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SAFETY PRECAUTIONS Please read the followings before servicing your refrigerator . 1 . Check if an electric leakage occurs in the set . 6 . Prevent water flowing to electric elements in mechanical parts . 2 . When servicing current applying parts , unplug prior to servicing . 7 . When sloping the set , remove any materials on the set , especially thin plate type ( ex , : glass plates or books . ) . 3 . In case of testing with power injecting , wear rubber gloves to prevent electric shock . 8 . When servicing evaporator part , wear cotton gloves without fail . It is to prevent wound by sharp fin of 4 . if you use any appliances , check regular current , voltage evaporator . and capacity . 9 . Leave a breakage freezing cycle to a heavy service 6 . Don't touch metal products in cold freezer room with wet center . The gas in cycle inside may soil ambient air . hand . It may cause frostbite . SERVICING PRECAUTIONS AIR RECHARGING IN COMPRESSOR Test the refrigeration system by connecting it electrically It is necessary to execute the soldering operation with before refilling operation . This is necessary to ascertain the valve open so that the fumes caused by oil residue can function of the motor - compressor and identify the defects come out freely without blowholes between two tubes immediately , if the defects have been found , empty the old during heating the point to be soldered . system of eventual R - t 2 residue by breaking off the end of The extension fitted with the male Hansen is connected to the extension piece at its narrow point . ( Figure 1 ) the female fitting of the vacuum pump tube . ( Figure 3 ) Replace the filter and any damaged component & Unsolder Air evacuating from the system begins as soon as the and pull off the piece remaining inside the service tube and pump starts . The refrigeration system must be kept under then attach an extension completely with male Hansen and vacuum until the reading on the low - pressure gauge last , solder it to the same tube again . ( Figure 2 ) 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 4 ) POINT TO BED CHARGE TUBED FEMALE [ BROKEN EXTENSION HANSEN MALED HANSEN GAUGE SERVICE TUBED SOLDERINGD EXTENSION POINT Figure 1 Figure 2 Figure 3 Figure 4 - 3 -
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In case that a considerable leakage occurs and to stop the Before performing this operation ( if the vacuum pump and vacuum pump will be necessary and add a small quantity refilling cylinder are connected ) , make sure that the valve of Freon to the system , if vacuum should not be obtained placed between the vacuum pump and refilling tube are ( pressure gauge can't fall to 1 atmosphere . ) , start the closed to keep the Freon for adding to the system . ( Figure 6 ) refrigeration unit and find the leakage with the special leak - finder . When the defective soldering point is visible , FILLING ORD VALVE TO BE [ ] re - do it after opening the extension tube valve and reestablishing the normal outside pressure inside the REFILLING group . _ CHARGE TUBE OPENED WHEN [ ] Because the melted alloy is sucked into the tubes and _ L k _ block them , the pressure must be rebalanced when TO THE [ ] TO THE [ ] vacuum is in the system in soldering . As soon as the REFRIGERATIOND CHARGE [ ] vacuum operation is over , add the quantity in grams of R - SYSTEM CYLINDER 12 to the refrigeration system . Remember that every system has an exact quantity of R - 12 with a tolerance of TO THED VALVE TO BE [ ] - + 5grams than can be added . ( Figure 5 ) VACUUM [ CLOSEDD PUMP AFTER VACUUM Figure 6 In addition , check the graduated scale on the cylinder for the quantity of R - 12 to be added , for example , if we have 750 grams of Freon in the cylinder and must add 165 1 TO THED grams to the group , this amount will be reached when R - 12 has dropped to 585 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 - 12 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 T7YNTLD ' 7ERRAT [ ] , ON once because it may cause a blocking of motor - compressor . Therefore , proceed by adding original quantity of about 20 - 30 grams and close the valve immediately . SYSTEM The pressure rises and the motor - compressor must start , sucking the gas and making the pressure go down again . Regulate the valve again , maintaining the same manner until reaching the quantity of R - 12 established for the system being charged . When the system is running , the Figure 5 suction pressure must be stabilized from 0.30 to 0.6 atmosphere . - 4 -
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AIR RECHARGING IN COMPRESSOR Test the refrigeration system by connecting it electrically It is necessary to execute the soldering operation with before refilling operation . This is necessary to ascertain the valve open so that the fumes caused by oil residue can function of the motor - compressor and identify the defects come out freely without blowholes between two tubes immediately . If the defects have been found , empty the old during heating the point to be soldered . system of eventual R134a residue by breaking off the end The extension fitted with the male Hansen is connected to of the extension piece at its narrow point . ( Figure 1 ) the female fitting of the vacuum pump tube . ( Figure 3 ) Replace the filter and any damaged components . Unsolder Air evacuating from the system begins as soon as the and pull off the piece remaining inside the service tube and pump starts . The refrigeration system must be kept under then attach an extension completely with male Hansen and vacuum until the reading on the low - pressure gauge last , solder it to the same tube again . ( Figure 2 ) indicates vacuum ( 0 absolute , - 1 atm . , - 760 mm hg ) in any case it is advisable to keep the pump running for about 60 minutes . ( Figure 4 ) POINT TO BEB CHARGE TUBED FEMALEC BROKEN EXTENSION HANSEN MALE £ ] HANSEN GAUGE SERVICE TUBEB SOLDERINGE ] EXTENSION POINT Figure 1 Figure 2 Figure 3 Figure 4 - 5 -
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In case that a considerable leakage occurs and to stop the Before performing this operation ( if the vacuum pump and vacuum pump will be necessary and add a small quantity refilling cylinder are connected ) , make sure that the valve of Freon to the system , if vacuum should not be obtained placed between the vacuum pump and refilling tube are ( pressure gauge can't fall to 1 atmosphere . ) , start the closed to keep the Freon for adding to the system . ( Figure 6 ) 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 FILLING ORB VALVE TO BE D reestablishing the normal outside pressure inside the group . REFILLING _ CHARGE TUBE OPENED WHEN [ ] Because the melted alloy is sucked into the tubes and block them , the pressure must be rebalanced when TO THE [ ] TO THE [ ] vacuum is in the system in soldering . As soon as the REFRIGERATION [ ] CHARGED vacuum operation is over , add the quantity in grams of SYSTEM CYLINDER R134a to the refrigeration system . Remember that every system has an exact quantity of R134a with a tolerance of TO THEE VALVE TO BED - + 5grams than can be added . ( Figure 5 ) VACUUM [ CLOSEDD PUMP AFTER VACUUM Figure 6 In addition , check the graduated scale on the cylinder for the quantity of R134a to be added , for example , if we have 750 grams of Freon in the cylinder and must add 165 grams to the group , this amount will be reached when TO THED R134a has dropped to 585 grams , remembering that the R - 134a CYLINDER 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 R134a 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 _ - _ _ TO THEE ] motor - compressor . Therefore , proceed by adding original quantity of about REFRIGERATION [ ] 20 - 30 grams and close the valve immediately . SYSTEM The pressure rises and the motor - compressor must start , sucking the gas and making the pressure go down again . Regulate the valve again , maintaining the same manner until reaching the quantity of R134a established for the Figure 5 system being charged . When the system is running , the suction pressure must be stabilized from 0.10 to 0.4 atmosphere . - 6 -
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1 . SPECIFICATIONS 1 - 1 GR - 151 ITEMS SPECIFICATIONS ITEMS SPECIFICATIONS EVAPORATOR ROLL BOND TYPE DOOR TYPE 1DOOR NET CAPACITY 124 l DIMENSION 484 ( W ) X850 ( H ) X549 ( D ) mm NET WEIGHT CONDENSER TYPE WALL CONDENSER 30 Kg REFRIGERANT ( FLUSH BACK ) R _ 12 ( 80g ) LUBRICANT DEFROSTING SYSTEM MANUAL R - 12 ( 80g ) R - 134a ( 95g ) LUBRICANT VS Series TEMPERATURE CONTROL KNOB DIAL HTS * 150 FREOL ( z22G COMPRESSOR INSULATION DOOR POLYURETHANE ( 200cc ) ( 200cc ) NS Series CABINET POLYURETHANE HTS * 150 FREOL ( z22G COMPRESSOR ( 180cc ) ( 180cc ) 2 . PARTS IDENTIFICATION EVAPORATOR ( Door Inside ) _ _ - The heart of the refrigerator . \ 4 , , \ - It evaporates the refrigerant \ \ \ fluid and thereby absorbs \ \ heat from the surrounding . \ THERMOSTAT Regulates the operation of the motor and controlls the temperature inside the ICE CUBETRAY ( DoorInside ) refrigerator . Ice cube is easy to remove from the tray DRIP TRAY Catches the water that 3AN drips off the evaporator Keeps any kinds of bottles . when defrosting . PLASTIC COATED SHELVES Have full width and can slide out , - Tight fitting door seal keeps all the cooling power locked inside . GLASS LID & VEGETABLE - No hooks or latches . CONTAINER NOTE : This is a basic model . The shape of refrigerator is subject to change . - 7 -
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3 . DISASSEMBLY A . DOOR C . COMPRESSOR AND PTC 1 . Loosen 3 screws holding an upper hinge to separate the 1 . Remove Protector Cover , Power Cord and Lead Wire door body . ( Figure 7 ) first . ( Figure 11 ) 2 . Separate OLR 3 . Separate PTC . 4 . Remove the Compressor Base by loosening 4 bolts fixed to base plate of the set . ( Figure 12 ) Figure 7 B . THERMOSTAT Figure 11 Figure 12 1 . Seperator feeler of thermostat from evaporator . 2 . Loosen 1 screw holding the case to remove the Thermo 5 . Remove the Compressor by loosening 2 earth screws cover . ( Figure 9 ) 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 OLR Figure 8 Figure 9 3 . Pull Knob DiaL ( Figure 8 ) 4 . Pull out thermostat in the thermostat cover , and disconnecting lead wires . ( Figure 10 ) NOTE : Replace a proper specification new thermostat . Figure 10 - 8 -
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2000.03.13 100 / 70 CIRCUIT DIAGRAM THERMOSTAT BK YL : YELLOWK BK : BLAC BK BL : BLUE _ , i i GN ( GI _ . ) GN : GREEN Y " PK : PINK _ l 4N - I BL BL _ _ _ _ C _ IOMPRESSOR P . T . CSTARTER THE PLUG TYPE ON CIRCUIT DIAGRAM IS SUBJECT TO CHANGE IN DIFFRENT LOCALTIES . 3854 , JD1009E
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TROUBLESHOOTING DEFECT EFFECT CAUSE REMEDY GROUP PARTIALLY Evaporatordose notfrost even An empty refrigerantsystem Leakagemust be eliminatedby OR COMPLETELY though motor - compressorruns indicates a leakageof R _ 2T . his loss resolderingthedefectivepoint or OUT OF continually . is generallyto be lookedfor at the substitutingthe damaged REFRIGERANT soldering pointsconnectingthe evaporator . CHARGE various componentsor in an eventualhole in the evaporator made by the user . EXCESSIVELY This defect is indicatedby the If in the refrigerantsystema quantity The systemmust be emptiedand FULL presenceof water outside of R _ 2is introducedwhich is greater subsequentlyrefilled introducingthe refrigeratornearthe motor caused than that indicated , the excessgas correctquantityof R _ 2 . by formationsof ice onthe return dose net terminateits expansionin tube . the evaporatorbut proceedsintothe returntube . HUMIDITY IN THE This defect is indicatedby the partial The refrigerantsystemis humid The systemmust be emptiedand SYSTEM frostingof the evaporatorand by when thereis a small percentageof then refilledafter eliminatingthe continualdefrostingcycles water present which , notcompletely humidity . determinedby the interruptionof the retainedby the dehydratorfilter , enters intocirculationwiththe Freen flow of gas onthe evaporator . The motor compressorkeeps running . and freezes at the capillaryexit in the evaporator . PRESENCE OFAIR Poorperformanceof the refrigerant There is air in a refrigeratingsystem Groupmust bedrained and IN THE SYSTEM system which is indicated : onthe when duringthe filling phase subsequentlyrefilled aftercarefully vacuum is not effectedor it is not evaporatorwith a slight frost which creatingvacuum . dose not freezeand an excessive adequatelydone . overheatingof the condenserand motor - compressor . Becauseof the lackof circulation BLOCKED Eventualimpuritiescontained inthe Torestorethe systemit must be CAPILLARY Freoninthe system , thereis no Freonor in the componentsof the emptied , substitutethe capillaryor frostingof the evaporator , while a refrigerationsystem before theevaporatorentirely in casethe slight overheatingof the first spiral assembly and not retainedbythe capillaryis coaxialwith respectto of the condenseris noted . the returntube , then refill it . filter canobstruct the capillary . MOTOR - The system dose notwork andthe In caseof short circuit , the The motor - compressormust be breakdownis dueto the electric COMPRESSOR " clixson " intervenesinterrupting replacedand then proceedwith SHOR % CIRCUITED deliveryto the motor - compressor . winding : if blocked , there is a refilling . mechanicalfailure in the motor - OR BLOCKED compressor . In this casethere is a mechanical MOTOR - Nofrost formson the evaporator The motor - compressormust be COMPRESSOR even if the motor - compressoris failure inthe diaphramvalves which : replacedand then proceedwith DOSE NOT apparentlyrunning regulary . remainingcontinuallyopen , do not refilling . COMPRESS permit the pistonto suckand compressorthe which consequentelydose notcirculate in the system . In caseof mechanicalfailure in the The causeof the excessivenoiseis NOISY MOTOR - The motor - comprossormust be COMPRESSOR motor - compressorthere in an normallyto be soughtfor in a substitutedand then proceedwith excessivenoisewhen the systemis mechanical breakdown , and only the refilling . functioning : in casea suspension rarely in the unhookingof one of the spring is unhooked , bangingwill be suspensionsprings . heard and therewill be especially strong vibrationswhen the system starts up and stops . - 10 -
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NO COOLING Replace the doesn't run . flows at the contacting Poor contacting point Thermostat . The Compressor ] _ _ H point of the Thermostat . Check if the current I _ Replace the device . - _ flowing of starting Broken H tchethcckeurrentI _ _ _ S , thorted system . Replace the " _ ) flows at the main coil of Coil shorted Compressor . H Check if the current the Compressor . . _ _ _ . Check the components components . _ Replace the J on the main circuit . Poor running of the Increase the voltage . voltage . Low voltage Compressor . Measure the starting I _ H Replace the device . flows at the contacting Poor contacting point point of the starting and broken Check if the current _ 4 _ H system . " - - ) flowing of the sub coil of Shorted Compressor . tChoc if ' eco rent H oo'aoe ' e the Compressor . t ls the current amount of I . I The coil of the I . I Repair the normal ? worn out . the electric components i _ Compressor Motor is _ 1 Compressor . I i Frost doesn't form at the I , J Repair the Compressor runs . Poor compressing . Compressor . Evaporator when Refrigerant leaks . H operating set for more than 30 min . - 11 -
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COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS Separate the PTC - STARTER from voltage . ( Rating the Compressor and measure the voltage _ + 10 % ) voltage between M and C of the [ _ Power Source I _ [ qual to the applied Compressor . The applied voltage is not in the to use in the fixed range of Rating Voltage _ + 10 % . H dvice the customer range . Check the YES resistance of the M - C , S - C , and M - S . Test the resistance among Compressor Motor . Replace the Compressor . 11 [ _ Check the I I Test the resistance of the both YES , [ _ PTC . resistance of the J _ l terminals in the PTC - STARTER . NO Replace the PTC - STARTER . OLP works within 30 sec . Check OLR regular OLR YES , _ . in forcible OLP operation by turning instant power on Check if applying a 1 . _ and off . NO , _ Replace OLP . I NO f Measure minimum starting voltage after checking steps 1 - 3 above . Check the Normal . And measure the pressure balance of 85 % below . starting state . of the PTC with the interval of . _ Starts at the voltage more than 5 min . Starts at the voltage of Normal . state at the regular more than 90 % . J voltage above . _ _ _ _ Check the starting , _ NO Replace the PTC .
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PTC First , separate the PTC from the Compressor and check the Poor starting or no voltage between NO 5 and 6 operating of the in the PTC with a multitester Compressor . or Wheatstone Bridge . Check another electric range of 15 - 28 for Normal . _ The value is in the components . the 22 ¥ PTC . Replace the Abnormal _ - _ The value is 0 . H F4PTC . Replace the Abnormal " _ The value is i - . _ ' _ PTC . Separate the OLP from the Compressor and YE _ Celheecctrkic acnoomthpeornents . . - . ) check resistance value between two terminals of OLP with Tester . " - ' N - ' Q - - _ Replace OLP " l - 13 -
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5 . EXPLODED VIEW I - 14 -