REFRIGERATOR SERVICE MANUAL CAUTION

REFRIGERATOR SERVICE MANUAL CAUTION
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REFRIGERATOR
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT, READ THE "SAFETY
PRECAUTIONS" IN THIS MANUAL.
MODEL: GC-051
CONTENTS
SAFETY PRECAUTIONS ................................................................................................................................................... 2
SERVICING PRECAUTIONS .............................................................................................................................................. 3
SPECIFICATIONS ............................................................................................................................................................... 4
PARTS IDENTIFICATION .................................................................................................................................................... 4
DISASSEMBLY ................................................................................................................................................................... 5
DOOR ............................................................................................................................................................................... 5
THERMOSTAT .................................................................................................................................................................. 5
COMPRESSOR AND PTC ................................................................................................................................................ 5
CIRCUIT DIAGRAM ............................................................................................................................................................ 6
TROUBLESHOOTING .................................................................................................................................................... 7-10
NO COOLING .................................................................................................................................................................... 8
COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS ....................................................................................... 9
PTC
................................................................................................................................................................................ 10
EXPLODED VIEW .............................................................................................................................................................. 11
REPLACEMENT PARTS LIST
........................................................................................................................................ 12-
SAFETY PRECAUTIONS
Please read the following instructions before servicing your
refrigerator.
1. Check the refrigerator for current leakage.
7. Close the top door before opening the bottom door.
Otherwise, you might hit your head when you stand up.
2. To prevent electric shock, unplug before servicing.
8. When tilting the refrigerator, remove any materials on
the refrigerator, especially the thin plates(ex. Glass
shelf or books.)
3. Always check line voltage and amperage.
4. If you use any kind of appliance, check regular current,
voltage and capacity.
9. When servicing the evaporator, wear cotton gloves.
This is to prevent injuries from the sharp evaporator
fins.
5. Don't touch metal products in the freezer with wet
hands. This may cause frostbite.
6. Prevent water from following onto electric elements in
the mechanical parts.
10. Leave the disassembly of the refrigerating cycle to a
specialized service center. The gas inside the circuit
may pollute the environment.
-2-
SERVICING PRECAUTIONS
vacuum operation is over, add the quantity in grams of
R-134a to the refrigeration system. Remember that every
system has an exact quantity of R-134a with a tolerance of
±5 grams that can be added. (Figure 4)
AIR RECHARGING IN COMPRESSOR
Test the refrigeration system connecting it electrically before
refilling operation. It is necessary to ascertain the function
of the motor-compressor and identify the defects
immediately. If defects have been found, empty the old
system of possible R-134a residue by breaking off the end
of the extension piece at its narrow point. (Figure 1)
Replace the filter and any damaged components. Unsolder
and pull off the piece remaining inside the service tube and
then attach an complete extension with male Hansen and
at last, solder it to the same tube again. (Figure 2)
CHARGE TUBE
EXTENSION
POINT TO BE BROKEN
FEMALE
HANSEN
TO THE R-134a CYLINDER
MALE HANSEN
TO THE REFRIGERATION
SYSTEM
Figure 4
SERVICE TUBE EXTENSION
SOLDERING POINT
Figure 1
Figure 2
Before performing this operation (if the vacuum pump and
refilling cylinder are connected), make sure that the valve
placed between the vacuum pump and the refilling tube are
closed in order to keep the Freon for addition to the system.
(Figure 5)
It is necessary to execute the soldering operation with
valve open so that the fumes caused by oil residue can
come out freely without blowholes between two tubes
during the heating the of the point to be soldered.
The extension fitted with the male Hansen is connected to
the female fitting of the vacuum pump tube. (Figure 3)
FILLING OR
CHARGE TUBE
VALVE TO BE OPENED
WHEN REFILLING
TO THE REFRIGERATION
SYSTEM
TO THE CHARGE
CYLINDER
VALVE TO BE CLOSED
AFTER VACUUM
TO THE
VACUUM
PUMP
TO THE
VACUUM
PUMP
PRESSURE
GAUGE
Figure 5
In addition, check the graduated scale on the cylinder for
the quantity of R-134a to be added, for example, if we
have 750 grams of Freon in the cylinder and must add 140
grams to the group, this amount will be reached when
R-134a has dropped to 610 grams, remembering that the
indicator shows a lower limit of meniscus. Do this after
choosing the scale corresponding to the gas pressure
different scales reported as the same gas pressure
indicated by the pressure gauge on the top of the column.
To make R-134a flow into the system, open the valve
placed at the base of the cylinder and connected to the
filling tube. The amount of Freon cannot be added to the
system all at once because it may cause a blocking of motorcompressor. Therefore, proceed by adding the original
quantity of about 20-30 grams and close the valve
immediately.
The pressure rises and the motor compressor must start
sucking the gas and lowering the pressure again. Regulate
the valve again, maintaining the same manner until
reaching to the quantity of R-134a established for the
system being charged. When the system is running, the
suction pressure must be stabilized between 0.30 to
0.6(0.10 to 0.4) atmosphere.
Figure 3
Air evacuating from the system begins as soon as the
pump starts. The refrigeration system must be kept under
vacuum until the reading on the low-pressure gauge
indicates vacuum (0 absolute, -1 atm., -760 mm hg) in any
case it is advisable to keep the pump running for about 30
minutes. (Figure 3)
In case that a considerable leakage occurs it will be
necessary to stop the vacuum pump and to add asmall
quantity of Freon to the system, if vacuum should not be
obtained (pressure gauge can't fall to 1 atmosphere), start
the refrigeration unit and find the leakage with the special
leak-finder. When the defective soldering point is visible,
re-do it after opening the extension tube valve and
reestablishing the normal outside pressure inside the
group.
Because the melted alloy is sucked into the tubes and
block them, the pressure must be rebalanced when
vacuum is in the system in soldering. As soon as the
-3-
1. SPECIFICATIONS
ITEMS
SPECIFICATIONS
DOOR TYPE
1 DOOR
CONDENSER TYPE
WALL CONDENSER
ITEMS
INSULATION
SPECIFICATIONS
DOOR
POLYURETHANE
CABINET
POLYURETHANE
(FLUSH BACK)
EVAPORATOR
ROLL BOND TYPE
DEFROSTING SYSTEM
MANUAL
DIMENSION (mm)
443X450X501 (WXDXH)
TEMPERATURE CONTROL
KNOB DIAL
NET WEIGHT (kg)
15kg
REFRIGERANT
R-134a (55g)
LUBRICANT OIL
FREOL @22G (180cc)
2. PARTS IDENTIFICATION
EVAPORATOR
- The heart of the refrigerator.
- It evaporates the refrigerant
fluid and thereby absorbs
heat from the surrounding.
- Made of pure aluminum.
THERMOSTAT
Regulates the operation of
the motor and controls the
temperature inside the
refrigerator.
BUTTER RACK
Keeps butter.
ICE CUBE TRAY
Ice cube is easy to remove
from the tray
MAGNETIC DOOR SEAL
Keeps the refrigerator
virtually airtight all along
the edge, but is
nevertheless easy to open.
PLASTIC SHELF
It has full width and can
slide out and catches the
water that drips off the
evaporator when
defrosting.
BOTTLE SUPPORTER
Keeps bottles, cans or jars.
-4-
3. DISASSEMBLY
A. DOOR
C. COMPRESSOR AND PTC
1. Loosen 1 screw holding an cover hinge and 3 screws
holding an upper hinge to separate the door body.
(Figure 7)
1. Remove Protector Cover, Power Cord and Lead Wire
first. (Figure 10)
2. Separate OLP.
3. Separate PTC.
4. Remove the Compressor Base by loosening 4 bolts
fixed to base plate of the set. (Figure 11)
Figure 7
Figure 10
Note: Reversing the doors is not covered by the
warranty.
B. THERMOSTAT
Figure 11
5. Remove the Compressor by loosening 2 earth screws
next to Compressor.
NOTE : Replace the Compressor, after peeling off
painted part of earth terminal.
• Compressor inhales the gas evaporated from Evaporator
and condenses this gas and then delivers to Condenser.
• PTC is abbreviation of Positive Temperature Coefficient
and is attached to the Compressor, and operates motor.
• OLP prevents Motor coil from being started inside
Compressor.
• Do not turn the Adjust Screw of OLP in any way for
nomal operation of OLP.
1. Pull Knob Dial
2. Loosen 1 screw holding the case and pull it out to
remove the Thermo cover. (Figure 8)
Figure 8
3. Pull out thermostat in the thermostat cover, and
disconnect lead wires. (Figure 9)
NOTE : Replace a new thermostat with proper specification.
Figure 9
-5-
4. CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
THERMOSTAT
BK
GN(GN/YL)
BK
YL : YELLOW
BK : BLACK
BL : BLUE
GN : GREEN
OVER LOAD
PROTECTOR
POWER SUPPLY CORD
YL
C
5
BL
3
6
S
COMPRESSOR
P.T.C STARTER
THE PLUG TYPE ON CIRCUIT DIAGRAM IS SUBJECT
TO CHANGE IN DIFFRENT LOCALTIES.
J652-00041A
NOTE : These are basic circuit diagram and the specifications vary in different localities.
-6-
5. TROUBLESHOOTING
DEFECT
EFFECT
CAUSE
REMEDY
GROUP PARTIALLY
OR COMPLETELY
OUT OF
REFRIGERANT
CHARGE
Evaporator dose not frost even
though motor-compressor runs
continually.
An empty refrigerant system
indicates a leakage of R12. This loss
is generally to be looked for at the
soldering points connecting the
various components or in an
eventual hole in the evaporator
made by the user.
Leakage must be eliminated by
resoldering the defective point or
substituting the damaged
evaporator.
EXCESSIVELY
FULL
This defect is indicated by the
presence of water outside
refrigerator near the motor caused
by formations of ice on the return
tube.
If in the refrigerant system a quantity
of R12 is introduced which is greater
than that indicated, the excess gas
dose not terminate its expansion in
the evaporator but proceeds into the
return tube.
The system must be emptied and
subsequently refilled introducing the
correct quantity of R-134a.
HUMIDITY IN THE
SYSTEM
This defect is indicated by the partial
frosting of the evaporator and by
continual defrosting cycles
determined by the interruption of the
flow of gas on the evaporator. The
motor compressor keeps running.
The refrigerant system is humid
when there is a small percentage of
water present which, not completely
retained by the dehydrator filter,
enters into circulation with the Freon
and freezes at the capillary exit in
the evaporator.
The system must be emptied and
then refilled after eliminating the
humidity.
PRESENCE OF AIR
IN THE SYSTEM
Poor performance of the refrigerant
system which is indicated: on the
evaporator with a slight frost which
dose not freeze and an excessive
overheating of the condenser and
motor-compressor.
There is air in a refrigerating system
when during the filling phase
vacuum is not effected or it is not
adequately done.
Group must be drained and
subsequently refilled after carefully
creating vacuum.
BLOCKED
CAPILLARY
Because of the lack of circulation
Freon in the system, there is no
frosting of the evaporator, while a
slight overheating of the first spiral
of the condenser is noted.
Eventual impurities contained in the
Freon or in the components of the
refrigeration system before
assembly and not retained by the
filter can obstruct the capillary.
To restore the system it must be
emptied, substitute the capillary or
the evaporator entirely in case the
capillary is coaxial with respect to
the return tube, then refill it.
MOTORCOMPRESSOR
SHORT-CIRCUITED
OR BLOCKED
The system dose not work and the
"clixson" intervenes interrupting
delivery to the motor-compressor.
In case of short circuit, the
breakdown is due to the electric
winding: if blocked, there is a
mechanical failure in the motorcompressor.
The motor-compressor must be
replaced and then proceed with
refilling.
MOTORCOMPRESSOR
DOSE NOT
COMPRESS
No frost forms on the evaporator
even if the motor-compressor is
apparently running regulary.
In this case there is a mechanical
failure in the diaphram valves which:
remaining continually open, do not
permit the piston to suck and
compressor the which
consequentely dose not circulate in
the system.
The motor-comprossor must be
replaced and then proceed with
refilling.
NOISY MOTORCOMPRESSOR
In case of mechanical failure in the
motor-compressor there in an
excessive noise when the system is
functioning: in case a suspension
spring is unhooked, banging will be
heard and there will be especially
strong vibrations when the system
starts up and stops.
The cause of the excessive noise is
normally to be sought for in a
mechanical break down, and only
rarely in the unhooking of one of the
suspension springs.
The motor-comprossor must be
substituted and then proceed with
the refilling.
-7-
NO COOLING
The Compressor
doesn't run.
Check if the current
flows at the contacting
point of the Thermostat.
Poor contacting point
Replace the
Thermostat.
Check the current
flowing of starting
system.
Shorted
Broken
Replace the device.
Check if the current
flows at the main coil of
the Comprossor.
Coil shorted
Replace the
Compressor.
Check the components
on the main circuit.
Poor running of the
Compressor.
Replace the
components.
Measure the starting
voltage.
Low voltage
Increase the voltage.
Poor contacting point
and broken
Replace the device.
Shorted
Replace the
Compressor.
Is the current amount of
the electric components
normal?
The coil of the
Compressor Motor is
worn out.
Repair the
Compressor.
Frost doesn't form at the
Evaporator when
operating set for more
than 30 min.
Refrigerant leaks.
Poor compressing.
Repair the
Compressor.
Check if the current
flows at the contacting
point of the starting
system.
Check if the current
flowing of the sub coil of
the Compressor.
Compressor runs.
-8-
COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS
1
Power Source
Separate the PTC-STARTER from
the Compressor and measure the
voltage between M and C of the
Compressor.
The applied voltage is not in the
range of Rating Voltage ± 10%.
2
Check the
resistance of the
Compressor Motor.
Equal to the applied
voltage. (Rating
voltage ± 10%)
YES
Advice the customer
to use in the fixed
range.
4
YES
Test the resistance among
M-C, S-C, and M-S.
2
3
NO
3
Replace the Compressor.
3
Check the
resistance of the
PTC.
Test the resistance of the both
terminals in the PTC-STARTER.
NO
4
Check OLP.
Check if applying a
regular OLP.
YES
YES
4
Replace the
PTC-STARTER.
OLP works within 30 sec.
in forcible OLP operation
by turning instant power on
and off.
4
YES
5
NO
Replace OLP.
NO
5
Check the
starting state.
Measure minimum starting voltage
after checking steps 1-3 above.
And measure the pressure balance
of the PTC with the interval of
more than 5 min.
Starts at the voltage
of 85% below.
Starts at the voltage of
more than 90%.
Check the starting
state at the regular
voltage above.
Normal.
YES
Normal.
NO
Replace the PTC.
-9-
5
PTC
First, separate the PTC from
the Compressor and check the
voltage between NO 5 and 6
in the PTC with a multitester
or Wheatstone Bridge.
Separate the OLP from
the Compressor and
check resistance value
between two terminals of
OLP with Tester.
The value is in the
range of 15-28 for
the 22Ω PTC.
Normal
Check another
electric
components.
The value is 0.
Abnormal
Replace the
PTC.
The value is ∞.
Abnormal
Replace the
PTC.
YES
Check another
electric components.
NO
Replace OLP.
5
6
Poor starting or no
operating of the
Compressor.
- 10 -
6. EXPLODED VIEW
NOTE: 1. The shape of parts are subject to change in different localities.
2. : optional parts GC-051S
*
318A
281A
317A
281B
127A
302A
410A
411A
*
110C
110B
416A
104A
110A
110F
283A
125A
313A
207A
307A
308A
309A
312A
136A
*
151A
201A
- 11 -
315A
310A
REPLACEMENT PARTS LIST
BUYER NAME:CIL
MODEL NAME:GC-051SA
LG REFERENCE NO:GC-051SA.CSWPCIL
COLOR:Super White
S AL LOC No.
PART No.
Description
SPEC
R
104A
4778JQ3003A LEG,ADJUST
R
110A
6930JR1001A THERMOSTAT
R
110B
3550JD1062B COVER,THERMO
R
110C
4940JA3007A
KNOB,THERMO
R
125A
3390JA3006A
TRAY,ICE
R
136A
5026JA1179A
SHELF,R
R
201A
5433JA2037A
DOOR FOAM ASSEMBLY,R
R
203A
4987JQ1004A GASKET ASSEMBLY,DOOR
R
207A
4270JA3002A
BAR
R
281A
3550JA2124A
COVER,HINGE
R
281B
4775JA3018A
HINGE ASSEMBLY,U
R
283A
4775JA2021C HINGE ASSEMBLY,L
R
302A
5421JA1141A
R
307A
2521CRA2401 COMPRESSOR,SET ASSEMBLY
R
308A
6748C-0003C P.T.C ASSEMBLY
NS24LBEG BR1EOIL
P330MC LUCON PX9001F
#250 MURATA
R
309A
6750C-0004D O.L.P
4TM117SFBYY-520
R
310A
3550CT0008A COVER,P.T.C
R
312A
J734-00005A
R
313A
1PZZJQ3008A PIN,DRAWING
R
315A
3102JQ1005B COMP BASE
R
317A
5850JQ2001E DRIER
R
318A
4930JQ3001A HOLDER,DRIER
R
410A
4810JQ2009A BRACKET,TIMER
R
411A
6411JR1001F
EVAPORATOR ASSEMBLY
RUBBER,SEAT
POWER CORD ASSEMBLY
REMARK
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