LG GR-154 series Service Manual

REFRIGERATOR

SERVICE MANUAL

CAUTION

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

COLOR : SUPER WHITE

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MODEL: GR-154***

Ref.No.
GR-1

54

CONTENTS

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(Page)

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

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

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

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

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

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

FREEZER DOOR .........................................................................................................................................................5

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

FREEZER DOOR, HANDLE ....................................................................................................................................... 6

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

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

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

TROUBLESHOOTING ............................................................................................................................................ 9 - 10

ANOTHER ELECTRIC COMPONENTS........................................................................................................................11

REFRIGERATING CYCLE .....................................................................................................................................12 - 13

EXPLODED VIEW . ................................................................................................................................................15 - 16

REPLACEMENT PARTS LIST .....................................................................................................................................17

SAFETY PRECAUTIONS

Please read the following instructions before servicing your
refrigerator.

1. Check the set for electric losses.

2. Unplug prior to servicing to prevent electric shock.

3. Whenever testing with power on, wear rubber gloves to
prevent electric shock.

4. If you use any kind of appliance, check regular current,
voltage and capacity.

5. Don't touch deep-frozen products in the freezer with wet
hands. This may cause frostbite.

6. Prevent water from following onto electric elements in the
mechanical parts.

7. When tilting the set, remove any materials on the set,
especially the thin plates(ex. Glass shelf or books.)

8. Leave the disassembly of the refrigerating cycle to a
specialized service center. The gas inside the circuit may
pollute the environment.

9. When you discharge the refrigerant, wear the protective
safety glasses or goggle for eye safety.

10. When you repair the cycle system in refrigerator, the work

area is well ventilated.
Especially if the refrigerant is R600a, there are no fire or
heat sources. (No smoking)

SERVICING PRECAUTIONS

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Features of refrigerant (R600a)

• Achromatic and odor less gas.

• Flammable gas and the ignition (explosion) at 494°C.

• Upper/lower explosion limit: 1.8%~8.4%/Vol.

Features of the R600a refrigerator

• Charging of 60% refrigerant compared with a R134a model

• The suction pressure is below 1bar (abs) during the operation.

• Because of its low suction pressure, the external air may flow in the cycle
system when the refrigerant leak, and it causes malfunction in the compressor.

• The displacement of compressor using R600a must be at least 1.7 times larger
than that of R134a.

• Drier type is XH-9.

• The EVAPORATOR or any other cycle part that has welding joint is hidden in
the foam. (If not hidden inside, the whole electric parts must be tested with the
LEAKAGE TEST according to the IEC Standard.)

• The compressor has label of the refrigerant R600a.

• Only the Service man must have an access to the system.

Installation place

• Must be well ventilated.

• Must be 20 m

3

or larger.

• Must be no-smoking area.

• No ignitable factors must be present.

Utilities

• Refrigerant cylinder (MAX NET 300g)

• Manometer

• Vacuum pump (600L/min)

• Piercing Clamp

• Quick coupler

• Hoses (5m-1EA, 1m-3EA)

• LOKRING

• Portable Leakage detector (3g/year¯)

• Nitrogen cylinder (for leakage test)

• Concentration gauge

Make sure before Servicing

• Refrigerant
Confirm the refrigerant by checking Name Plate on innerliner and the label on
the compressor.

• If the refrigerant is R600a, you must not weld or apply a heat source.

Air Recharging in Compressor

Before refilling the refrigerant, you must perform the test according to Chapter 5
(TROUBLESHOOTING CHART). When the defects are found, you must
discharge the residual refrigerant (R600a) in the outdoor. For discharging the
refrigerant R600a, break the narrow portion of tube extension by hand or with a
pipe cutter as shown in Figure 1. Leave it for 30min in outside to stabilize the
pressure with ambient. Then, check the pressure by piercing the dryer part with
piercing pliers. If the refrigerant is not completely discharged, let the refrigerator
alone for more 30min in outside.

Attach the service tube installed with a Schrader valve (one-way
valve) by using the LOKRING (Figure 2). Then, connect the
Schrader valve (one-way valve) to the pump that is connected to
the discharging hose leading to the outside. When discharging the
residual refrigerant, repeat 3 cycle that includes 3min of the pump
running->pump off->30sec of the compressor running.

After the refrigerant (R600a) is completely discharged, repair any
defective parts and replace the dryer. At any case you must use the
LOKRING for connecting or replacing any part in the cycle (No Fire,
No Welding). Connect the Schrader valve to pump with the coupler.
And then turn the pump on for vacuum state (Figure 3). Let the
pump run until the low-pressure gauge indicates the vacuum (gauge
pressure 0, absolute pressure -1atm or -760mmHg). Recommended
vacuum time is 30 min. Charge the N2 gas in order to check for
leakage from welding points and the LOKRING. If leakages are
found, repair the defects and repeat the vacuum process.

After the system is completely vacuumed, fill it with the refrigerant
R600a up to what has been specified at your refrigerator Name
Plate. The amount of refrigerant (R600a) must be precisely
measured within the error of ±1g by an electron scale (Figure 4).

If you use the manifold connected with both the refrigerant
(R600a) cylinder and the vacuum pump simultaneously,
make sure the pump valve is closed (Figure 5).

Connect the charging hose (that is connected to the refrigerant (R600a) cylinder) to
the Schrader valve installed on the service tube. Then, charge the refrigerant (R600a)
by controlling the Throttle valve. When you do so, do not fully open the Throttle valve
because it may make damage to the compressor. Gradually charge the refrigerant
(R600a) by changing open and close the Throttle Valve (5g at each time). The
charging hose must use a one-way valve to prevent the refrigerant refluence. Close
the Schrader valve cap after the refrigerant (R600a) is completely recharged.

After you completely recharge the refrigerant (R600a), perform the leakage test by
using a portable leakage detector or soapy water.
Test the low pressure (suction) parts in compressor off time and high pressure parts
in compressor on time. If the leakages are found, restart from the refrigerant (R600a)
discharging process and repairs defects of leaks.

After the leakage test, check the temperature of each parts of the cycle. Check with
hands if the CONDENSER and the case (HOT-LINE pipe) that is contacted to the
door gasket are warm. Confirm that frost is uniform distributed on the surface of
the freezer room and the back wall of fridge room.

POINT TO BE
BROKEN

CHARGE TUBE
EXTENSION

SCHRADER VALVE
(ONE-WAY VALVE)

LOKRING

SERVICE TUBE
EXTENSION

Figure 1 Figure 2

TO THE
VACUUM
PUMP

PRESSURE
GAUGE

Figure 3

WEIGH SCALE

THROTTLE
VALVE

COUPLE

REFRIGERANT
(R600a)

CHARGING HOSE

Figure 4

FILLING OR
CHARGE TUBE

VALVE TO BE OPENED
WHEN REFILLING

VALVE TO BE CLOSED
AFTER VACUUM

TO THE VACUUM PUMP

TO THE
REFRIGERATION
SYSTEM

TO THE CHARGE
CYLINDER

Figure 5

1. SPECIFICATIONS

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2. PARTS IDENTIFICATION

1-1 GR-154

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

STORAGE CAPACITY

FREEZER

100

TOTAL 100

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

NET WHIGHT(kg) 40

TEMPERATURE CONTROL BUTTON

DEFROSTING SYSTEM MANUAL

OUT CASE Coated Steel sheet

INNER CASE ABS

INSULATION CYCLOPENTANE

ITEMS SPECIFICATIONS

DRAWER 4EA

ICE TRAY

COMPRESSOR P.T.C Starting Type

CONDENSE

R Wire Condenser

REFRIGERANT

R600a (40g)

LUBRICANT OIL

HTS 60 MT(210cc)

ITEMS SPECIFICATIONS

YES

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

3. DISASSEMBLY

-5-

Figure 6

2. Remove the LEG ③.

▶ Reversible

4. Before refitting the door, swap the Hinge Cap ④ by pulling it
out from its current location and repositioning it on the other
side of the door. Care should be taken not to damage the
adjacent surfaces when removing the Hinge Cap.

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

6. After refitting the door, fix the Lower Hinge(L) in the

opposite 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 is
steady and check that the door opens and closes
properly.