LG GC 181 Manual

REFRIGERATOR SERVICE MANUAL

MODEL: GC-181SA.CSWQRAN

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

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CONTENTS

-2-

SAFETY PRECAUTIONS

(Page)

SAFETY PRECAUTIONS .............................................................................................................................................. 2

SERVICING PRECAUTIONS ......................................................................................................................................... 3

SPECIFICATIONS ...........................................................................................................................................................4

PARTS IDENTIFICATION ...............................................................................................................................................4

DISASSEMBLY ......................................................................................................................................................... 5 - 6

DOOR .......................................................................................................................................................................... 5

EVA DOOR ..................................................................................................................................................................5

TOP TABLE ................................................................................................................................................................ 6

COVER FEELER ..........................................................................................................................................................6

THERMOSTAT ............................................................................................................................................................6

COMPONENTS ...........................................................................................................................................................7-8

CIRCUIT DIAGRAM ...................................................................................................................................................... 8

TROUBLESHOOTING ............................................................................................................................................ 9 - 12

NO COOLING ............................................................................................................................................................ 10

COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS ............................................................................... 11

PTC............................................................................................................................................................................ 12

EXPLODED VIEW . ................................................................................................................................................13 - 14

REPLACEMENT PARTS LIST .....................................................................................................................................15

Please read the following before servicing yourrefrigerator.

1. Check if electric leakage occurs in the set.2. When servicing current applying parts, unplug prior to

servicing.3. If testing with power on, wear rubber gloves to prevent

electric shock.4. Be sure to check regular current, voltage, and capacity.5. Don't touch metal products in a cold freezer compartment

with wet hands. It may cause frostbite or other injury.6. Prevent water flowing to electric elements in mechanical

parts.7. When tilting the set, remove any materials on the set,

especially thin plate type (ex,: glass plates or books.)8. When servicing evaporator part, wear cotton gloves to

prevent injury by sharp fins of the evaporator.9. Do not open the sealed refrigeration system. It could

cause injury or pollute the air. Leave this job to anautherized servicer with the appropriate refrigerantrecovery equipment.

AIR RECHARGING IN COMPRESSORTest the refrigeration system by connecting it electrically beforebeginning the refilling operation. This is necessary to ascertainthe function of the motor-compressor and identify defectsimmediately. If defects have been found, empty the old systemof R134a residue by breaking off the end of the extension pieceat its narrow point. (Figure 1) Use the appropriate refrigerant recovery equipment.Replace the filter and any damaged components. Unsolder andpull off the piece remaining inside the service tube and thenattach an extension with male Hansen, and last, solder it to thesame tube again. (Figure 2)

POINT TO BE�BROKEN

CHARGE TUBE�EXTENSION

FEMALE�HANSEN

MALE�HANSEN

SOLDERING�POINT

SERVICE TUBE�EXTENSION

Figure 1 Figure 2



SERVICING PRECAUTIONS

-3-

If case that a considerable leakage occurs, it will be necessaryto stop the vacuum pump and add a small quantity of Freon tothe system, if vacuum should not be obtained (pressure gaugedoesn't fall to 1 atmosphere.) Start the refrigeration unit andfind the leakage with a special leak-finder. When the defectivesoldering point is visible, repair it after opening the extensiontube valve and reestablishing the normal outside pressureinside the system.Because the melted solder is sucked into the tubes and blocksthem, the pressure must be rebalanced when vacuum is in thesystem for soldering. As soon as the vacuum operation is over,add the quantity (in grams) of R134a to the refrigerationsystem. Remember that every system has an exact quantity ofR134a with a tolerance of ±5 grams than can be added. (Figure 5)

TO THE�R-134a CYLINDER

TO THE�REFRIGERATION�SYSTEM

FILLING OR�CHARGE TUBE

VALVE TO BE �OPENED WHEN �REFILLING

TO THE�REFRIGERATION�SYSTEM

TO THE �CHARGE�CYLINDER

VALVE TO BE�CLOSED�AFTER VACUUM

TO THE�VACUUM�

PUMP

TO THE�VACUUM�

PUMP

PRESSURE�GAUGE

Before performing this operation (if the vacuum pump andrefilling cylinder are connected), make sure that the valveplaced between the vacuum pump and refilling tube are closedto keep the Freon from adding to the system.(Figure 6)In addition, check the graduated scale on the cylinder for thequantity of R134a to be added; for example, if we have 750grams of Freon in the cylinder and must add 165 grams to thegroup, this amount will be reached when R134a has dropped to585 grams, remembering that the indicator shows a lower limitof meniscus. Do this after choosing the scale corresponding tothe gas pressure different scales reported as the same gaspressure indicated by the pressure gauge on the top of thecolumn.To make R134a flow into the system, open the valve placed atthe base of the cylinder and connected to the filling tube. Theamount of Freon cannot be added to the system all at oncebecause it may cause a blocking of motor-compressor.Therefore, proceed by adding original quantity of about 20-30grams and close the valveimmediately thereafter.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 untilreaching the quantity of R134a established for the system beingcharged. When the system is running, the suction pressuremust be stabilized from 0.10 to 0.4 atmosphere.

It is necessary to execute the soldering operation with valveopen so that the fumes caused by oil residue can come outfreely without blowholes between two tubes during heating thepoint to be soldered.The extension fitted with the male Hansen is connected to thefemale fitting of the vacuum pump tube. (Figure 3) Airevacuating from the system begins as soon as the pump starts.The refrigeration system must be kept under vacuum until thereading on the low-pressure gauge indicates vacuum (0absolute, -1 atm., -760 mm hg.) In any case, it is advisable tokeep the pump running for about 60 minutes. (Figure 4)

Figure 3

Figure 4

Figure 5



1. SPECIFICATIONS

-4-

2. PARTS IDENTIFICATION

ITEMS SPECIFICATIONS

FREEZER 14

STORAGE CAPACITY REFRIGERATOR 126

TOTAL 140

DIMENSIONS (mm) 550 (W) X 600 (D) X 850 (H)

NET WHIGHT(kg) 36

TEMPERATURE CONTROL KNOB DIAL

DEFROSTING SYSTEM MANUAL

OUT CASE Coated Steel sheet

INNER CASE ABS

INSULATION CYCLOPENTANE

1-1 GR-181

ITEMS SPECIFICATIONS

VEGETABLE TRAY Drawer Type

EGG TRAY 1 Piece

ICE TRAY 1 Piece (Plastic)

COMPRESSOR P.T.C Starting Type

EVAPORATOR ROLL BOND TYPE

CONDENSER Wire Condenser

REFRIGERANT R-134a (105g)

LUBRICANT OIL FREOL @ 15G(210cc)

EVAPORATOR(Door Inside)- The heart of the refrigerator.- It evaporates the refrigerant

fluid and thereby absorbsheat from the surroundingarea.

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

from the tray.

DRIP TRAYCatches the water thatdrips off the evaporator

when defrosting.

SHELVES MAGNETIC GASKET- Tight fitting door seal keeps

all the cooling power lockedinside.

- No hooks or latches.GLASS LID & VEGETABLECONTAINER

LEG ADJUST

COMMODITY RACKS

EGG TRAY

EVA DOOR

BOTTLE RACK

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

THERMOSTAT CONTROL DIALRegulates the operation ofthe motor and controlls thetemperature inside therefrigerator.



3. DISASSEMBLY

-5-

A. DOOR

1. Unscrew the 2xBOLTS ▼, then remove the hinge (L) ※.

2. Remove the LEG 〒.

3. Gently pull the door downwards to remove it.

ý Reversible

4. Before refitting the door, swap the Hinge Cap → by pulling itout from its current location and repositioning it on the otherside of the door. Care should be taken not to damage theadjacent surfaces when removing the Hinge Cap.

5. Unscrew the Upper Hinge pin (U) ← and screw it into theopposite side hole.

6. After refitting the door, fix the Lower Hinge(L) in theapposite side by using 2xBOLTS.

7. Fix the Leg.

8. Carefully place the appliance in an upright position. Adjust the Leveling screw to make sure the appliance issteady and check that the door opens and closesproperly.

Figure 7

B. EVA DOOR

1. Open the EVA DOOR, and Grasp the Bottom side of theEVA DOOR Hinge.

2. Take it out forwards ※ by lifting it slightly up ▼.

ý Reversible

3. Rotate the EVA DOOR 180 degrees, and insert EVADOOR to opposite side top hole first, then in to theBottom side hole.

4. Check that EVA DOOR is installed properly.

Figure 8

1. First unplug the appliance.2. Remove foods and accessories like shelves or trays

which are not fixed in the refrigerator.3. Carefully lay the appliance on a cushion like packing

material to avoid the damage of refrigeration circuit.4. Use ‘+’ driver or spanner to fix or remove the bolts.

PRECAUTION

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



-6-

D. COVER FEELER1. Open the eva door.

2. Pull it downwards softely by pushing the hooks of thecover feeler inside.

3. Separate the cover feeler from the evaporator.

E. THERMOSTAT1. Remove the shelves and Drip tray in order to make access

easier.2. Separate Cover feeler from Evaporator.3. Separate Cover Lamp by twisting up and down (Figure 11).4. Loosen 1 screw holding the case to remove the Thermostat

Enclosure. (Figure 12)5. Pull Knob Dial.

6. Pull out thermostat in the thermostat cover, anddisconnect wires. (Figure 13)

NOTE : Replace a proper specification new thermostat.

Figure 13

Figure 10

1

2

Figure 9

Figure 11 Figure 12

C. TOP TABLE1. Unscrew 2 bolts at the rear of top table.

2. Hold the rear of top table and push forwoards withlifting up top table slightly.



4. COMPONENTS

-7-

1. COMPRESSOR

1) RoleThe compressor intakes low temperature and lowpressure gas evaporated from Evaporator of theRefrigerator, and condenses this gas to high temperatureand high pressure gas, and then plays delivering role toCondenser.

2) CompositionThe Compressor is Composed of Compressor Apparatuscompressing gas, Compressor Motor moving CompressorApparatus and Case protecting Compressor Apparatusand Motor. There are PTC-Starter, and Over LoadProtector (OLP) in the Compressor outside. On the otherhand, because the Compressor consists of 1/1000mmprocessing precision components and is sealed afterproduction in absence of dust or humidity, deal and repairwith care.

3) Note for Usage(1) Be careful not to allow over-voltage and over current.(2) No Strike

If applying forcible power or strike (dropping orcareless dealing), poor operation and noise may occur

(3) Use proper electric components appropriate to theCompressor.

(4) Note to Keep Compressor.If Compressor gets wet in the rain and rust in the pin ofHermetic Terminal, the result may be poor operationand poor contact may cause.

(5) Be careful that dust, humidity, and flux welding don'tinflow in the Compressor inside in replacing theCompressor. Dust, humidity, and flux due to weldingwhich inflows to Cylinder may cause lockage andnoise.

2. PTC-STARTER

1) Composition of PTC-Starter(1) PTC (Positive Temperature Coefficient) is a no-contact

semiconductor starting device which uses ceramicmaterial and this material consists of BaTiO3.

(2) The higher the temperature is, the higher becomes theresistance value. These features are used as startingdevice for the Motor.

2) Role of PTC-Starter

(1) PTC is attached to Hermetic Compressor used forRefrigerator, Show Case and starts Motor.

(2) Compressor for household refrigerator applies tosingle-phase induction Motor.For normal operation of the single-phase induction motor, inthe starting operation flows in both main coil and sub-coil.After the starting is over, the current in subcoil is cut off. Theproper features of PTC play all the above roles. So, PTC isused as a motor starting device.

3) PTC-Applied Circuit DiagramAccording to Starting Method for the Motor

4) Motor Restarting and PTC Cooling

(1) For restarting after power off during normalCompressor Motor operation, plug the power cordafter 5 min. for pressure balance of Refrigerating Cycleand PTC cooling.

(2) During normal operation of the Compressor Motor,PTC elements generate heat continuously. Therefore,if PTC isn't cooled for a while after the power has beenshut off, Motor can't operate again.

5) Relation of PTC-Starter and OLP

(1) If the power is off during operation of Compressor and thepower is on before the PTC is cooled, (instant shut- off within2 min. or reconnect a power plug due to misconnecting), thePTC isn't cooled and a resistance value grows. As a result,current can't flow to the subcoil and the Motor can't operateand the OLP operates by flowing over current in only in themain-coil.

(2) While the OLP repeats on and off operation about 3-5 times,PTC is cooled and Compressor Motor performs normaloperation.If OLP doesn't operate when PTC is not cooled,Compressor Motor is worn away and causes circuitshort andfire. Therefore, use a properly fixed OLP without fail.

6) Note to Use PTC-Starter

(1) Be careful not to allow over-voltage and over-current.(2) No Strike

Don't apply a forcible power or strike.(3) Keep apart from any liquid.

If liquid such as oil or water away enter the PTC,PTC materials it may break due to insulationbreakdown of the material itself.

(4) Don't change PTC at your convenience.Don't disassemble PTC and mold. If the exterior to thePTC-starter is damaged, resistance value is alteredand it may cause poor starting of the compressormotor may cause.

(5) Use a properly fixed PTC.

PTC STARTER HERMETICTERMINAL

COMPRESSORMOTOR

C

MS M

3 6

5

S

PTC

OVERLOAD PROTECTOR(O.L.P)

RSIRFigure 13



CIRCUIT DIAGRAM

PO

WE

R S

UP

PLY

CO

RD

CA

PAC

ITO

R-R

OV

ER

LO

AD

PR

OT

EC

TO

R

GN(GN/YL)

YL

PK

COMPRESSOR

P.T.C STARTER

BL

PR

YL

LAMP

DOORS/W

BLBL

BK

BK

THERMOSTAT

2

5

63

THE PLUG TYPE ON CIRCUIT DIAGRAM IS SUBJECTTO CHANGE IN DIFFRENT LOCALTIES. 3854JD1020K

YL : YELLOWBK : BLACKBL : BLUEGN : GREENPR : PURRLEPK : PINK

4. CIRCUIT DIAGRAM

-8-

3. OLP (OVER LOAD PROTECTOR)

1) Definition of OLP

(1) OLP (OVER LOAD PROTECTOR) is attached to theHermetic Compressor and protects the Motor bycutting off current in Compressor Motor in case ofover-rising temperature by Bimetal in the OLP.

(2) When over-voltage flows to Compressor motor, theBimetal works by heating the heater inside the OLP,and the OLP protects Motor by cutting off currentwhich flows to the Compressor Motor.

2) Role of the OLP

(1) The OLP is attached to the Hermetic Compressorused for the Refrigerator and Show Case and preventsthe Motor Coil from being started in the Compressor.

(2) Do not turn the Adjust Screw of the OLP in any way fornormal operation of the OLP.(Composition andconnection Diagram of OLP)

CONTACTING�POINT

COVER

BIMETAL

CONTACTING�POINT

HEATER

TERMINALS

ADJUST�SCREW

HEATER

BIMETAL

Figure 14



5. TROUBLESHOOTING

-9-

DEFECT EFFECT CAUSE REMEDY

SYSTEMPARTIALLY ORCOMPLETELY OUTOF REFRIGERANTCHARGE

EXCESSIVELYFULL

HUMIDITY IN THESYSTEM

PRESENCE OF AIRIN THE SYSTEM

BLOCKEDCAPILLARY

MOTOR-COMPRESSORSHORT-CIRCUITEDOR BLOCKED

MOTOR-COMPRESSORDOSE NOTCOMPRESS

NOISY MOTOR-COMPRESSOR

Evaporator does not frost eventhough motor-compressor runscontinually.

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

This defect is indicated by thepartial frosting of the evaporatorand by continual defrosting cyclesdetermined by the interruption ofthe flow of gas on the evaporator.The motor compressor keepsrunning.

Poor performance of therefrigerant system which isindicated on the evaporator with aslight frost which does not freezeand an excessive overheating ofthe condenser and motor-compressor.

Because of the lack of circulationFreon® in the system, there is nofrosting of the evaporator, while aslight overheating of the first spiralof the condenser is noted.

The system does not work and the "OLP" intervenes interruptingdelivery to the motor-compressor.

No frost forms on the evaporator,even 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 R134a. This loss is generally to be lookedfor at the soldering pointsconnecting the various componentsor in an eventual hole in theevaporator made by the user.

If in the refrigerant system aquantity of R134a is introducedwhich is greater than thatindicated, the excess gas does not terminate its expansion in the evaporator but proceeds intothe return tube.

The refrigerant system is humidwhen there is a small percentageof water present, which, notcompletely retained by thedehydrator filter, enters intocirculation with the Freon® andfreezes at the capillary exit in theevaporator.

There is air in the refrigeratingsystem when during the fillingphase vacuum is not effected or itis not adequately done.

Impurities contained in the Freon®or in the components of therefrigeration system beforeassembly 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 whichremaining continually open, do notpermit the compressor to operate. Consequentely, Freon® does notcirculate in the system.

The cause of the excessive noiseis normally to be sought for in amechanical breakdown, and onlyrarely in the unhooking of one ofthe suspension springs.

Leakage must be eliminated byresoldering the defective point orsubstituting the damagedevaporator.

The system must be emptied andsubsequently refilled introducingthe correct quantity of R134a.

The system must be emptied andthen refilled after eliminating thehumidity.

Group must be drained andsubsequently refilled aftercarefully creating vacuum.

To restore the system it must beemptied, substitute the capillary orthe evaporator entirely in case thecapillary 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-compressor must bereplaced and then proceed withthe refilling.



-10-

NO COOLING

The Compressordoesn't run.

Poor running of theCompressor.

Compressor runs.

Measure the startingvoltage.

Check if the current flowsat the contacting point ofthe starting system.

Check if the current flowsto the sub coil of theCompressor.

Is the current amount ofthe electric componentsnormal?

Frost doesn't form at theEvaporator whenoperating set for morethan 30 min.

Poor contacting point

Shorted or Broken

Coil shorted

Low voltage Increase the voltage.

Replace the device.

Replace theCompressor.

Repair the Compressor.

Repair the Compressor.

Shorted Poor contactingpoint and broken

Shorted

The coil of theCompressor Motor isworn out.

Refrigerant leaks. Poorcompressing.

Check the current flowingof starting system.

Check the componentson the main circuit.

Check if the current flowsat the contacting point ofthe Thermostat.

Check if the current flowsat the main coil of theComprossor.

Replace theThermostat.

Replace the device.

Replace thecomponents.

Replace theCompressor.



-11-

COMPRESSOR AND ANOTHER ELECTRIC COMPONENTS

1�

2

3

4

5

2

4

3

3

4

4

5

5

NO

NO

NO

NO

NO

YES

YESYES

YES

YES

YESPower Source

Check theresistance of theCompressor Motor.

Check the starting state at the regularvoltage above.

Check theresistance ofthe PTC.

Check OLP.

Check the startingstate.

Separate the PTC-STARTER from theCompressor and measure the voltagebetween M and C of the Compressor.

Equal to the appliedvoltage. (Ratingvoltage ± 10%)

Advice the customer touse in the specifiedrange.

Advice the customer to usein the specified range.

Measure minimum starting voltageafter checking steps 1-3 above.Measure the pressure balance of thePTC at the interval of more than 5 min.

Starts at the voltage of more than 90%.

Replace OLP.

Normal.

Normal.

Replace the PTC.

Replace thePTC-STARTER.

The applied voltage is not in the rangeof Rating Voltage ± 10%.

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

Check if applying aregular OLP.

Test the resistance of the bothterminals in the PTC-STARTER.

Replace the Compressor.

Starts at the voltage of 85% below.



-12-

PTC

YES

NO

Poor starting or nooperating of theCompressor.

First, separate the PTC from theCompressor and check the voltagebetween NO 5 and 6 in the PTCwith a multitester or WheatstoneBridge.

Observation value is220~240V/50Hz : 33Ω±30%

The value is 0.

The value is ∞.

Check anotherelectriccomponents.

Replace the PTC.

Normal

Abnormal

Abnormal Replace the PTC.

Separate the OLP from theCompressor and checkresistance value between twoterminals of OLP with Tester.

Check other electriccomponents.

Replace OLP.



5. EXPLODED VIEW

-13-

411A

310A

309A

308A

307A

312A 315A

127A 104A

314A

283B

410A

410G

323B

106B

107A

281B

302A

302B

107B

282D

282D

318A

317A



-14-

120D

110C

408B

110A

302C

406B

409B

120A

110B

155A

151A

237A

235A

241C

233A

231A

281D

230A

241A

136B

136B

136A140A

140A

126A

125A

136A

EXPLODED VIEW



LG GC 181 Manual

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