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REFRIGERATOR SERVICE MANUAL

CAUTION
BEFORE SERVICING THE UNIT, READ THE "SAFETY PRECAUTIONS" IN THIS MANUAL.

MODEL: GC-151

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 ........................................................................................................................................................ 11-12 ......................................................................................................................................... 13-

EXPLODED VIEW

REPLACEMENT PARTS LIST

SAFETY PRECAUTIONS
Please read the following instructions before servicing your refrigerator. 1. Check the refrigerator for current leakage. 2. To prevent electric shock, unplug before servicing. 3. Always check line voltage and amperage. 4. If you use any kind of appliance, check regular current, voltage and capacity. 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. 7. Close the top door before opening the bottom door. Otherwise, you might hit your head when you stand up. 8. When tilting the refrigerator, remove any materials on the refrigerator, especially the thin plates(ex. Glass shelf or books.) 9. When servicing the evaporator, wear cotton gloves. This is to prevent injuries from the sharp evaporator fins. 10. Leave the disassembly of the refrigerating cycle to a specialized service center. The gas inside the circuit may pollute the environment.

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SERVICING PRECAUTIONS
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)
POINT TO BE BROKEN CHARGE TUBE EXTENSION FEMALE HANSEN

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)

TO THE R-134a CYLINDER

MALE HANSEN

TO THE REFRIGERATION SYSTEM

Figure 4
SERVICE TUBE EXTENSION SOLDERING POINT

Figure 1

Figure 2

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)

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)
FILLING OR CHARGE TUBE VALVE TO BE OPENED WHEN REFILLING

TO THE REFRIGERATION SYSTEM

TO THE CHARGE CYLINDER

TO THE VACUUM PUMP PRESSURE GAUGE

VALVE TO BE CLOSED AFTER VACUUM TO THE VACUUM PUMP

Figure 5

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

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.

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1. SPECIFICATIONS
ITEMS DOOR TYPE CONDENSER TYPE SPECIFICATIONS 1 DOOR WALL CONDENSER (FLUSH BACK) DEFROSTING SYSTEM TEMPERATURE CONTROL MANUAL KNOB DIAL ITEMS INSULATION DOOR CABINET EVAPORATOR DIMENSION (mm) NET WEIGHT (kg) REFRIGERANT LUBRICANT OIL SPECIFICATIONS POLYURETHANE POLYURETHANE ROLL BOND TYPE 484X549X850 (WXDXH) 30kg R-134a (115g) FREOL @22G (180cc)

2. PARTS IDENTIFICATION
EVAPORATOR(Door Inside) - The heart of the refrigerator. - It evaporates the refrigerant fluid and thereby absorbs heat from the surrounding.

ICE CUBE TRAY(Door Inside) Ice cube is easy to remove from the tray

THERMOSTAT Regulates the operation of the motor and controlls the temperature inside the refrigerator.

DRIP TRAY Catches the water that drips off the evaporator when defrosting. PLASTIC COATED SHELVES Have full width and can slide out.

SUPPORTER CAN Keeps any kinds of bottles.

GLASS LID & VEGETABLE CONTAINER

MAGNETIC GASKET - Tight fitting door seal keeps all the cooling power locked inside. - No hooks or latches.

NOTE : This is a basic model. The shape of refrigerator is subject to change. -4-

3. DISASSEMBLY
A. DOOR
1. Loosen 3 screws holding an upper hinge to separate the door body. (Figure 7)

C. COMPRESSOR AND PTC

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

Note: Reversing the doors is not covered by the warranty. B. THERMOSTAT

1. Pull Konb Dial. 2. Loosen 1 screw holding the case and pull it out to remove the Thermo cover. (Figure 8)

Figure 10

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 attatched 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 normal operation of OLP.

Figure 8 3. Pull out thermostat in the theremostat cover, and disconnect lead wires.(Figure 9) NOTE : Replace a new thermostat with proper specification.

Figure 9

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4. CIRCUIT DIAGRAM

NOTE: Lamp is option part.

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5. TROUBLESHOOTING
DEFECT
GROUP PARTIALLY OR COMPLETELY OUT OF REFRIGERANT CHARGE

EFFECT
Evaporator dose not frost even though motor-compressor runs continually.

CAUSE
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. 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 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. There is air in a refrigerating system when during the filling phase vacuum is not effected or it is not adequately done.

REMEDY
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.

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 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. 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. The system dose not work and the "clixson" intervenes interrupting delivery to the motor-compressor.

Group must be drained and subsequently refilled after carefully creating vacuum.

BLOCKED CAPILLARY

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. In case of short circuit, the breakdown is due to the electric winding: if blocked, there is a mechanical failure in the motorcompressor. 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 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.

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. The motor-compressor must be replaced and then proceed with refilling.

MOTORCOMPRESSOR SHORT-CIRCUITED OR BLOCKED

MOTORCOMPRESSOR DOSE NOT COMPRESS

No frost forms on the evaporator even if the motor-compressor is apparently running regulary.

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 motor-comprossor must be substituted and then proceed with the refilling.

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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.

Replace the components.

Poor running of the Compressor.

Measure the starting voltage.

Low voltage

Increase the voltage.

Check if the current flows at the contacting point of the starting system.

Poor contacting point and broken

Replace the device.

Check if the current flowing of the sub coil of the Compressor.

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.

Compressor runs.

Frost doesn't form at the Evaporator when operating set for more than 30 min.

Refrigerant leaks. Poor compressing.

Repair the Compressor.

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COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS

Separate the PTC-STARTER from the Compressor and measure the voltage between M and C of the Compressor. Equal to the applied voltage. (Rating voltage 10%)

Power Source

YES

The applied voltage is not in the range of Rating Voltage 10%.

Advice the customer to use in the fixed range.

Check the resistance of the Compressor Motor.

Test the resistance among M-C, S-C, and M-S. NO Replace the Compressor.

YES

Check the resistance of the PTC.

Test the resistance of the both terminals in the PTC-STARTER.

YES

NO

Replace the PTC-STARTER.

Check OLP.

Check if applying a regular OLP.

YES

OLP works within 30 sec. in forcible OLP operation by turning instant power on and off.

YES NO

5
Replace OLP.

NO

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.

Normal.

Starts at the voltage of more than 90%.

Check the starting state at the regular voltage above. NO Replace the PTC.

YES

Normal.

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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.

Poor starting or no operating of the Compressor.

The value is in the range of 15-28 for the 22 PTC.

Normal

Check another electric components.

The value is 0.

Abnormal

Replace the PTC.

The value is .

Abnormal

Replace the PTC.

Separate the OLP from the Compressor and check resistance value between two terminals of OLP with Tester.

YES

Check another electric components.

NO

Replace OLP.

5
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6. EXPLODED VIEW
NOTE: 1. The shape of parts are subject to change in different localities. 2. : optional parts GC-151S

- GLASS, COVER-T/V : 149B - STELL, COVER-T/V : 136C, 149A - LAMP : 406B, 408B, 409B

302A

410G 410A

281B

411A 416A

328A 328B 313A

318A 317A

283A

307A 308A 104A 309A 312A

310A 315A

127A

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*: optional parts GC-151S

126A

110A

*
125A

409B

408B

*
110C

406B

110B

110F

136A

*
136A

201A

281D

136C

* * *

149A 207A

149B

151A

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REPLACEMENT PARTS LIST

BUYER NAME:CIL COLOR:Super White S AL LOC No. R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R 104A 110A 110B 110C 125A 126A 127A 136A 149B 151A 201A 207A 281B 283A 302A 307A 308A 309A 310A 312A 313A 315A 317A 318A 328B 406B 408B 409B 410A 411A PART No. Description SPEC REMARK MODEL NAME:GC-151SA LG REFERENCE NO:GC-151SA.CSWPCIL

4778JQ3003A LEG,ADJUST 6930JR1001G THERMOSTAT 3550JD1062H COVER,THERMO 4940JA3007A KNOB,THERMO 3390JA3006A TRAY,ICE 3390JA3020A TRAY,DRIP 3580JD1041B DOOR,EVA 5026JA1180C SHELF,R 4890JA2002D GLASS,SHELF 3390JA3052C TRAY,VEGETABLE 5433JA2038D DOOR FOAM ASSEMBLY,R 4270JA3002C BAR 4775JA3010C HINGE ASSEMBLY,U 4775JA2021C HINGE ASSEMBLY,L 5421JA0037A EVAPORATOR ASSEMBLY 2521CRA3001 COMPRESSOR,SET ASSEMBLY 6748C-0003C P.T.C ASSEMBLY 6750C-0004A O.L.P 3550CT0008A COVER,P.T.C J734-00005A RUBBER,SEAT 1PZZJQ3008A PIN,DRAWING 3103JQ3001C COMP BASE ASSEMBLY,STD 5850JQ2001E DRIER 4930JQ3001A HOLDER,DRIER 5040JQ3006A RUBBER,DAMPING 6600JR2001B SWITCH,[PUSH] 6621JR2002A SOCKET ASSEMBLY,LAMP 6912JR3001B LAMP,[VACUUM] 4810JQ2009A BRACKET,TIMER 6411JR1001F POWER CORD ASSEMBLY 240V 15W CLEAR E14/26X18 NGS T22 PS103 PEC 250VAC 0.5A 13.5MM S/WHITE NS30LAEG BR1EOIL P330MC LUCON PX9001F #250 MURATA 4TM149NFBYY-520