LG - GC 151 Manual

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CAUTIONBEFORE SERVICING THE UNIT, READ THE "SAFETYPRECAUTIONS" IN THIS MANUAL.

MODEL: GC-151

REFRIGERATORSERVICE MANUAL

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

REPLACEMENT PARTS LIST ................. .................. .................. .................. .................. ................. .................. ............. 13-

CONTENTS

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 wethands. 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.

SAFETY PRECAUTIONS

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AIR RECHARGING IN COMPRESSORTest the refrigeration system connecting it electrically beforerefilling operation. It is necessary to ascertain the functionof the motor-compressor and identify the defectsimmediately. If defects have been found, empty the old

system of possible R-134a residue by breaking off the endof the extension piece at its narrow point. (Figure 1)

Replace the filter and any damaged components. Unsolderand pull off the piece remaining inside the service tube andthen attach an complete extension with male Hansen andat last, solder it to the same tube again. (Figure 2)

It is necessary to execute the soldering operation withvalve open so that the fumes caused by oil residue cancome out freely without blowholes between two tubesduring the heating the of the point to be soldered.

The extension fitted with the male Hansen is connected tothe female fitting of the vacuum pump tube. (Figure 3)

Air evacuating from the system begins as soon as thepump starts. The refrigeration system must be kept undervacuum until the reading on the low-pressure gaugeindicates vacuum (0 absolute, -1 atm., -760 mm hg) in anycase it is advisable to keep the pump running for about 30minutes. (Figure 3)

In case that a considerable leakage occurs it will benecessary to stop the vacuum pump and to add asmallquantity of Freon to the system, if vacuum should not beobtained (pressure gauge can't fall to 1 atmosphere), startthe refrigeration unit and find the leakage with the specialleak-finder. When the defective soldering point is visible,re-do it after opening the extension tube valve andreestablishing the normal outside pressure inside thegroup.

Because the melted alloy is sucked into the tubes andblock them, the pressure must be rebalanced whenvacuum is in the system in soldering. As soon as the

vacuum operation is over, add the quantity in grams ofR-134a to the refrigeration system. Remember that everysystem has an exact quantity of R-134a with a tolerance of±5 grams that can be added. (Figure 4)

Before performing this operation (if the vacuum pump andrefilling cylinder are connected), make sure that the valveplaced between the vacuum pump and the refilling tube areclosed in order to keep the Freon for addition to the system.(Figure 5)

In addition, check the graduated scale on the cylinder forthe quantity of R-134a to be added, for example, if wehave 750 grams of Freon in the cylinder and must add 140grams to the group, this amount will be reached whenR-134a has dropped to 610 grams, remembering that theindicator shows a lower limit of meniscus. Do this afterchoosing the scale corresponding to the gas pressuredifferent scales reported as the same gas pressureindicated 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 thefilling tube. The amount of Freon cannot be added to thesystem all at once because it may cause a blocking of motor-compressor. Therefore, proceed by adding the originalquantity of about 20-30 grams and close the valveimmediately.

The pressure rises and the motor compressor must startsucking the gas and lowering the pressure again. Regulatethe valve again, maintaining the same manner untilreaching to the quantity of R-134a established for thesystem being charged. When the system is running, thesuction pressure must be stabilized between 0.30 to0.6(0.10 to 0.4) atmosphere.

SERVICING PRECAUTIONS

- 3 -

POINT TO BE BROKEN

SERVICE TUBE EXTENSION

CHARGE TUBEEXTENSION

FEMALEHANSEN

MALE HANSEN

SOLDERING POINT

Figure 1 Figure 2

TO THEVACUUMPUMP

PRESSUREGAUGE

Figure 3

TO THE R-134a CYLINDER

TO THE REFRIGERATIONSYSTEM

Figure 4

FILLING ORCHARGE TUBE

VALVE TO BE OPENEDWHEN REFILLING

VALVE TO BE CLOSEDAFTER VACUUM

TO THE CHARGECYLINDER

TO THE REFRIGERATIONSYSTEM

TO THEVACUUMPUMP

Figure 5



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1. SPECIFICATIONS

2. PARTS IDENTIFICATION

- 4 -

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

DRIP TRAYCatches the water thatdrips off the evaporator

when defrosting.

PLASTIC COATED

SHELVESHave full width and can

slide out.

GLASS LID & VEGETABLECONTAINER

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

THERMOSTATRegulates the operation of

the motor and controlls the

temperature inside therefrigerator.

SUPPORTER CANKeeps any kinds of bottles.

MAGNETIC GASKET- Tight fitting door seal

keeps all the cooling

power locked inside.

- No hooks or latches.

ITEMS SPECIFICATIONS

DOOR TYPE 1 DOOR

CONDENSER TYPE WALL CONDENSER

(FLUSH BACK)

DEFROSTING SYSTEM MANUAL

TEMPERATURE CONTROL KNOB DIAL

ITEMS SPECIFICATIONS

INSULATION DOOR POLYURETHANE

CABINET POLYURETHANE

EVAPORATOR ROLL BOND TYPE

DIMENSION (mm) 484X549X850 (WXDXH)

NET WEIGHT (kg) 30kg

REFRIGERANT R-134a (115g)

LUBRICANT OIL FREOL @22G (180cc)



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A. DOOR

1. Loosen 3 screws holding an upper hinge to separate the

door body. (Figure 7)

B. THERMOSTAT

1. Pull Konb Dial.

2. Loosen 1 screw holding the case and pull it out to

remove the Thermo cover. (Figure 8)

3. Pull out thermostat in the theremostat cover, and

disconnect lead wires.(Figure 9)

NOTE : Replace a new thermostat with proper specification.

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)

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.

3. DISASSEMBLY

- 5 -

Figure 7

Figure 10 Figure 11

Figure 8

Figure 9

Note: Reversing the doors is not covered by thewarranty.



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4. CIRCUIT DIAGRAM

- 6 -

NOTE: Lamp is option part.



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5. TROUBLESHOOTING

- 7 -

DEFECT EFFECT CAUSE REMEDY

GROUP PARTIALLY

OR COMPLETELY

OUT OF

REFRIGERANT

CHARGE

EXCESSIVELY

FULL

HUMIDITY IN THE

SYSTEM

PRESENCE OF AIR

IN THE SYSTEM

BLOCKED

CAPILLARY

MOTOR-COMPRESSOR

SHORT-CIRCUITED

OR BLOCKED

MOTOR-

COMPRESSORDOSE NOT

COMPRESS

NOISY MOTOR-COMPRESSOR

Evaporator dose not frost eventhough motor-compressor runscontinually.

This defect is indicated by thepresence of water outsiderefrigerator near the motor causedby formations of ice on the returntube.

This defect is indicated by the partialfrosting of the evaporator and bycontinual defrosting cycles

determined by the interruption of theflow of gas on the evaporator. Themotor compressor keeps running.

Poor performance of the refrigerantsystem which is indicated: on theevaporator with a slight frost whichdose not freeze and an excessiveoverheating of the condenser andmotor-compressor.

Because of the lack of circulationFreon in the system, there is nofrosting of the evaporator, while a

slight overheating of the first spiralof the condenser is noted.

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

No frost forms on the evaporatoreven if the motor-compressor isapparently running regulary.

In case of mechanical failure in themotor-compressor there in anexcessive noise when the system isfunctioning: in case a suspensionspring is unhooked, banging will beheard and there will be especiallystrong vibrations when the systemstarts up and stops.

An empty refrigerant systemindicates a leakage of R12. This lossis generally to be looked for at the

soldering points connecting thevarious components or in aneventual hole in the evaporatormade by the user.

If in the refrigerant system a quantityof R12 is introduced which is greaterthan that indicated, the excess gasdose not terminate its expansion inthe evaporator but proceeds into thereturn tube.

The refrigerant system is humidwhen there is a small percentage ofwater present which, not completely

retained by the dehydrator filter,enters into circulation with the Freonand freezes at the capillary exit inthe evaporator.

There is air in a refrigerating systemwhen during the filling phasevacuum is not effected or it is notadequately done.

Eventual impurities contained in theFreon or in the components of therefrigeration system before

assembly and not retained by thefilter can obstruct the capillary.

In case of short circuit, thebreakdown is due to the electricwinding: if blocked, there is amechanical failure in the motor-compressor.

In this case there is a mechanicalfailure in the diaphram valves which:remaining continually open, do notpermit the piston to suck andcompressor the whichconsequentely dose not circulate in

the system.

The cause of the excessive noise isnormally to be sought for in amechanical break down, and onlyrarely in the unhooking of one of thesuspension springs.

Leakage must be eliminated byresoldering the defective point orsubstituting the damaged

evaporator.

The system must be emptied andsubsequently refilled introducing thecorrect quantity of R-134a.

The system must be emptied andthen refilled after eliminating thehumidity.

Group must be drained andsubsequently refilled after carefullycreating vacuum.

To restore the system it must beemptied, substitute the capillary orthe evaporator entirely in case the

capillary is coaxial with respect tothe return tube, then refill it.

The motor-compressor must bereplaced and then proceed withrefilling.

The motor-comprossor must bereplaced and then proceed withrefilling.

The motor-comprossor must besubstituted and then proceed withthe refilling.



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NO COOLING

- 8 -

The Compressor

doesn't run.

Poor running of the

Compressor.

Compressor runs.

Check if the current

flows at the contacting

point of the Thermostat.

Check the current

flowing of starting

system.

Check the components

on the main circuit.

Measure the starting

voltage.


flows at the contactingpoint of the starting

system.

Is the current amount of

the electric components

normal?


flowing of the sub coil of

the Compressor.

Frost doesn't form at the

Evaporator when

operating set for more

than 30 min.


flows at the main coil of

the Comprossor.

Poor contacting point

Coil shorted

Low voltage

Shorted

Poor contacting point

and broken

The coil of the

Compressor Motor is

worn out.

Refrigerant leaks.

Poor compressing.

Increase the voltage.

Shorted

Broken

Replace the

Thermostat.

Replace the

components.

Replace the device.

Replace the

Compressor.

Repair the

Compressor.

Repair the

Compressor.

Replace the

Compressor.

Replace the device.



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COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS

- 9 -

1

2

3

4

5

2

4

3

3

4

4

5

5

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YESPower Source

Check theresistance of the

PTC.

Check OLP.

Check the

starting state.

Check the

resistance of the

Compressor Motor.

Separate the PTC-STARTER from

the Compressor and measure the

voltage between M and C of theCompressor.

Equal to the applied

voltage. (Rating

voltage ± 10%)

Advice the customer

to use in the fixed

range.

Replace thePTC-STARTER.

Starts at the voltage

of 85% below.

Replace the PTC.

Check the starting

state at the regular

voltage above.

Replace OLP.

Normal.

Normal.

OLP works within 30 sec.

in forcible OLP operation

by turning instant power on

and off.

The applied voltage is not in the

range of Rating Voltage ± 10%.

Test the resistance amongM-C, S-C, and M-S.

Test the resistance of the both

terminals in the PTC-STARTER.

Check if applying aregular OLP.

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

more than 90%.

Replace the Compressor.



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PTC

- 10 -

6 5

YES

NO

Poor starting or no

operating of theCompressor.

First, separate the PTC from

the Compressor and check the

voltage between NO 5 and 6in 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 therange of 15-28 for

the 22Ω PTC.

Check another

electric components.

Replace OLP.

The value is 0.

The value is ∞.

Normal

Check anotherelectric

components.

Replace the

PTC.

Replace the

PTC.

Abnormal

Abnormal



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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

6. EXPLODED VIEW

- 11 -

411A

317A

310A

309A

308A

307A

312A

315A

127A

281B

302A

104A

283A318A

313A

416A

410A

*410G

*328A328B



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*: optional parts GC-151S

- 12 -

*151A

125A

*149B

207A

201A

*406B

126A

136A

136A

*136C

*281D

110B 110C

*409B

110A

*408B

*149A

110F



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REPLACEMENT PARTS LIST

MODEL NAME:GC-151SA LG REFERENCE NO:GC-151SA.CSWPCIL

S AL LOC No. PART No. Description SPEC REMARK

R 104A 4778JQ3003A LEG,ADJUST

R 110A 6930JR1001G THERMOSTATR 110B 3550JD1062H COVER,THERMO

R 110C 4940JA3007A KNOB,THERMO

R 125A 3390JA3006A TRAY,ICE

R 126A 3390JA3020A TRAY,DRIP

R 127A 3580JD1041B DOOR,EVA

R 136A 5026JA1180C SHELF,R

R 149B 4890JA2002D GLASS,SHELF

R 151A 3390JA3052C TRAY,VEGETABLE

R 201A 5433JA2038D DOOR FOAM ASSEMBLY,R

R 207A 4270JA3002C BAR

R 281B 4775JA3010C HINGE ASSEMBLY,U

R 283A 4775JA2021C HINGE ASSEMBLY,L

R 302A 5421JA0037A EVAPORATOR ASSEMBLY

R 307A 2521CRA3001 COMPRESSOR,SET ASSEMBLY NS30LAEG BR1EOIL

R 308A 6748C-0003C P.T.C ASSEMBLY

P330MC LUCON PX9001F #250

MURATA

R 309A 6750C-0004A O.L.P 4TM149NFBYY-520

R 310A 3550CT0008A COVER,P.T.C

R 312A J734-00005A RUBBER,SEAT

R 313A 1PZZJQ3008A PIN,DRAWING

R 315A 3103JQ3001C COMP BASE ASSEMBLY,STD

R 317A 5850JQ2001E DRIER

R 318A 4930JQ3001A HOLDER,DRIER

R 328B 5040JQ3006A RUBBER,DAMPING

R 406B 6600JR2001B SWITCH,[PUSH]

PS103 PEC 250VAC 0.5A

13.5MM S/WHITE

R 408B 6621JR2002A SOCKET ASSEMBLY,LAMP

R 409B 6912JR3001B LAMP,[VACUUM]

240V 15W CLEAR E14/26X18

NGS T22

R 410A 4810JQ2009A BRACKET,TIMER

R 411A 6411JR1001F POWER CORD ASSEMBLY

BUYER NAME:CIL

COLOR:Super White

Documents

LG - GC 151 Manual