- 1 XHPS740P08K00 Screw : 4mm x 8mm 8 AB 7- 2 XEPS740P25000 Screw : 4mm x 25mm 2 AB 7- 3 LX-CZA038WRE0 Special screw 4 AA 7- 4 LX-CZ0052WRE0 Special screw 2 AA 7- 5 LX-EZA042WRE0 Special screw 2 AB 7- 6 XBPWW40P04000 Screw : 4mm x 4mm 1 AB 7- 7 XFPS740P08000 Screw : 4mm x 8mm 3 AB 7- 8 XFTS740P08000 Screw : 4mm x 8mm 2 AB 7- 9 XHPS730P06000 Screw : 3mm x 6mm 1 AB 7-10 XHTS740P08RV0 Screw : 4mm x 8mm 1 AG 7-11 XOTS740P12000 Screw : 4mm x 12mm 12 AA 7-12 XOTS840P08000 Screw : 4mm x 8mm 1 AB 7-13 XOTWW40P10000 Screw : 4mm x 10mm 4 AA

R-21JCA-F

HOW TO ORDER REPLACEMENT PARTS

To have your order filled promptly and correctly, please furnish the following information.

1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION

Order Parts from the authorized SHARP parts Distributor for your area. Defective parts requiring return should be returned as indicated in the Service Policy.

R-21JCA-F

2-1

7-3

OVEN AND CABINET PARTS

7-3

1-10

1-9

4-28

7-13

7-3

4-9

6-6

4-10

6-8

7-6

4-34

4-27

4-24

4-26

7-12

4-25

1-13

7-1

1-4

6-5

4-26

6-4

4-14

4-19

4-2

4-36

4-16

4-32

4-15

7-13

6-3

7-9

1-4

1-1

7-7

4-15

7-10

7-13

7-1

1-8

4-40

7-8

7-11

4-24

1-12

4-18

4-23

4-21

4-20

7-4

7-7

4-6

7-7

4-33

4-6

1-3

4-3

4-4

4-5

1-1

4-7

7-1

4-11

7-1

1-15

1-6

4-12

1-14

7-1

1-5

4-13

4-39

7-5

1-7

4-35

7-2

4-21

4-22

4-21

4-20

6-10

4-29

1-11

7-1

4-1

4-38

4-20

4-30

2-2

4-31

4-8

1-2

4-37

4-20

4-41

7-11

2-4

4-17

7-11

4-24

2-5

2-4

2-3

7-8

7-11

R-21JCA-F

CONTROL PANEL PARTS

3-3

3-2-2

3-2

3-1

3-2-1

3-4

3-5

DOOR PARTS

5-2

5-1-15

5-1-16

5-1

5-1-14

5-1-12

5-1-2

5-1-16

5-1-18

5-1-4-2

5-1-4

5-1-4-3

5-1-4-4

5-1-4-5

5-1-4-1

5-1-13

5-1-16

5-1-1

5-1-4-5

5-1-12

5-1-16

5-1-8

5-1-9

5-3

5-1-7

5-1-17

5-1-11

5-1-3

5-1-5

5-1-8

5-1-6

5-1-10

5-1-17

MISCELLANEOUS

6-2

6-9

Actual wire harness may be different from illustration.

R-21JCA-F

PACKING AND ACCESSORIES

TRAY HOLDER

(SPADFA435WRE0)

MENU STICKER

6-7

INSTRUCTION BOOK

6-1

Into the

Oven Cavity

TOP PAD ASSEMBLY

(FPADBA385WRK0)

WRAP COVER

(SSAKHA034WRE0)

DOOR PROTECTION SHEE

(SPADPA204WRE0)

BOTTOM PAD ASSEMBLY

(FPADBA386WRK0)

Not Replaceable Items.

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 permission of the publisher.

PACKING CASE

SPAKCD803WREZ

'05 SHARP CORP. (10S0.80E) Printed in U.S.A

Sharp R-21JCA-F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual