Sharp SJ-D59M-GL, Service Manual

Page 1: ...REPLACEMENT PARTS LIST 25 Refrigerant HFC 134a Refer to HFC 134a COOLING UNIT Service Manual for handling this refrigerant DESTINATION T In the interests of user safety Required by safety regulations in some countries the set should be restored to its original condition and only parts identical to those specified should be used REFRIGERATOR FREEZER MODELS SJ D59M GL GY SLG SJ P60M GL GY SLG SJ D64...

Page 2: ...king or crunching sound Sound produced by expansion and contraction of inner walls and internal parts during cooling Squeaking sound Sound produced by expansion and contraction of internal parts Sound of flowing fluid gurgling sound fizzing sound Sound of refrigerant flowing in pipes sound may become louder from time to time 3 IT IS NORMAL for the refrigerator to produce the following sounds Do no...

Page 3: ...0 5 liter 11 67 cu ft R 370 5 liter 13 09 cu ft R 405 5 liter 14 32 cu ft Defrosting System Heater system Start Automatic Finish Automatic Temperature control Automatic Adjustable No frost freezer Yes Interior lamp 2 Caster 4 Evaporating pan 1 Refrigerator R glass shelf ass y 2 3 Compartment V glass shelf ass y 1 Vegetable case 1 V parting plate 1 R door pocket 1 2 Egg tray 2 Bottle pocket 2 Utili...

Page 4: ...eezer shelf F shelf ass y 4 Ice cube maker 5 Ice cube box Ice storage box 6 Deodorizing unit 7 Freezer temp control knob 8 Fresh case Chilled case 9 Refrigerator fan 10 Refrigerator temp control knob 11 Refrigerator shelf R glass shelf ass y 59 60 64 65 type 2 shelves 69 70 type 3 shelves 12 Refrigerator light Lamp 13 Shelf V glass shelf ass y 14 Vegetable crisper Vegetable case 15 Separator plate...

Page 5: ...cle time 10 8 9 0 hours 50 60Hz Delay time 4 3 3 6 min 50 60Hz Lamp socket F R 250V 1A E 12 Hard plastic body type F lamp 240V 10W E 12 R lamp 240V 15W E 12 R fan thermo R fan thermo S101 250V 8A Open Close 7 15 C ass y R fan thermo heater RSS2 350V 2W 10kΩ 1 1W at 230V Compressor FL2088 220 240V 50Hz Cooling capacity 245W 50Hz Main coil 9 11Ω Aux coil 16 6Ω at 25 C Starting relay PGT0SAT 33Ω at 2...

Page 6: ...ls a SJ D59M P60M SJ D64M P65M b c d 294 90 90 587 603 450 630 355 177 587 615 615 607 607 174 264 125 b a c d 242 110 285 310 310 335 227 133 133 110 615 615 615 600 Unit mm The dimensions between shelves can be changed by setting the shelves on the other rails 294 587 603 450 630 355 177 587 615 615 607 607 174 264 125 180 135 135 171 666 242 110 110 285 310 310 310 335 227 133 133 110 90 90 615...

Page 7: ...BROWN Live ORANGE YELLOW RED PINK BLUE Neutral BLACK SKY BLUE GREEN YELLOW Earth WHITE PC MAIN PWB DOOR PWB Br G B 2PIN PLUG CORD C M A FM FM L L F LAMP F DEF TIMER THERMOSTAT DEFROST HEATER DEFROST THERMO COMPRESSOR PROTECTOR DOOR SWITCH THERMO FUSE R TM R LAMP R FM HEATER STARTING RELAY R FAN THERMO PC PLASMACLUSTER UNIT IONIZER K Br G B 2PIN PLUG CORD C M A FM FM L L F DEF TIMER THERMOSTAT DEFR...

Page 8: ...1 SKY BLUE SOURCE CORD TERMINAL BLOCK COMPRESSOR STARTING RELAY PROTECTOR 1 2 3 4 3 1 4 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 7 6 8 9 1 2 3 4 5 7 6 8 9 GY 1 OR 2 BL 2 SB 1 SB 2 SB 3 BR 3 BR 5 OR 3 OR 2 OR 4 W 2 OR 1 OR 4 BR 6 BL 3 GY 3 R 1 BR 2 Y 1 R 1 BK 1 GY 2 Y 1 Y 2 BL 1 BK 1 W 1 BR 1 W 2 W 1 Y 2 TERMINAL BOX C M A GY 3 BLUE 2 GRAY 2 ORANGE PWB HARNESS MAI...

Page 9: ... HEATER R FAN THERMO R LAMP BOX ASS Y L R FAN MOTOR R LAMP 15W LAMP SOCKET BROWN 1 BROWN 2 BLUE 1 GRAY 1 SKY BLUE SOURCE CORD TERMINAL BLOCK COMPRESSOR STARTING RELAY PROTECTOR 3 1 4 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 7 6 8 9 1 2 3 4 5 7 6 8 9 GY 1 OR 2 BL 2 SB 1 SB 2 SB 3 BR 3 BR 5 OR 3 OR 4 OR 4 W 2 OR 1 R 1 BR 2 Y 1 R 1 BK 1 GY 2 Y 1 Y 2 BL 1 BK 1 W 1 BR...

Page 10: ...6 D3 VRS1 C13 0 1μ C15 100μ 10V C10 1μ 50V C9 0 1μ VRS2 Q7 KRA101M Q5 KRA101M Q4 KRC101M Q3 KTA1046 Q6 KRA101M Q1 KRA101M Q2 KRC101M C2 2200μ 35V R19 OPEN C16 0 1μ C18 0 1μ C19 1000μ 25V C8 0 1μ C6 0 1μ C4 0 1μ C20 100μ 10V C17 100μ 10V 12V 12V 12V 5V G I I O O G HS IC2 IC1 IC4 7812 7805 C3 0 1μ 50V TRNS IN4005E PST993E IC3 D1 IN4007E D2 ISS270A D7 ISS270A ZD1 LED1 C1 0 1μ C11 0 1μ C12 0 1μ C5 1μ ...

Page 11: ...Approx 6 C Approx 4 C The values shown above refer to the case where the freezer temp control knob is set at MED Figure F 2 When the temperature of the refrigerator is higher R fan thermo senses the temperature and the refrigerator is cooled efficiently by running of R fan motor R fan thermo heater energizes when the door is opened intend to promote to running of R fan motor NOTE The refrigerator ...

Page 12: ...uring the operation time delay time of defrost time defrosted water is drained outside the refrigerator Timer contact is changed to cooling operation and the compressor starts running and the timer motor stops Defrost thermostat contact becomes ON when it s cooled And the timer motor starts running Figure F 3 Figure F 3 Figure F 4 Figure F 5 Figure F 6 TM COMP Defrost thermostat ON Compressor runn...

Page 13: ...ay be felt hot if touched by hand while the compressor is in operation If you are asked about this please explain that the hot pipe serve to prevent the dew generation Figure F 7 4 INSPECTION OF INITIAL STARTING 1 Inspection of cooling unit 1 Set the temperature control knob to MAX and check that the compressor starts to operate 2 Depress the door switch to run the fan and check that cool air is b...

Page 14: ...tion is controlled as follows 3 Plasmacluster Control 1 Plasmacluster operation will be performed when the following conditions gather 1 Lamp Under lighting 2 Compressor Under operation 3 Door Closed 4 Within The Plasmacluster operation time 2 If the sum total of Plasmacluster operation time will reach at the set time The Plasmacluster operation Time Plasmacluster operation will stop 3 After an op...

Page 15: ...C box cover RA sealer B RA sealer C Dial sealer R air guider A RA sealer A Damper thermo Defrost timer R fan thermo ass y Ionizer K Plasma holder Holder cover Plasma harness Figure A 1 Figure A 2 1 Forming sensor of Damper thermo Stick thermo cap sealer Less than 130 mm Damper thermostat 3 1 mm 5 1 mm Less than 12 mm 25 2 mm NOTE Minimum bending radius is R5mm There should be no gas leak by reform...

Page 16: ... by the paper tepe 10 25 5 Paper tape W30X50mm Paper tape W30X40mm B B Connecter should insert surely ２Ｐ Plasma holder Ionizer K Ionizer K Holder cover Holder cover Ionizer K Ionizer K Plasma harness R aire guider A R aire guider A R aire guider A Plasma holder Plasma holder 5 5 15 5 3 2P 2P 2P 2P ２Ｐ SEC B B Plasma harness Plasma harness Plasma harness RA sealer A RA sealer A RA sealer A RA sealer...

Page 17: ... Warning label R lamp box Propeller fan 80 R fan motor R fan motor holder A Fan clamp R fan motor holder B Figure A 6 Figure A 5 10 5mm Cut R C box cover Nylon band R fan thermo ass y Fan cover Defrost timer R fan thermo ass y Nylon band SEC G G G G 4 Fixing of Defrost timer R fan thermo ass y cover to R C box cover ...

Page 18: ...p Slit Slit of each Fan clamp and Propeller fan should not be at same position Detail of F Figure A 10 Figure A 9 Lamp 15W Warning label Figure A 11 1 Fixing of Lamp and Lamp socket 1 1 Screw Lamp 15W into Lamp socket 1 2 Fix Lamp socket on R lamp box by tapping screws Tapping screw Lamp socket Lamp 15W R lamp box ALUMINUM TAPE Figure A 7 Figure A 8 Fan motor Lamp socket DOUBLE CLAMPING WIRES 1 3 ...

Page 19: ... V cover sealer C Lead E V cover ass y Fan motor holder A Fan motor holder B Propeller Fan 100 Fan clamp Motor cushion U sealer handle Fan motor Figure A 12 Figure A 13 1 Sticking of Sealers to E V cover E V cover sealer B E V cover sealer D b E V cover sealer D a E V cover sealer A E V cover Sticking start b Sticking start a Sticking start Overlap 10mm min Front side Back side Sticking start ...

Page 20: ...sert it to the shaft of Fan motor Fan clamp Propeller fan 100 Fan clamp Slit Slit of each Fan clamp and Propeller fan should not be at same position Shaft 4 0 5mm Detail of D D 2 2 Insert the terminals of Lead EV cover ass y to R fan motor 2 3 Fix two Motor cushions to R fan motor and set it at Fan motor holder A and B Then fix with Tapping screw Fan motor holder A Fan motor holder B Motor cushion...

Page 21: ... Set metal side below F F Fuse ass y E V cover Fuse ass y Lead E V cover ass y Sec F F Sec E E Not come out of claw Take out lead wire from square hole to front and seal with E V cover sealer C FRONT SIDE more than 3 5mm more than 3 5mm Figure A 17 Figure A 19 1 2 3 4 5 6 7 8 9 F thermostat 3 F thermostat 4 Fuse 8 Fuse 7 Fan motor 1 2 Fan motor 9 RED inserted BROWN inserted WHITE Defrost thermo 5 ...

Page 22: ...capillary tube of F thermostat 42mm 13mm 20mm 20mm 230mm R10mm R10mm Note Bending radius of capillary tube should be from R5mm to R10mm Figure A 20 F F SEC F F 5 3 Set to E V cover Figure A 22 5 2 Insert terminal of Lead EV cover ass y RED BROWN front side back side Figure A 21 ...

Page 23: ...0M COOLING UNIT Figure C 1 Cooling unit Hot pipe L Side condenser Hot pipe DP condenser Hot pipe R Side condenser Evaporator Suction pipe Sub condenser Compressor Capillary tube Dryer Back condenser Mark Refrigerant flow Mark Brazing portion ...

Page 24: ...ipe to Dryer Hot pipe to Dryer Dryer Dryer support L band C Compressor oil cooler to Connector pipe Backcon connector to Hot pipe S P Connector to Compressor s suction tube Charge pipe to Compresser Compresser discharge pipe to Sub condenser ass y Sub condenser ass y to Compresser oil cooler Suction pipe ass y to S P connector Dryer to Capillary tube Connector pipe to Back condenser Compressor but...