LG GC-151 User manual

CAUTION
BEFORE SERVICING THE UNIT, READ THE "SAFETY
PRECAUTIONS" IN THIS MANUAL.
MODEL: GC-151
REFRIGERATOR
SERVICE MANUAL
http://biz.lgservice.com

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 wet
hands. 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
- 2 -

AIR RECHARGING IN COMPRESSOR
Test the refrigeration system connecting it electrically before
refilling operation. It is necessary to ascertain the function
of the motor-compressor and identify the defects
immediately. If defects have been found, empty the old
system of possible 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 complete extension with male Hansen and
at last, solder it to the same tube again. (Figure 2)
It is necessary to execute the soldering operation with
valve open so that the fumes caused by oil residue can
come out freely without blowholes between two tubes
during the heating the of the point to be soldered.
The extension fitted with the male Hansen is connected to
the female fitting of the vacuum pump tube. (Figure 3)
Air evacuating from the system begins as soon as the
pump starts. The refrigeration system must be kept under
vacuum until the reading on the low-pressure gauge
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 3)
In case that a considerable leakage occurs it will be
necessary to stop the vacuum pump and to add asmall
quantity of Freon to the system, if vacuum should not be
obtained (pressure gauge can't fall to 1 atmosphere), start
the 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
reestablishing the normal outside pressure inside the
group.
Because the melted alloy is sucked into the tubes and
block them, the pressure must be rebalanced when
vacuum is in the system in soldering. As soon as the
vacuum operation is over, add the quantity in grams of
R-134a to the refrigeration system. Remember that every
system 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 and
refilling cylinder are connected), make sure that the valve
placed between the vacuum pump and the refilling tube are
closed in order to keep the Freon for addition to the system.
(Figure 5)
In addition, check the graduated scale on the cylinder for
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
R-134a has dropped to 610 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-134a 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 motor-
compressor.
Therefore, proceed by adding the original
quantity of about 20-30 grams and close the valve
immediately.
The pressure rises and the motor compressor must start
sucking the gas and lowering the pressure again. Regulate
the valve again, maintaining the same manner until
reaching to the quantity of R-134a established for the
system being charged. When the system is running, the
suction pressure must be stabilized between 0.30 to
0.6(0.10 to 0.4) atmosphere.
SERVICING PRECAUTIONS
- 3 -
POINT TO BE BROKEN
SERVICE TUBE EXTENSION
CHARGE TUBE
EXTENSION FEMALE HANSEN
MALE HANSEN
SOLDERING POINT
Figure 1 Figure 2
TO THE
VACUUM
PUMP
PRESSURE
GAUGE
Figure 3
TO THE R-134a CYLINDER
TO THE REFRIGERATION
SYSTEM
Figure 4
FILLING OR
CHARGE TUBE VALVE TO BE OPENED WHEN REFILLING
VALVE TO BE CLOSED
AFTER VACUUM
TO THE CHARGE
CYLINDER
TO THE REFRIGERATION
SYSTEM
TO THE
VACUUM
PUMP
Figure 5

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 TRAY
Catches the water that
drips off the evaporator
when defrosting.
PLASTIC COATED
SHELVES
Have full width and can
slide out.
GLASS LID & VEGETABLE
CONTAINER
NOTE : This is a basic model. The shape of refrigerator is subject to change.
THERMOSTAT
Regulates the operation of
the motor and controlls the
temperature inside the
refrigerator.
SUPPORTER CAN
Keeps 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)

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 the
warranty.

4. CIRCUIT DIAGRAM
- 6 -
NOTE: Lamp is option part.

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-
COMPRESSOR
DOSE NOT
COMPRESS
NOISY MOTOR-
COMPRESSOR
Evaporator dose not frost even
though motor-compressor runs
continually.
This defect is indicated by the
presence of water outside
refrigerator near the motor caused
by formations of ice on the return
tube.
This defect is indicated by the partial
frosting of the evaporator and by
continual defrosting cycles
determined by the interruption of the
flow of gas on the evaporator. The
motor compressor keeps running.
Poor performance of the refrigerant
system which is indicated: on the
evaporator with a slight frost which
dose not freeze and an excessive
overheating of the condenser and
motor-compressor.
Because of the lack of circulation
Freon in the system, there is no
frosting of the evaporator, while a
slight overheating of the first spiral
of the condenser is noted.
The system dose not work and the
"clixson" intervenes interrupting
delivery to the motor-compressor.
No frost forms on the evaporator
even if the motor-compressor is
apparently running regulary.
In case of mechanical failure in the
motor-compressor there in an
excessive noise when the system is
functioning: in case a suspension
spring is unhooked, banging will be
heard and there will be especially
strong vibrations when the system
starts up and stops.
An empty refrigerant system
indicates a leakage of R12. This loss
is generally to be looked for at the
soldering points connecting the
various components or in an
eventual hole in the evaporator
made by the user.
If in the refrigerant system a quantity
of R12 is introduced which is greater
than that indicated, the excess gas
dose not terminate its expansion in
the evaporator but proceeds into the
return tube.
The refrigerant system is humid
when there is a small percentage of
water present which, not completely
retained by the dehydrator filter,
enters into circulation with the Freon
and freezes at the capillary exit in
the evaporator.
There is air in a refrigerating system
when during the filling phase
vacuum is not effected or it is not
adequately done.
Eventual impurities contained in the
Freon or in the components of the
refrigeration system before
assembly and not retained by the
filter can obstruct the capillary.
In case of short circuit, the
breakdown is due to the electric
winding: if blocked, there is a
mechanical failure in the motor-
compressor.
In this case there is a mechanical
failure in the diaphram valves which:
remaining continually open, do not
permit the piston to suck and
compressor the which
consequentely dose not circulate in
the system.
The cause of the excessive noise is
normally to be sought for in a
mechanical break down, and only
rarely in the unhooking of one of the
suspension springs.
Leakage must be eliminated by
resoldering the defective point or
substituting the damaged
evaporator.
The system must be emptied and
subsequently refilled introducing the
correct quantity of R-134a.
The system must be emptied and
then refilled after eliminating the
humidity.
Group must be drained and
subsequently refilled after carefully
creating vacuum.
To restore the system it must be
emptied, substitute the capillary or
the evaporator entirely in case the
capillary is coaxial with respect to
the return tube, then refill it.
The motor-compressor must be
replaced and then proceed with
refilling.
The motor-comprossor must be
replaced and then proceed with
refilling.
The motor-comprossor must be
substituted and then proceed with
the refilling.

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.
Check if the current
flows at the contacting
point of the starting
system.
Is the current amount of
the electric components
normal?
Check if the current
flowing of the sub coil of
the Compressor.
Frost doesn't form at the
Evaporator when
operating set for more
than 30 min.
Check if the current
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.

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
YES
Power Source
Check the
resistance 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 the
Compressor.
Equal to the applied
voltage. (Rating
voltage ± 10%)
Advice the customer
to use in the fixed
range.
Replace the
PTC-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 among
M-C, S-C, and M-S.
Test the resistance of the both
terminals in the PTC-STARTER.
Check if applying a
regular 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.

PTC
- 10 -
65
YES
NO
Poor starting or no
operating of the
Compressor.
First, separate the PTC from
the Compressor and check the
voltage between NO 5 and 6
in 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 the
range of 15-28 for
the 22ΩPTC.
Check another
electric components.
Replace OLP.
The value is 0.
The value is ∞.
Normal Check another
electric
components.
Replace the
PTC.
Replace the
PTC.
Abnormal
Abnormal

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
283A
318A
313A
416A
410A
*410G
*328A
328B

*: optional parts GC-151S
- 12 -
*151A
125A
*149B
207A
201A
*406B
126A
136A
136A
*136C
*281D
110B 110C
*409B
110A
*408B
*149A
110F

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 THERMOSTAT
R 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