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Refrigerator: Service Manual
Refrigerator: Service Manual
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REFRIGERATOR
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT, READ THE "SAFETY
PRECAUTIONS" IN THIS MANUAL.
Ref. No.
GR-332
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.
2. To prevent electric shock, unplug before servicing. Otherwise, you might hit your head when you stand up.
3. Always check line voltage and amperage. 8. When tilting the refrigerator, remove any materials on
the refrigerator, especially the thin plates(ex. Glass
4. If you use any kind of appliance, check regular current,
shelf or books.)
voltage and capacity.
9. When servicing the evaporator, wear cotton gloves.
5. Don't touch metal products in the freezer with wet
This is to prevent injuries from the sharp evaporator
hands. This may cause frostbite.
fins.
6. Prevent water from following onto electric elements in
10. Leave the disassembly of the refrigerating cycle to a
the mechanical parts.
specialized service center. The gas inside the circuit
may pollute the environment.
-2-
MALE HANSEN
TO THE REFRIGERATION
SYSTEM
Figure 4
VALVE TO BE CLOSED
TO THE AFTER VACUUM
VACUUM
PUMP TO THE
VACUUM Figure 5
PUMP
PRESSURE
GAUGE
In addition, check the graduated scale on the cylinder for
Figure 3 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
Air evacuating from the system begins as soon as the R-134a has dropped to 610 grams, remembering that the
pump starts. The refrigeration system must be kept under indicator shows a lower limit of meniscus. Do this after
vacuum until the reading on the low-pressure gauge choosing the scale corresponding to the gas pressure
indicates vacuum (0 absolute, -1 atm., -760 mm hg) in any different scales reported as the same gas pressure
case it is advisable to keep the pump running for about 30 indicated by the pressure gauge on the top of the column.
minutes. (Figure 3) To make R-134a flow into the system, open the valve
In case that a considerable leakage occurs it will be placed at the base of the cylinder and connected to the
necessary to stop the vacuum pump and to add asmall filling tube. The amount of Freon cannot be added to the
quantity of Freon to the system, if vacuum should not be system all at once because it may cause a blocking of motor-
obtained (pressure gauge can't fall to 1 atmosphere), start compressor. Therefore, proceed by adding the original
the refrigeration unit and find the leakage with the special quantity of about 20-30 grams and close the valve
leak-finder. When the defective soldering point is visible, immediately.
re-do it after opening the extension tube valve and The pressure rises and the motor compressor must start
reestablishing the normal outside pressure inside the sucking the gas and lowering the pressure again. Regulate
group. the valve again, maintaining the same manner until
Because the melted alloy is sucked into the tubes and reaching to the quantity of R-134a established for the
block them, the pressure must be rebalanced when system being charged. When the system is running, the
vacuum is in the system in soldering. As soon as the suction pressure must be stabilized between 0.30 to
0.6(0.10 to 0.4) atmosphere.
-3-
( ) : OPTION
*
-4-
FREEZER
COMPARTMENT
Freezer Temperature
Control Dial Wine Rack(Option)
Ice Trays
Freezer Shelf
(Plastic or Steel) Freezer Door Rack
Twisting Ice Serve(Option)
or
General Type Ice Making
REFRIGERATOR
COMPARTMENT Egg Storage Rack
Deodorizer
(Option) Dairy Corner
Chilled Room (Option)
Temperature Movable Rack
Control Dial
Lamp
F.I.R Lamp (Option) Bottle Guide
-5-
HINGE COVER
BOLT
HINGE
Figure 9
Figure 6
3-3 THERMOSTAT
3. Pull out the door gasket to remove from the door foam 1. Remove the Cover Lamp-R by the use of '–––' type
Ass'y. driver inserting in the low holes of the cover.
2. Loose 2 screw.
3. Pull the Control Box-R.
GASKET
4. Disconnect the Housing of lead wire.
5. Separate the INSU'Multi Duct and Control Box-R.
6. Dissasemble the Knob.
7. Separate the Thermostat and Control Box-R.
8. Separate the Thermostat and Resistor.
9. Disconnect the lead wire.
INSU' MULTI DUCT
THERMOSTAT
Figure 7 RESISTOR
CONT' BOX-R
● Refrigerator Door
1. Loosen hexagonal bolts fixing the lower hinge to the
body to remove the refrigerator door only.
COVER LAMP-R
Figure 10
LOWER HINGE
2. Pull out the door gasket to remove from the door foam
Ass'y.
CAP
Figure 11
-6-
BRACKET
FAN Figure 17
GRILLE
Figure 12
3-7 CONTROL BOX-R
1. Remove the Cover Lamp-R.
3-5 DEF' CONTROL ASSY
Def control Assy consists of Defrost Thermostat and FUSE–M.
Defrost Thermostat functions to defrost automatically and it
CONTROL BOX-R
is attached to metal side of the Evaporator and senses
Temp.
Fuse-M is a kind of safety device for preventing over-
heating of the Heater when defrosting.
At the temperature of 77°C, it stops the emission of heat COVER LAMP
from the Heater.
1. Pull out the Shroud after removing the Grille.
2. Separate the connector connected with the Def Control Figure 18
Assy and replace the Def Control Assy after cutting the
Tie Wrap and removing the Holder Fuse. (Figure 14)
2. Loosen 2 screws.
FAN DEF-THERMO
SHROUD-F 3. Full the Control Box-R.
4. Separate the lead wire Housing.
FUSE-M
HOLDER FUSE
Figure 13 Figure 14
-7-
Separating the Hinge-C D and the Refrigerator Separating the Hinge Lower F.
3 Door E. 4
5
4 6
-8-
Move the Cap H, Bracket I of the Refrigerator Move the Cap J and Assemble the Hinge-C K.
7 Door. 8 After removing the washer.
8 10
Assembe the Door Stopper-F K for Right Move the Cap L and Assemble the Freezer
9 Opening Type. 10 Door C.
3
3 12
5
11
Move the Pin Position M of the Hinge Upper. Assemble the Hinge Upper B and the Cap A.
11 12
13
2
1
-9-
- 10 -
5. CIRCUIT DIAGRAM
YES
No Voltage. OLP disconnected? Replace OLP. 5
Check connection
condition.
Reconnect.
YES
Check the Check the resistance 3
2 resistance of among M-C, S-C and
Motor M-S in Motor NO Replace Compressor.
Compressor. Compressor. 3 4 5
YES
Check the Check the resistance 4
3 resistance of of two terminals in
NO Replace
PTC-Starter. PTC-Starter. 5
PTC-Starter.
YES
YES
Check if applying OLP works within 5
4 Check OLP.
a regular OLP. 30 sec. in forcible
OLP operation by NO
Replace OLP.
turning instant power
on and off.
NO
Check YES
5 Measure minimum Components start in O.K.
starting state. starting voltage after 5 the voltage of Rating
min. for balancing cycle Voltage ±10%
pressure and cooling
the PTC. below. 1
NO
- 12 -
The value is ∞.
YES
Separate the OLP Check another
from Compressor and electric components.
check resistance
value between two
terminals of OLP with NO
a Tester. (Figure 23) Replace OLP.
4
6 5
3
Figure 22 Figure 23
6-3 DEFROST TIMER
Position the Cam Shaft to NO Replace the
Normal operation of The resistance is ∞.
the point of first 'click' Defrost Timer.
the Defrost Timer is
sound and check the
impossible.
current between terminals
No. 1 (brown) and
No. 2 (bright orange). Next, YES The resistance is
No defrosting. Replace the
position the Cam Shaft to 0 Ω or variable. Defrost Timer.
the point of second 'click'
sound and check the
current between terminals
Poor cooling. No. 1 (brown) and The resistance is about .Check the other
No. 4 (black). (Figure 24). 220V 50/60Hz : 7~30k Ω
120V 50/60Hz : 3~ 5k Ω electric components.
NO Replace the
Turn the Cam Shaft.
Defrost Timer.
Cam Shaft
Figure 24
- 13 -
- 14 -
Cooling is • Is the power cord unplugged from the outlet? • Plug to the outlet.
impossible. • Check if the power S/W is setted to OFF. • Set the switch to ON.
• Check if the fuse of power S/W is shorted. • Replace a regular fuse.
• Measure the voltage of power outlet. • If voltage is low, wire newly.
Cooling ability • Check if the set is placed close to wall. • Place the set with the space of about 10cm.
is poor. • Check if the set is placed close to stove, gas • Place the set apart from these heat sources.
• cooker and direct rays. •
• Is the ambient temperature high or • Make the ambient temperature below.
• the room door closed?
• Check if putting in hot food. • Put in food after they get cold.
• Did you open the door of the set too often • Don't open the door too often and close
• or check if the door is closed up? • it firmly.
• Check if the Thermostat is set to WARM. • Set the knob to MID.
Freezing ability • Is the ambient temperature too LOW(10˚C)? • For colder freezer, turn the CLOD AIR CONTROL
is poor to "7"~"9", and the TEMP. CONTROL to 7~9.
• Check if thermostat is set to 1~3? • Check if the registor is well attached to
thermostat with Al Tape.
Food in the • Are food placed in cooling air outlet? • Place food in high temperature section.
Refrigerator • (Front Part)
are frozen. • Check if the Thermostat is set to COLD. • Set the knob to MID.
• Is the ambient temperature within 5°C? • Set the knob to WARM.
Dew or ice • Are watery food kept? • Seal up watery food with vinyl wrap.
forms in the • Check if putting in hot food. • Put in food after getting cold.
chamber of • Did you open the door of the set too • Don't open the door too often and close
the set. • often or check if the door is closed up. • it firmly.
Dew forms • Check if ambient temperature and humidity • Wipe dew with a dry cloth. This happening
in the Out Case. • are high. • is solved in low temperature and humidity
• naturally.
• Is the gap in the door packing? • Fill up the gap.
Abnormal • Is the set positioned in a firm and even place? • Adjust the Leveling Screw, and place
noise generates. • in the firm place.
• Does any unnecessary objects exist • Remove the objects.
• in the back side of the set?
• Check if the Cover Evaporating Tray is omitted. • Place it on an original position.
• Check if the cover of mechanical room • Place the cover at an original position.
• in below and front side is taken out.
To close the door • Check if the door packing becomes dirty • Clean the door packing.
is not handy. • by filth such as juice.
• Is the set positioned in a firm and even place? • Position in the firm place and adjust the
• Leveling Screw.
• Are too much food put in the set? • Keep foods from reaching to the door.
Ice and food • Check if the inside of the set becomes dirty. • Clean the inside of the set.
smell unpleasant. • Did you keep smelly foods without wraping? • Wrap smelly food.
• It smells plastic. • The new products smell plastic, but it is
• removed after 1-2 weeks.
● In addition to the items described above, refer to the followings to solve the complaint.
Check Refrigerating
The cycle is faulty. Repair the cycle.
Cycle.
- 15 -
TEMPERATURE
STATE OF STATE OF THE
CAUSE OF THE REMARKS
THE SET EVAPORATOR
COMPRESSOR
PARTIAL Freezer and Low flowing sound of A little high • A little Refrigerant
LEAKAGE Refrigerator Refrigerant is heard and more than • discharges.
don't get cold frost forms in inlet only ambient • Normal cooling is possible
LEAKAGE
WHOLE Freezer and Flowing sound of Refrigerant Equal to ambient • No discharging of Refrigerant.
LEAKAGE Refrigerator is not heard and frost isn't temperature. • Normal cooling is possible
don't get cold formed. • when injecting Refrigerant
at all. • of regular amount.
PARTIAL Freeze room and Flowing sound of Refrigerant A little high • Normal discharging of
CLOGGED BY DUST
WHOLE Freezer and Flowing sound of Refrigerant Equal to ambient • Normal discharging of
CLOG Refrigerator is not heard and frost isn't temperature. • Refrigerant.
don't get cold. formed.
MOISTURE Cooling operation Flowing sound of Refrigerant Low than • Cooling operation restarts
CLOG stops periodically. is not heard and frost melts. ambient • when heating the inlet of
temperature • capillary tube.
COMPRESSION
COMP- Freezer and Low flowing sound of A little high • The pressure of high
DEFECTIVE
NO COMP- No compressing Flowing sound of Refrigerant Equal to ambient • No pressure of high pressure
RESSION operation. is not heard and no frost. temperature. • part in compressor.
▼ Leakage Detection
Observe discharging point of refrigerant which may be in oil discharging part in compressor and hole of evaporator.
- 16 -
2 Welding Nitrogen Weld under Nitrogen To protect oxide - Refer to repair note in each part.
pressure atmosphere. scale formation. - R-134a refrigerant is more
(N2 pressure: susceptible to leaks than R-12 and
0.1~0.2 kg/cm2) requires more care during welding.
- Do not apply force to pipes before and
after welding to protect pipe from cracking.
3 N2 sealed Confirm Confirm air leaking sounds To protect - In case of evaporator parts, if it
parts N2 leak when removing rubber cap. moisture doesn't make sound when removing
Sound: usable penetration. rubber cap, blow dry air or N2 gas for
No sound: not usable more than 1 min and use the parts.
Vacuum EA High and low pressure sides Vacuum efficiency can be improved
are evacuated at the same by operating compressor during
time for models above 200 l. evacuation.
Vacuum EA Use R-134a exclusive To protect mixing The rubber pipes for R-12 refrigerant
piping manifold. of mineral and shall be melted when they are used for
ester oils. R-134a refrigerant (causes of leak).
5 Refrigerant EA Use R-134a exclusively. Do not mix with - Do not weigh the refrigerant at too
weighing Weighing allowance: ±5g R-12 refrigerant. hot or too cold an area.
Note: Winter: -5g (77°F[25°C] is adequate.)
Summer: +5g - Make Copper bombe
Socket: 2SV Plug: 2PV R-134a
Note: Do not burn O-ring (rubber)
during welding.
7 Leak check - Do not use soapy water for Defect - Check oil leak at refrigerant leak
check. It may be sucked refrigerant leak area. Use electronic leak detector if
into the pipe by vacuum. area. oil leak is not found.
- The electronic leak detector is very
sensitive to halogen gas in the air. It
also can detect R-141b in urethane.
Please practice, therefore, many
times before use.
- 17 -
8. EXPLODED VIEW
The parts of refrigerator and the shape of each part are subject to change in different localities.
Capacitors and fuse are optional parts.
*: optional parts.
281A
103B
281B 301A
103A
401A
501F
411A 501A
281D
418A
416A
* 410G
125L
282B
501K
* 410H
129A
410C * 410B
406B
*
410J 410A
304A
* 604E
* 604F
120A
120E
120B
105A 120C
409B
317A
318A 409C
307A 310A
283B
314A
308A
106A
309A 329D
323B
106B
329C *
407A
103C
158F
158C
420A 109B
327A 315A
312A
319A
328A 328B
319C
315B
315C
- 33-
Downloaded from www.Manualslib.com manuals search engine
#EV#
405C
405A
330B
404A
329A
200A
203A
205A
332A 201A
*
212G
205A
*110B
* 125A
* 131A
* 125H
* *
125J 149A
* 149D
* 149A
235A
243A
210A
241A
*149B
233A
230A
* 140A
249A 231A
* 149C
* 149C
* 149C
* 149C
237A
241B
154A
241C
241D
243A
151A
- 19 -