Refrigerator: Service Manual
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-T382GV
SAFETY PRECAUTIONS
Please read the followings before servicing your refrigerator.
1. Check if an electric leakage occurs in the set. 7. When you stand up during observing the lower part
2. To prevent electric shock, unplug prior to servicing. with the upper door open, move with care to prevent
head wound which may happen by hitting the upper
3. In case of testing with power on, wear rubber gloves to
door.
prevent electric shock.
8. When sloping the set, remove any materials on the set,
4. If you use any appliances, check regular current, voltage
especially thin plate type. (ex.: glass shelf or books.)
and capacity.
9. When servicing evaporator part, wear cotton gloves
5. Don't touch metal products in cold freezer with wet hand.
without fail. It is to prevent wound by sharp fin of
It may cause frostbite.
evaporator.
6. Prevent water flowing to electric elements in mechanical
10. Leave a breakage of refrigerating cycle to a heavy
parts.
service center. The gas in cycle inside may soil
ambient air.
-2-
SERVICING PRECAUTIONS
Air Recharging in Compressor vacuum operation is over, add the quantity in grams of R-
Test the refrigeration by connecting it electrically before 134a to the refrigerant system. Remember that every
refilling operation. It is necessary to ascertain the function system has an exact quantity of R-134a with a tolerance of
of the motor-compressor and identify the defects ±5 grams that can be added. (Figure 4)
immediately. If the defects have been found, empty the old
system of eventual 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 extension completely with male Hansen and
last, solder it to the same tube again. (Figure 2) TO THE R-134a CYLINDER
POINT TO BE
BROKEN CHARGE TUBE
EXTENSION
FEMALE
HANSEN
TO THE REFRIGERATION
SYSTEM
MALE HANSEN
Figure 4
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 refilling tube are
It is necessary to execute the soldering operation with closed to keep the Freon for adding to the system. (Figure 5)
valve open so that the fumes caused by oil residue can
come out freely without blowholes between two tubes
FILLING OR VALVE TO BE OPENED
during heating the point to be soldered. CHARGE TUBE WHEN REFILLING
The extension fitted with the male Hansen is connected to
the female fitting of the vacuum pump tube. (Figure 3)
PRESSURE
GAUGE In addition, check the graduated scale on the cylinder for
the quantity of R-134a to be added, for example, if we have
Figure 3 750 grams of Freon in the cylinder and must add 165
grams to the group, this amount will be reached when R-
134a has dropped to 585 grams, remembering that the
Air evacuating from the system begins so soon as the indicator shows a lower limit of meniscus. Do this after
pump starts. The refrigeration system must be kept under choosing the scale corresponding to the gas pressure
vacuum until the reading on the low-pressure gauge different scales reported as the same gas pressure
indicates vacuum (0 absolute, -1 atm., -760 mm hg) in any indicated by the pressure gauge on the top of the column.
case it is advisable to keep the pump running for about 30
To make R-134a flow into the system, open the valve
minutes. (Figure 3)
placed at the base of the cylinder and connected to the
In case that a considerable leakage occurs and to stop the filling tube. The amount of Freon cannot be added to the
vacuum pump will be necessary and add a small quantity system all at once because it may cause a blocking of
of Freon to the system, if vacuum should not be obtained motor-compressor. Therefore, proceed by adding original
(pressure gauge can't fall to 1 atmosphere), start the quantity of about 20-30 grams and close the valve
refrigeration unit and find the leakage with the special leak- immediately.
finder. When the defective soldering point is visible, re-do it The pressure rises and the motor-compressor must start,
after opening the extension tube valve and reestablishing sucking the gas and making the pressure go down again.
the normal outside pressure inside the group. Regulate the valve again, maintaining the same manner
Because the melted alloy is sucked into the tubes and until 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
atmosphere.
-3-
1. SPECIFICATIONS
ITEMS SPECIFICATIONS ITEMS SPECIFICATIONS
FREEZER 83 FREEZER 1 EA
SHELF
NET CAPACITY REFRIGERATOR 230 REFRIGERATOR 2 EA
(l)
TOTAL 313 VEGETABLE TRAY Drawer Type
-4-
2. PARTS IDENTIFICATION
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 Bottle Guide
Control Dial
Lamp Movable Rack
F.I.R Lamp (Option)
Shelves Refrigerator Door
(Plastic or Steel) Rack
Multi Flow Duct
Distributes cold air to
each part of refrigerator
compartment. Leveling Screw
Vegetable Drawer
Used to keep fruits
and vegetables, etc.
fresh and crisp.
-5-
3. DISASSEMBLY
3-1 DOOR 3-2 DOOR SWITCH
● Freezer Door 1. To remove the door switch, pull out it with a '—' type
1. Remove the hinge cover by pulling it upwards. driver as shown in (figure 9).
2. Loosen hexagonal bolts fixing the upper hinge to the 2. Disconnect the lead wire from the switch.
body and lift the freezer door.
HINGE
COVER HINGE
COVER
BOLT
BOLT
HINGE
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 driver
Ass'y. inserting in the low holes of the cover.
2. Loose 2 screw.
GASKET 3. Pull the Control Box-R.
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.
Figure 10
LOWER HINGE
2. Pull out the door gasket to remove from the door foam
Ass'y.
CAP
Figure 11
-6-
6. Disconnect the housing of lead wire. 3-6 REFRIGERATOR ROOM LAMP
7. Separate the Fan Assy. 1. Remove the cover lamp-R by pulling with a '–––' type
8. Loose 2 screw fixed to the Bracket. driver.
9. Pull out Shroud-F remove the Fan Motor Assy. 2. Remove the lamp-R by turning.
10. Separate the Motor Bracket and Rubber.
BRACKET
FAN
Figure 17
GRILLE Figure 12
FAN DEF-THERMO
SHROUD-F 2. Loosen 2 screws.
3. Full the Control Box-R.
4. Separate the lead wire Housing.
FUSE-M
Figure 13 HOLDER FUSE Figure 14
-7-
4. ADJUSTMENT
4-1 COMPRESSOR 4-2-3 PTC-Applied Circuit Diagram
4-1-1 Role ● According to Starting Method of Motor
The compressor inhales low temperature and low pressure
gas evaporated from Evaporator of the Refrigerator, and
condenses this gas to high temperature and high pressure OVERLOAD PROTECTOR
gas, and then plays delivering role to Condenser.
C
4-1-2 Composition
The Compressor is Composed of Compressor Apparatus PTC COMPRESSOR
5 MOTOR
compressing gas, Compressor Motor moving Compressor
Apparatus and Case protecting Compressor Apparatus S M
and Motor. There are PTC-Starter, and Over Load S M
3 6
Protector (OLP) in the Compressor outside. On the other
hand, because the Compressor consists of 1/1000mm processing HERMETIC
PTC STARTER
precision components and is sealed after producing without dust TERMINAL
or humidity, deal and repair with care. RSIR
-8-
4-3 OLP (OVER LOAD PROTECTOR) CONTACTING
4-3-1 Definition of OLP POINT
COVER
(1) OLP (OVER LOAD PROTECTOR) is attached to
Hermetic Compressor and protects Motor by cutting off BIMETAL
current in Compressor Motor by Bimetal in the OLP in
case of over-rising temperature.
(2) When over-voltage flows to Compressor motor, Bimetal CONTACTING
works by heating the heater inside OLP, POINT
and OLP protects Motor by cutting off current which HEATER
flows to Compressor Motor.
TERMINALS
4-3-2 Role of OLP
(1) OLP is attached to Hermetic Compressor used to
Refrigerator and Show Case and prevents Motor Coil BIMETAL
from being started in the Compressor.
ADJUST
(2) Do not turn the Adjust Screw of OLP in any way for SCREW
normal operation of OLP.
(Composition and connection Diagram of OLP
Figure 21
HEATER
5. CIRCUIT DIAGRAM
-9-
6. TROUBLESHOOTING
6-1 COMPRESSOR AND ELECTRIC COMPONENTS
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
Check if applying YES
Check OLP. OLP works within 5
4 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
- 10 -
6-2 PTC AND OLP
Normal operation of Separate the PTC from Observation value is Check another
Compressor is Compressor and 220V/50Hz : 22 Ω ±30% electric components.
impossible or poor. measure the resistance 115V/60Hz : 6.8 Ω ±30%
between No. 5 and 6 240V/50Hz : 33 Ω ±30%
127, 220V/60Hz :
(only RSIR Type) or No.
22 Ω ±30%
4 and 5 of PTC with a
Tester or Whistone
Bridge. (Figure 22) The resistance value is Replace
0 or several PTC.
hundreds Ω .
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
- 11 -
6-4 ANOTHER ELECTRIC COMPONENTS
▼ Cooling is impossible
- 12 -
6-5 SERVICE DIAGNOSIS CHART
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 (1)" • Set the knob to "MID (2)"
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 (3)". • Set the knob to "MID (2)"
• Is the ambient temperature within 5°C? • Set the knob to "WARM (1)"
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.
- 13 -
6-6 REFRIGERATING CYCLE
▼ Troubleshooting Chart
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.
- 14 -
▼ General Control of Refrigerating Cycle
WELDING (1) H 30
ROD (1) • Chemical Ingredients • Recommend H34 containing 34% Ag in the
(1) • Ag: 30%, Cu: 27%, Zn: 23%, Cd: 20% • Service Center.
(1) • Brazing Temperature: 710~840°C
(2) Bcup-2
1
(1) • Chemical Ingredients
(1) • Cu: About 93%
(1) • P: 6.8~7.5%
(1) • The rest: within 0.2%
(1) • Brazing Temperature: 735~840°C
FLUX (1) • Ingredients and how to make • Make amount for only a day. (1)
(1) ••Borax 30% • Holding period: 1 day
(1) ••Borax 35% • Close the cover of container to prevent dust
2 (1) • Fluoridation kalium: 35% • putting in the FLUX.
(1) • Water: 4% • Keep it in a stainless steel container.
(1) • Mix the above ingredients and boil until
(1) • they are transformed into liquid.
DRIER (1) Assemble the drier within 30min. • Don't keep the drier in a outdoor because
ASM (1) after unpacking. • humidity damages to it.
3 (2) Keep the unpacked drier at the temperature
of 80~100°C.
VACUUM (1) When measuring with pirant Vacuum • Apply M/C Vacuum Gauge without fail.
(1 )gauge of charging M/C, vacuum • Perform vacuum operation until a proper
(1 )degree is within 1 Torr. • vacuum degree is built up.
(2) If the vacuum degree of the cycle inside is • If a proper vacuum degree isn't built up,•
(2) 10 Torr. below for low pressure and 20 Torr. • check the leakage from
4 (2) for high pressure, it says no vacuum • the Cycle Pipe line part and
(2) leakage state. • Quick Coupler Connecting part.
(3) Vacuum degree of vacuum pump must be
(3) 0.05 Torr. below after 5 min.
(4) Vacuum degree must be same to the
value described item (2) above for more than
20 min.
NIPPLE (1) Check if gas leaks with soapy water. • Check if gas leaks from connecting part of
6 AND (2) Replace Quick Coupler in case of leakage. • Coupler.
COUPLER
- 15 -
7. 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
301A
281B
103A
303B
303A 401A
411A
418A
416A
* 410G
125L
* 410H
282B
129A
410C * 410B
* 410J
410A
406B
304A
* 604E
* 604F
*
282J 120G
120E
110A
105A 120B
120C
317A
318A
409B
307A 310A
283B
314A
308A
309A 106A
323B
106B *
409C
329C 103C
420A 109B 158C
315A
312A 327A 120A
319A
328A 328B
407A
319C
315C 315B
- 16 -
405C
405A
330B
404A
329A
200A
203A
205A
201A
332A
* 212G
201A
205A
*212G
* 110B
* 125A
* 131A
212A
*
125H
* *125J
149A
*149D 212C
* 136C
235A
243A
* *
136D 241A 230A
149B 210A
233A
* 140A 231A
233B
231A
* 149C
233B
* 149C 237A
* 136A
* 136B
* 149C
244A
* 149C
241C
244C
* 136A
*136B
154A
241A
241D
151A 243A
210A
- 17 -
405C
405A
330B
404A
329A
200A
203A
205A
201A
332A
* 212G
201A
205A
* 212G
* 110B
125A
* 131A
212A
* 125H
* * 125J
149A
* 149D 212C
* 136C
235A
243A
* *
136D 210A
241A
149B 230A
233A
* 140A 231A
233B
231A
* 149C
233B
* 149C 237A
* 136A
* 136B
* 149C
244A
* 149C
241C
244C
* 136A
* 136B
154A
241A
241D
151A 243A
210A
- 17 -
P/No. 3828JD8425Y Nov.,2003 Printed in Korea