Sharp R-405HK User manual

R-405HK
R-405HW
R-403HW
Intheinterestofuser-safetytheovenshouldberestoredtoitsoriginal
condition and only parts identical to those specified should be used.
WARNING TO SERVICE PERSONNEL: Microwave ovens con-
tain circuitry capable of producing very high voltage and
current, contact with following parts may result in a severe,
possibly fatal, electrical shock. (High Voltage Capacitor, High
Voltage Power Transformer, Magnetron, High Voltage Recti-
fier Assembly, High Voltage Harness etc..)
TABLEOFCONTENTS 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
TESTPROCEDURE ..............................................................................................................................................6
CPUUNITCIRCUIT...............................................................................................................................................8
PARTS LIST........................................................................................................................................................10
PACKINGANDACCESSORIES .........................................................................................................................14
S43M207R405HE
R-405HK
R-405HW
R-403HW
MICROWAVEOVENS
MODELS
SUPPLEMENTAL SERVICE MANUAL
SHARP ELECTRONCS CORPORATION This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135
R-405HK
R-403HW
This is a supplemental Service Manual for Microwave Oven models R-405HK/HW & R-403HW. These models are quite
similar to the base models R410HK/R-410HW/R-409HK; (S33M206R410HE).
This supplemental manual must be used in conjunction with the base model service manual for complete operation,
service, safety and replacement parts information.

R-405HK
R-405HW
R-403HW
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROWAVE
ENERGY
(a) Do not operateor allow theoven to beoperated with thedoor open.
(b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other
microwavesource,andmake repairs as necessary: (1) interlockoperation,(2)properdoorclosing,(3)
sealandsealingsurfaces (arcing, wear, and other damage),(4)damagetoorloosening of hinges and
latches,(5) evidence of dropping orabuse.
(c) Before turning onmicrowave power foranyservice test orinspection within the microwavegenerating
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
manualbefore the ovenis released tothe owner.
(e) A microwave leakage check to verify compliance with the Federal Performance Standard should be
performedoneachovenpriorto 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
ELECTRONICSCORPORATIONimmediately @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.

1
R-405HK
R-405HW
R-403HW
WARNINGTO SERVICE PERSONNEL
Microwave ovens contain circuitry capable of pro-
ducing very high voltage and current, contact with
following parts
may result in a severe, possibly
fatal, electrical shock.
(Example)
HighVoltageCapacitor,HighVoltagePowerTrans-
former,Magnetron,HighVoltageRectifierAssem-
bly, High Voltage Harness etc..
Read the Service Manual carefully and follow all
instructions.
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
secondsaftertheovenhasbeenswitchedoff.Waitfor60
secondsandthenshort-circuittheconnectionofthehigh-
voltagecapacitor(thatistheconnectingleadofthehigh-
voltage rectifier) against the chassis with the use of an
insulated screwdriver.
Whenever troubleshooting is performed the power supply
mustbedisconnected.Itmay,in somecases,benecessary
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.
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. Reconnectthepower supply cord after theoutercase 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. Reconnectthepower supply cord after theoutercase is
installed.
4. Run the oven and check all functions.
Microwaveovensshouldnotbeoperatedempty.To testfor
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
remainscoldcarryoutBeforeServicingprocedureandre-
examine the connections to the component being tested.
When all service work is completed and the oven is fully
assembled,themicrowavepoweroutputshouldbechecked
and a microwave leakage test should be carried out.
Don't Touch !
Danger High Voltage

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R-405HK
R-405HW
R-403HW MICROWAVE MEASUREMENT PROCEDURE
A. Requirements:
1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven
shouldnotexceed1mW/cm2atanypoint5cmormorefromtheexternalsurfaceoftheoven,measuredpriortoacquisition
byapurchaser,andthereafter(throughthe useful lifeoftheoven),5mW/cm2atanypoint5cmormore from theexternal
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 oven tray in the oven cavity.
3) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5O C (68OF) in the center of the oven cavity.
Thewatercontainershallbe alowformof600ml(20oz) beakerwithaninsidediameterofapprox. 8.5 cm(3-1/2in.)and
made of an electrically nonconductive material such as glass or plastic.
Theplacing of this standardloadin the oven isimportant not only toprotectthe oven, but alsotoinsure that any leakage
is measured accurately.
4) Set the cooking control on Full Power Cooking Mode.
5) Closethedoorandselectacookcycleofseveralminutes.Ifthewaterbeginstoboilbeforethesurveyiscompleted,replace
it with 275 ml of cool water.
C. Leakage test:
Closed-door leakage test (microwave measurement):
1) Grasptheprobeofthesurveyinstrumentandholditperpendiculartothegapbetweenthedoorandthebodyoftheoven.
2) Movetheprobeslowly,notfasterthan1in./sec.(2.5cm/sec.)alongthegap,watchingforthemaximumindicationonthe
meter.
3) Checkforleakageatthedoorscreen,sheetmetalseamsandotheraccessiblepositionswherethecontinuityofthemetal
has been breached (eg., around the switches, indicator, and vents).
Whiletestingforleakagearoundthedoor,pullthedoorawayfromthefrontoftheovenasfarasispermittedbytheclosed
latch assembly.
4) Measurecarefullyatthepointofhighestleakageandmakesurethatthehighestleakageisnogreaterthan4mW/cm2,and
that the primary interlock switch/secondary interlock relay does turn the oven OFF before any door movement.
NOTE: After servicing, record data on service invoice and microwave leakage report.

3
R-405HK
R-405HW
R-403HW
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
SUPPLEMENTAL SERVICE MANUAL
MICROWAVEOVENS
R-405HK/R-405HW/R-403HW
FOREWORD
ThissupplementalManualhasbeenpreparedtoprovideSharpElectronics
Corp. Service Personnel with Operation and Service Information for the
SHARPMICROWAVEOVENS,R-405HK,R-405HWandR-403HW.
Models R-405HK, R-405HW and R-403HW are quite similar to base
modelsR-410HK/HW&R-409HK(Ref.#S33M206R410HE)
Itisrecommendedthatservicepersonnelcarefullystudytheentiretextof
this manual so that they will be qualified to render satisfactory customer
service.
Checktheinterlockswitchesandthedoorsealcarefully.Specialattention
shouldbegiventoavoidelectricalshockandmicrowaveradiationhazard.
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
ariskof electricalshockonly duringservicing.Service person-
nel - 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.
PRODUCTDESCRIPTION
GENERALINFORMATION
TESTPROCEDURE
WIRINGDIAGRAM
PARTS LIST

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R-405HK
R-405HW
R-403HW
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.
Intheeventofanelectricalshortcircuit,groundingreducestheriskofelectricshockbyprovidinganescapewirefortheelectric
current.
WARNING: Improper use of the grounding plug can result in a risk of electric shock.
ElectricalRequirements
The electrical requirements are a 120 volt 60 Hz, AC only,
15or20amp.fusedelectricalsupply.Itisrecommendedthataseparatecircuitservingonlythisappliancebeprovided.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.
Whereatwo-prongedwall-receptacleisencountered,itisthepersonalresponsibilityandobligationofthecustomertocontact
SPECIFICATION
ITEM DESCRIPTION
Power Requirements 120 Volts
14.0Amperes,1600 watts
60Hertz
Singlephase,3wiregrounded
PowerOutput 1100watts(IEC705TEST PROCEDURE)
Operatingfrequencyof2450MHz
CaseDimensions Width 21-11/16"
Height 12-3/8"
Depth 17-3/8"
CookingCavityDimensions Width 15"
Height 9-7/16"
1.4 Cubic Feet Depth 16-3/4"
ControlComplement Touch Control System
Clock ( 1:00 - 12:59 )
Timer (0 - 99 min. 99 seconds)
MicrowavePowerforVariableCooking
Repetition Rate;
P-HI .................................................. Fullpowerthroughoutthecooking time
P-90 ....................................................................approx. 90% of Full Power
P-80 ....................................................................approx. 80% of Full Power
P-70 ....................................................................approx. 70% of Full Power
P-60 ....................................................................approx. 60% of Full Power
P-50 ....................................................................approx. 50% of Full Power
P-40 ....................................................................approx. 40% of Full Power
P-30 ....................................................................approx. 30% of Full Power
P-20 ....................................................................approx. 20% of Full Power
P-10 ....................................................................approx. 10% of Full Power
P-0 ......................................................Nopower throughoutthecookingtime
MINUTE PLUS button, Cook center, Defrost center, Number selection pads,
PowerLevelpad,Timer/Clockpad,Stop/Clearpad,ReheatCenter,Popcornand
Minute plus.
Oven Cavity Light Yes
SafetyStandard UL Listed FCC Authorized
DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J

5
R-405HK
R-405HW
R-403HW
a qualified electrician and have it replaced with a properly grounded
three-pronged wall receptacle or have a grounding adapter properly
groundedandpolarized.Iftheextensioncordmustbeused,itshouldbe
a 3-wire, 15 amp. or higher rated cord. Do not drape over a countertop
ortablewhereitcanbepulledonbychildrenortrippedoveraccidentally.
CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR RE-
MOVE THE ROUND GROUNDING PRONG FROM THIS
PLUG.
OVEN DIAGRAM
1. One touch door open button.
Push to open door.
2. Door latches.
The oven will not operate unless the
door is securely closed.
3. Removable turntable support.
4. Removable turntable.
The turntable will rotate clockwise or
counterclockwise.
5. Oven lamp.
It will light when oven is operating or
door is opened.
6. Oven door with see-through window.
7. Ventilation openings. (Rear)
8. Auto-Touch control panel.
9. Time display: Digital display, 99
minutes 99 seconds.
10.Wave guide cover.
11.Power supply cord
TOUCH CONTROL PANEL
3-Pronged
Plug
Grounded
Receptacle Box
Grounding Pin
3-Pronged Receptacle
NOTE:
The directed features are disa-
bled after one minute when the
ovenisnotinuse.Thesefeatures
are automatically enabled when
the door is opened and closed or
theSTOP/CLEARpadispressed.
R-405HK
4
11
7
3
1
10
5
2
6
9
8
R-403HW
R-405HK/HW

6
R-405HK
R-405HW
R-403HW
Key Unit
Pin
NO. G1
Pin
NO. G13
Key unit ribbon cable
Key unit (Membrane Switch) front view
G10G11G12G13 G9
G8 G7 G6 G5 G4 G3 G2 G1
POPCORN 9
3
6
2
5
8
0
1
4
7
TIMER
CLOCK
COOK
START
STOP
CLEAR
POWER
LEVEL
CLEAR
DEFROST MINUTE
PLUS
REHEAT
**
*
*
When door is close, key can be operated.
TEST PROCEDURES
PROCEDURE
LETTER COMPONENT TEST
JKEY UNIT TEST
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
3. Dischargehighvoltagecapacitor.
4. Usinganohmmeterandreferringtothekeyunitmatrixindicatedonthecontrolunitcircuit,checkthe
circuitbetweenthepinsofthekeyunitthatcorrespondtotheCLEARpad.Whenthepadispressed,
theohmmetershouldindicateshortcircuit.Whenthepadisreleased,theohmmetershouldindicate
opencircuit.Ifincorrectreadingsareobtained,thekeyunitisfaultyandmustbereplaced.Aboutthe
other pads, the above method may be used.
5. Reconnectallleadsremovedfromcomponentsduringtesting.
6. Re-installtheoutercase(cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
6. Re-install 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-405HK/HW
R-403HW
G10G11G12G13 G9
G8 G7 G6 G5 G4 G3 G2 G1
POPCORN
9
3
6
2
5
8
0
1
4
7
TIMER
CLOCK
COOK
START
STOP
CLEAR
POWER
LEVEL
DEFROST MINUTE
PLUS
REHEAT

7
R-405HK
R-405HW
R-403HW
TEST PROCEDURES
PROCEDURE
LETTER COMPONENT TEST
LDEFROSTTEST(R-405HK/HW)
WARNING:Theovenshouldbefullyassembledbeforefollowingprocedure.
(1) Place one cup of water in the center of the turntable tray in the oven cavity.
(2)Openthedoor.
(3) Touch the " DEFROST " pad.
(4) Touch the number pad " 2 ".
(5) Touch the number pad " 5 ".
(6)Closethedoor.
(7) Touch the "START " pad.
(8) The oven is in Defrost cooking condition.
(9) The oven will operate as follows
MENU 1ST STAGE 2NDSTAGE 3RDSTAGE
STEAKS/CHOPS LEVEL TIME LEVEL TIME LEVEL TIME
0.5lb 60% 20sec. 40% 20sec. 30% 45sec.
(10) If improper operation is indicated, the control unit is probably defective and should be checked.
DEFROSTTEST(R-403HW)
WARNING : The oven 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)Closethedoor.
(3) Touch the " DEFROST " pad.
(4) Touch the number pad " 2 ".
(5) Touch the number pad " 5 ".
(6) Touch the "START " pad.
(7) The oven is in Defrost cooking condition.
(8) The oven will operate as follows
MENU 1ST STAGE 2NDSTAGE 3RDSTAGE
STEAKS/CHOPS LEVEL TIME LEVEL TIME LEVEL TIME
0.5lb 60% 20sec. 40% 20sec. 30% 45sec.
(9) If improper operation is indicated, the control unit is probably defective and should be checked.

8
R-405HK
R-405HW
R-403HW
6
45
123
6
45
123
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
FigureS-3.CPUUnitCircuit(R-405HK/HW)
R74 - R78:270Kx5 C60 - C64:330pF/50Vx5
OVEN LAMP
TURNTABLE
MOTOR
FAN MOTOR
POWER
TRANSFORMER
DOOR
SENSING
SWITCH
G10
G11G12
G13 G9
G8 G7 G6 G5 G4 G3 G2 G1
NO
NO
B-1
B-2
C1
R3
C2
R2
2SA933AS
R5
Q2
R6
3.3K
1/4W
10u/35V
C5
D5 D6
27 1/4 W
R4
510
1/2W
(J1)
VRS1
10G471K
-5V
INT
BZ
M
D1 - D4
2200uF
25V
AN5 AN6
P20
P21
P22
P23
P24
P25
P26
P27
AN7
IC1
BL
NL
CF
1
1
24
2540
41
64
65
80
POPCORN
9
3
6
2
5
8
0
1
4
7
TIMER
CLOCK
COOK
START
STOP
CLEAR
**
*
*
When door is close, Keycan be operated.
LIQUID CRYSTAL DISPLAY
NO.
LBS.
CUPS
KG OZ.
COOK
SENSOR
DEFROST
AUTO%
VL2
VL1
AN7
AN6
AN5
AN4
AN3
AN2
AN1
AN0
P57
P56
P55
CNTR0
P53
P52
P51
P50
P47
P46
P45
P44
P43
INT0
SEG8
SEG9
SEG10
SEG11
SEG12
SEG13
SEG14
SEG15
SEG16
SEG17
SEG18
SEG19
SEG20
SEG21
SEG22
SEG23
SEG24
SEG25
P12
P13
P14
P15
P16
P17
P41
P40
RESET
P71
P70
XIN
XOUT
VSS
P27
P26
P25
P24
P23
P22
P21
P20
VL3
COM0
COM1
COM2
COM3
AVSS
VREF
VCC
SEG0
SEG1
SEG2
SEG3
SEG4
SEG5
SEG6
SEG7
CST4.00MGW
R67
15K
R66
15K
R65
15K
R64
15K
R63
15K
R62
15K
R61
15K
R60
15K
R80
1M
R110
15K
(G)
(F)
POWER
LEVEL
CLEAR
KEY UNIT
DEFROSTMINUTE
PLUS
REHEAT
R78
R77
R76
R75
R74
C64
C63
C62
C61
C60
R68
15K
R69
15K
R70
15K
R71
15K
R72
15K
P70
P71
P41
P45
(G)
CPU UNIT
R41
15K
R40
4.7K
C4
00.01uF 25V
POWER UNIT
DOOR
COM
Q20
DTA143EKA
Q4
DTA123JS
Q3
DTD143ES
SP1
Q30
DTA143EKA
C20
0.1uF50V
(F)
1SS270A x2 4.7K 1/4W
JUMPER
WIER
C10
47uF/16V
1N4002x4
WH-1
WH-1
1
2
LD4 LD3 LD2 LD1
AC(N)
COM
COM
AC(H)
ab
d
c
T1
PA151DR
D30 1SS270A
D311SS270A
RY2
DU12D1-1P(M)-R
RY1
DU12D1-1P(M)-R
D7
1SS270A
D8
1SS270A
GND
C11
0.1uF/50V C12
0.1uF50V
Q11
DTA143EKA
R12
15K
C13
0.01uF25V
R10
1K
ZD10
UDZ4.3B
Q102
SA1037AK
C14
R11
15K
0.01uF25V
(J10)
(J11)
GND
R13
10K
R14
10K
R15
10K
(J12)
AN4
(J15)
20K
(J17)
4.7K
(J13)
3.6K
4.7K
4.7K
(J16)
3.6K
(J14)
4.7K
COM0
COM1
COM2
COM3
COM2
COM1
SEG21
SEG20
SEG19
SEG18
SEG17
SEG16
SEG15
SEG14
SEG13
SEG12
SEG11
SEG10
SEG9
SEG8
SEG7
SEG6
SEG5
SEG4
SEG3
SEG2
SEG1
SEG0
:IF NOT SPECIFIED1/10W±5%
NOTE
0.1uF
50V