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REFRIGERATOR SERVICE MANUAL

CAUTION

PLEASE READ CAREFULLY THE SAFETY PRECAUTIONS OF THIS BOOK BEFORE CHECKING OR OPERATING THE REFRIGERATOR.

Ref. No. GR-B197DVCA

MODEL: GR-B197WV

COLOR: SUPER WHITE

CONTENTS
WARNINGS AND PRECAUTIONS FOR SAFETY.... 3 SPECIFICATIONS..... 4 PARTS IDENTIFICATION...... 12 HOW TO INSTALL THE REFRIGERATOR.... 18 HOW TO ADJUST DOOR HEIGHT OF THE REFRIGERATOR... 18 HOW TO INSTALL WATER PIPE.....19 HOW TO CONTROL THE AMOUNT OF WATER SUPPLIED TO THE ICEMAKER.. 23 MICOM FUNCTION..... 25 MICOM CIRCUIT DESCRIPTION..... 31 DESCRIPTION OF PWB CIRCUIT SENSOR RESISTANCE CHARACTERISTIC TABIE PWB PARTS DRAWING AND LIST PWB CIRCUIT DRAWING ICE MAKER AND DISPENSER WORKING PRINCIPLES AND REPAIR... 53 WORKING PRINCIPLES FUNCTION OF ICE MAKER ICE MAKER TROUBLESHOOTING ICE MAKER CIRCUITS CIRCUIT...... 58 TROUBLE DIAGNOSIS..... 60 TROUBLE SHOOTING..... 60 FAULTS...... 70 COOLING CYCLE HEAVY REPAIR..... 87 HOW TO DEAL WITH CLAIMS..... 94 HOW TO DISASSEMBLE AND ASSEMBLE.... 99 DOOR...... 99 HANDLE...... 100 SHROUD, GRILLE FAN..... 100 ICEMAKER...... 100 DISPENSER..... 101 WATER TANK AND WATER LINE.... 103 HOME BAR...... 103 EXPLODED VIEW..... 104 REPLACEMENT PARTS LIST..... 113
WARNINGS AND PRECAUTIONS FOR SAFETY
Please observe the following safety precautions in order to use safely and correctly the refrigerator and to prevent accident and danger during repair. 1. Be care of an electric shock. Disconnect power cord from wall outlet and wait for more than three minutes before replacing PWB parts. Shut off the power whenever replacing and repairing electric components. 2. When connecting power cord, please wait for more than five minutes after power cord was disconnected from the wall outlet. 3. Please check if the power plug is pressed down by the refrigerator against the wall. If the power plug was damaged, it may cause fire or electric shock. 4. If the wall outlet is over loaded, it may cause fire. Please use its own individual electrical outlet for the refrigerator. 5. Please make sure the outlet is properly earthed, particularly in wet or damp area. 6. Use standard electrical components when replacing them. 7. Make sure the hook is correctly engaged. Remove dust and foreign materials from the housing and connecting parts. 8. Do not fray, damage, machine, heavily bend, pull out, or twist the power cord. 9. Please check the evidence of moisture intrusion in the electrical components. Replace the parts or mask it with insulation tapes if moisture intrusion was confirmed. 10. Do not touch the icemaker with hands or tools to confirm the operation of geared motor. 11. Do not let the customers repair, disassemble, and reconstruct the refrigerator for themselves. It may cause accident, electric shock, or fire. 12. Do not store flammable materials such as ether, benzene, alcohol, chemicals, gas, or medicine in the refrigerator. 13. Do not put flower vase, cup, cosmetics, chemicals, etc., or container with full of water on the top of the refrigerator. 14. Do not put glass bottles with full of water into the freezer. The contents shall freeze and break the glass bottles. 15. When you scrap the refrigerator, please disconnect the door gasket first and scrap it where children are not accessible.

SPECIFICATIONS

1. Ref No. : GR-P247
ITEMS DIMENSIONS (mm) NET WEIGHT (kg) COOLING SYSTEM TEMPERATURE CONTROL DEFROSTING SYSTEM SPECIFICATIONS 890(W)X840(D)X1750(H) 128 Fan Cooling Micom Control Full Automatic Heater Defrost INSULATION COMPRESSOR EVAPORATOR CONDENSER REFRIGERANT LUBRICATING OIL DRIER CAPILLARY TUBE Cyclo-Pentane P.T.C. Starting Type Fin Tube Type Wire Condenser R134a (185g) FREOL @15G (320 cc) 10.83 MOLECULAR SIEVE XH-7 FREEZER LAMP REFRIGERATOR LAMP DISPENSER LAMP ANTI-FREEZING HEATER ANTI SWEAT HEATER ITEMS FIRST DEFROST DEFROST CYCLE DEFROSTING DEVICE SPECIFICATIONS 4 - 5 Hours 13 - 15 Hours Heater, Sheath Heater, L - Cord Dispenser Duct Door Heater Dispenser Heater Home Bar Heater Water Tank Heater Damper Heater 40W (1 EA) 40W (1 EA) 15W (1 EA)

Dispenser selection button
2. Description of Function
2-1. Funnction of Temperature Selection
Division Power Initially On 1st Press 2nd Press 3th Press 4th Press
Change of Indication Lamp
Temperature Control Freezer Control
Medium -19 C (-18 C) <-19 C> 3 C <2 C>
Medium Max -22 C (-20.5 C) <-20.5 C> 1.5 C <1 C>
Max -23 C (-22 C) <-22 C> 0C <0 C>

*( *<

Medium Min
-15 C <-16.5 C> 6 C (7 C) <4.5 C>
-17 C <-18 C> 4.5 C <3 C>

Refrigeration Control

* The temperature can vary 3 C depending on the load condition.
) : 127V/60Hz, 110~115V/60Hz, 115V/60Hz Rating ONLY. > : TAIBEI
1. When power is initially applied or reapplied after power cut, Medium is automatically selected. 2. When the temperature selection switch in the freezer and refrigerator compartments is pressed, the light is on in the following sequence: "Medium" "Medium Max" "Max" "Min" "Medium Min" "Medium" 3. The temperature setting condition of freezer and refrigerator compartments shall not be indicate in the standard model (GR-P247, GR-P207, GR-L247, GR-L207, GR-C247, GR-C207, GR-B247, GR-B207) when refrigerator or home bar door is closed.

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2-2. Control of Variable Speed Fan in the Refrigerator Compartment
1. Fan motor in the freezer compartment shall change from standard to high speed rpm in order to increase cooling speed and load corresponding speed. 2. High speed rpm is only used for the initial power application and load corresponding operation. But standard rpm is used in the general working conditions. 3. Fan motor in the freezer compartment operates normally when freezer, refrigerator, or home bar door opens and fan motor in the freezer compartment operates (the speed changes from high to standard rpm if fan motor operates at high speed rpm). But fan motor in the freezer compartment stops when refrigerator or home bar door is open and refrigerator compartment door is closed.

Defrost sensor short circuit
Standard No RPM defrosting
Defrost Heater, Temperature Fuse short circuit. Unplugged Connector (Indicated 4 hour later after trouble) Open air temperature detecting sensor short circuit Defrost sensor short circuit.
Abnormal Open Air Temperature Detecting sensor Abnormal ice making sensor Abnormal ice maker unit

Standard RPM

Faulty Ice Maker Unit Motor or Hall IC, L/Wire short circuit. Faulty motor driving circuit.

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Note 1) When open air temperature detecting sensor, refrigerator sensor 2, ice maker unit, ice making sensor are abnormal, it is not indicated in the trouble code. But it is indicated while checking LED (press freezer and refrigerator temperature control buttons for more than 1 second at the same time). A LED On. Normal : Room Temperature Detection Sensor Abnormal : A LED Off. Refrigerator Sensor 2 (lower shelf) Home Bar Sensor Normal : B LED On. The rest of LEDs are all on
Abnormal : B LED Off. Normal : C LED On.
Abnormal : C LED Off. Ice Maker Unit Normal : D LED On.
Abnormal : D LED Off. Note 2) When refrigerator sensor is abnormal, it opens for 10 minutes and closes for 15 minutes.

2-9. Test Function

1. Test function is to check the function of PWB and products and to find defective parts when the refrigerator is out of order. 2. Test button is on the main PWB of the refrigerator. Test mode completes after 2 hours in maximum and returns to normal conditions. 3. Function control button does not work but button recognition sound is heard during the test mode. 4. When test mode is completed, unplug and replug the power cord to return to the normal conditions. 5. When sensor is abnormal in the test mode, test mode is released and trouble code is indicated. 6. Test mode does not work even test button is pressed when trouble code indicator is on. Mode Test 1 Operation Press test button once Contents 1. Continuous compressor operation 2. Continuous freezer fan (high rpm) operation 3. Defrost heater off. 4. All display LEDs are on. 5. Electronic stepping motor damper open (baffle is open). 1. Compressor off. 2. Freezer fan (high rpm) off. 3. Freezer fan (standard rpm) on. 4. Defrost heater off. 5. Medium Weak led in freezer and refrigerator temperature indicators are on. 6. Step motor damper open condition (baffle is open) 1. Compressor is off. 2. Freezer fan off. 3. Defrost heater on. 4. Medium leds in freezer and refrigerator temperature indicators are on. 5. Step motor damper closed condition (baffle is closed) Return to initial conditions Remarks Forced start

2. Refrigerator Weak Cooling and Over Cooling Compensation Circuit
Temperature Compensation by Cutting JCR1 JCR2 JCR3 JCR4 +1 C +1 C -1 C -1 C +2 C -2 C
WEAK COOLING COMPENSATION JCR3 JCR4
OVER COOLING COMPENSATION JCR1 JCR2
REFRIGERATOR COMPARTMENT TEMPERATURE COMPENSATION 0 C (FACTORY SHIPPING)

REMARKS

CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT CUT
-1 C -1 C +1 C +1 C -2 C +2 C 0 C 0 C 0 C 0 C -1 C +1 C 0 C
The above option circuit is to compensate the refrigerator compartment temperature by cutting during service.

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1-10. Key Button Input and Display Lighting Circuit
1. GR-P247, GR-P207, GR-L247, GR-L207 This circuit is to judge the work of function control button on the operation panel and to light each function indication led (LED module). It is driven by SCAN method.

Freezer Temp Control

Refrigerator Temp Control

Crushed /Water /Cube

F5 F4 F3 F2 F1

R5 R4 R3 R2 R1

R FRZ TEMP REF TEMP

S SELECT

2. GR-C247, GR-C207, GR-B247, GR-B207, GR-B197

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2. Sensor Resistance Characteristic Table
Measured Temperature (C) -20 C -15 C -15 C -5 C 0 C +5 C +10 C +15 C +20 C +25 C +30 C +40 C +50 C Freezer Sensor 22.3 k 16.9 k 13.0 k 10.1 k 7.8 k 6.2 k 4.9 k 3.9 k 3.1 k 2.5 k 2.0 k 1.4 k 0.8 k Refrigerator Sensor 1 and 2, Defrost Sensor and Open Air Sensor 77 k 60 k 47.3 k 38.4 k 30 k 24.1 k 19.5 k 15.9 k 13 k 11 k 8.9 k 6.2 k 4.3 k
Tolerance of sensor resistance is 5 %. Leave the sensor at measuring temperature for more than 3 minutes when measuring sensor resistance. (necessary due to detecting speed) It is desirable to use digital tester as analogue tester has wider measuring temperature. Disassemble refrigerator sensor 1 and 2 from CON8 of main PWB assembly and measure it with digital tester. Disassemble freezer sensor from CON7 of main PWB assembly and measure it with digital tester.

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D7 J40 F-SNR D-SNR FD/SW J43 JR51 R37 IC10 J09 RF1 J12 R17 J16 J18 RR2 RR1 J10 RD1 J13 R56 J14 R46 J15 R42 J17 R53 J19 J20 R38 J11 RIM1 CE8 CE6 CE7 J41 J02 J03 J42 R36 J36 ZD3 ZD2 SW1 ZD4 J06 Q5 R59 R55 R45 R41 R50 R44 J21 J22 R52 J23 J24 R43 R39 R40 R54 J25 CC19 CC30 CC16 CC23 CC24 CC18 CC17 CC14 CC15 J07 BUZZER Q4 J27 CCCC7 CE5 J28 R26 OSC1 R15 R16 R27 R28 IC9 R29 CC10 CC11 R25 J50 Q3 JJ54 Q2 CC25 R32 J26 R47 CC26 JCON6 [DISPLAY] J45 J46 Q1 R48 J05 J04 ZD1 IC3 R8 CC1 R57 R58 J48 RCF1 RCRRJ47 CON8 CC27 IC11 J01 CC28 CC22 CC21 CC20 CONR49 CM4 CON9 ICE/M ICE/M STOP H/IC TEST MOTOR SNR S/W 5V S/W
CC29 DAMP R1-SNR R2-SNR RD/SW HTR STEP MOTOR

Failed DC Power Check DC power (5V, 12V).

Change main PWB

Is cube ice led off during troubleshooting check?
Failed ice making sensor Check the resistance of both ends (3,4) of ice making sensor of CON9. Defects between ice making sensor and board (Pin No. 58 of IC1)
Replace Ice making Sensor
Is Crushed Ice LED off during troubleshooting check?
Failed Ice Maker Unit Is the resistance of both ends of ice ejection motor of CON9 between 18 and 22? Is ice ejection motor drive circuit (IC11 and peripheral circuits) normal? Defects between Hall IC and Board (Pin No. 44 of IC1). Confirm ice ejection and level return when pressing test switch.

Replace Ice Maker Unit

Replace Main PWB
Are ice ejection and level return normal when test switch is pressed for more than 0.5 second? Does the bell sound once?
Failed ice maker unit test switch Are both ends of CON9 test switch open? Defects between test switch and board (Pin No. 45 of IC1). Are both ends (5,6) of CON9 ice maker stop switch short?

Replace Ice maker Unit

Is water suppy normal after Ice ejection and level return by ice ejection motor?
Poor water supply Is power applied to water supply valve? Does the water supply valve work normally? Is the water supply line normally connected?
Replace water supply valve

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4. Ice Maker Circuits

FOWARD REVERSE

ICE MAKER STOP SWITCH
The above ice maker circuits are applied to GR-P247, GR-P207 and GR-L247, GR-L207 and composed of ice maker unit in the freezer and ice maker driving part of main PWB. Water is supplied to the ice maker cube mould through the solenoid relay for ice valve of solenoid valve in the machine room by opening valve for the set time. Water supply automatically stops when water supply time is elapsed. This circuit is to realize the functions such as ice ejection of ice maker cube mould, ice full detection, leveling, ice making temperature detection, etc. Refer to the temperature detecting circuits of Main PWB for ice making temperature detection. Ice maker test switch input detection is the same as the door switch input detection circuit of main PWB. 1. It is to force to operate during operation test, service, and cleaning. The test switch is mounted under the automatic ice maker. The test function starts when the test switch is pressed for more than 0.5 second. 2. Test button does not work during ice ejection and water supply. It works when it is in the horizontal conditions. If cube mould is full of ice during test function operation, ice ejection control and water supply control do not work. 3. Ice ejection carries out irrespect of ice formation in the ice making tray if test switch is pressed for more than 0.5 second. Water shall be splashed if test switch is pressed before the water in the mould is completely frozen. Water shall be supplied while the mould returns to the horizontal conditions after ice ejection. Therefore the problems of ice ejection, leveling, and water supply can be checked by test switch. When test function performs normally, buzzer sounds and water supply shall carry out. Check it for repair if buzzer does not sound. 4. When water supply is completed, normal cycle works: Ice Making Ice Ejection Level Return Water Supply. 5. If ice maker stop switch is set to ON, normal cycle operates: Ice Making Ice Ejection Level Return Water Supply. If it is set to OFF, ice making conducts but ice ejection, level return, and water supply do not work.

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CIRCUIT
GR-B247, GR-B207, GR-C247, GR-C207, GR-B197

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GR-P247, GR-P207, GR-L247, GR-L207
HOME BAR PART(H/BAR-HEATER, DOOR S/W) SOLENOID WATER VALVE, CAPACITOR PART, THE PLUG TYPE, COMPRESSOR EARTH PART ON CIRCUIT DIAGRAM ARE SUBJECT TO CHANGE IN DIFFERENT LOCALITES AND ACCORDANCE WITH MODEL TYPE.

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TROUBLE DIAGNOSIS

1. TROUBLE SHOOTING

CLAIMS. 1. Faulty start CAUSES AND CHECK POINTS. 1) No power on outlet. 2) No power on cord. Bad connection between adapter and outlet. (faulty adapter) The Inner diameter of adapter. The distance between holes. The distance between terminals. The thickness of terminal. Bad connection between plug and adapter (faulty plug). The distance between pins. Pin outer diameter. 3) Shorted start circuit. No power on Disconnected copper wire. power cord. Internal electrical short. Faulty terminal contact. Loose contact. - Large distance between male terminal. - Thin female terminal. Terminal disconnected. Bad sleeve assembly. Disconnected. Weak connection. Short inserted cord length. Worn out tool blade. Power cord is disconnected. Faulty soldering. HOW TO CHECK * Measuring instrument : Multi tester s Check the voltage. If the voltage is within 85% of the rated voltage, it is OK. s Check the terminal movement.
s Check both terminals of power cord. Power conducts : OK. No power conducts : NG

O.L.P is off.

Capacity of O.L.P is small. Characteristics of O.L.P is bad. Bad connection. Power is Inner Ni-Cr wire blows out. disconnected. Bad internal connection. Faulty terminal caulking (Cu wire is cut). Bad soldering. s Check both terminals of O.L.P. If power conducts : OK. If not : NG.
No electric power on compressor. - Faulty compressor. Faulty PTC. Power does not conduct. - Damage. Bad characteristics. - Initial resistance is big. Bad connection with Too loose. compressor. Assembly is not possible. Bad terminal connection. 4) During defrost. Start automatic defrost. Cycle was set at defrost when the refrigerator was produced. s Check the resistance of both terminals. At normal temperature 6 : OK. If disconnected :.

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CLAIMS. 2. No cooling. CAUSES AND CHECK POINTS. 2) Refrigeration system is clogged. Moisture clogged. Residual moisture in the evaporator. Air Blowing. Not performed. Too short. Impossible moisture confirmation. Low air pressure. During rest time. After work. HOW TO CHECK s Check the clogged evaporator by heating (as soon as the cracking sound begins, the evaporator start freezing)

Leave it in the air. Caps are missed. Residual moisture.
Not dried in the compressor. Elapsed more than 6 months after drying Caps are missed. No pressure when it is open. Dry drier - Drier temperature. Leave it in the air. Check on package condition. Good storage after finishing. During transportation. During work.
No electric power on thermostat.
Insufficient drier capacity.
Residual moisture in pipes.

Caps are missed.

Air blowing. Not performed. Performed. Too short time. Low air pressure. Less dry air. Moisture penetration - Leave it in the air. - Moisture penetration. into the refrigeration oil. Short pipe insert. Weld joint clogged. Pipe gaps. Too large. Damaged pipes. s The evaporator does not cool from the beginnig (no evidece of misture attached). The evaporator is the same as before even heat is applied.
Too much solder. The capillary tube inserted depth. - Too much. Drier cloggeing. Capillary tube melts. - Over heat. Clogged with foreign materials. Desiccant powder. Weld oxides. Drier angle.
Reduced cross section by cutting. - Squeezed. Compressor cap is disconnected. Foreign materials are in the pipe.
Foreign material clogging.

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CLAIMS. 3. Refrigeration is weak. CAUSES AND CHECK POINTS. 1) Refrigerant Partly leaked. Weld joint leak. Parts leak. s Check visually. Inject P/U into drain hose. Inject through the hole. Seal with drain. HOW TO CHECK
2) Poor defrosting capacity. Drain path (pipe) clogged.
Foreign materials penetration.
P/U lump input. Screw input. Other foreign materials input.
Cap drain is not disconnected. Defrost heater does not generate heat. Parts disconnected. Plate heater Wire is cut. - Heating wire. - Contact point between heating and electric wire. Dent by fin evaporator. Poor terminal contacts. Wire is cut. - Lead wire. - Heating wire. - Contact point between heating and electric wire. Heating wire is corroded - Water penetration. Bad terminal connection. s Check terminal Conduction: OK. No conduction: NG. If wire is not cut, refer to resistance. P=Power V=Voltage R=Resistance V2 P= R V2 R= P

Cord heater

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CLAIMS. 3. Refrigeration is weak. Residual frost. CAUSES AND CHECK POINTS. Weak heat from heater. Sheath Heater - rated. Heater plate - rated. Heater cord-L - rated. No contact to drain. Loosened stopper cord. HOW TO CHECK
Bad heater assembly. Heater plate
Heater cord-L Not contact to the evaporator pipe. Location of assembly (top and middle). Too short defrosting time. Defrost Sensor. - Faulty characteristics. Seat-D(missing, location. thickness). Structural fault. Gasket gap. Air inflow through the fan motor. Bad insulation of case door. No automatic defrosting. Defrost does not return.

3) Cooling air leak. Bad gasket adhestion
Gap. Bad attachment. Contraction.

Door sag.

Bad adhesion. Weak binding force at hinge. s Check the fan motor conduction: OK. No conduction: NG.
4) No cooling air circulation. Faulty fan motor. Fan motor. Self locked. Wire is cut. Bad terminal contact. Contact distance. Button pressure. Melted contact. Contact. Refrigerator and freezer switch reversed. Button is not pressed. Poor door attachment. Door liner (dimension). Contraction inner liner. Misalignment. Bad terminal connection. P/U liquid leak. Faults.

Door switch.

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CLAIMS. 3. Refrigeration is weak. CAUSES AND CHECK POINTS. 4) No cooling air circulation. Faulty fan motor. Fan is constrained. Insufficient motor RPM Fan shroud contact. - Clearance. Damping evaporator contact. Accumulated residual frost. Fan overload. - Fan misuse. Bad low termperature RPM characteristics. Rated power misuse. Low voltage. Fan misuse. Bad shape. Loose connection. - Not tightly connected. Insert depth. Bent. HOW TO CHECK
Small cooling air discharge.

Faulty fan.

Shorud.
Ice and foreign materials on rotating parts.

5) Compressor capacity.

Rating misuse. Small capacity. Low valtage. Malfunction of charging cylinder. Wrong setting of refrigerant. Insufficient compressor. - Faulty compressor.
6) Refrigerant too much or too little.
7) Continuous operation - No contact of temperature controller. - Foreign materials.
s Check visually after disassembly.
8) Damper opens continuously. Foreign materials P/U liquid dump. jammed. EPS water sediment. Screw. Failed sensor. - Position of sensor. Characteristics Bad characteristics of its own temperatue. of damper. Parts misuse. Charge of temperature - Impact. characteristics. 9) Food storing place. - Near the outlet of cooling air.

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CLAIMS. 4. Warm refrigerator compartment temperature. CAUSES AND CHECK POINTS. 1) Colgged cooling path. P/U liquid leak. Foreign materials. P/U dump liquid. 2) Food storate. Store hot food. Store too much at once. Door open. Packages block air flow. HOW TO CHECK
5. No automatic operation. (faulty contacts.)
1) Faulty temperature sensor in freezer or refrigerator compartment. Faulty contact. Faulty temperature characteristics. 2) Refrigeration load is too much.

Bolt is loosened during transportaion. Not tightly fastened. Screw worn out. Adhesion surface. Not well fixed. Bigger door foam. Hinge-Pin tilted-Poor flatness. No washer. No grease and not enough quantity.

Malfunction.

Not closed Interference between door liner and inner liner. Refrigerator Stopper worn out. compartment is Bad freezer compartment door opened when freezer assembly. compartment is No stopper. closed (faulty stopper).
2) Odor. Temperature of refrigerator compartment. Deodorizer.
Faulty damper control. Button is set at "weak". Door is open (interference by food).
No deodorizer. Poor capacity. Seal condition. Store special odorous food. Long term storage. Odors from chemical procucts.

Food Storage.

Others.

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2. Faults

2-1. Power

Checks - Check the voltage with tester. - Check visually. - Check visually. - Reconnect the connecting parts. -Reconnect the connecting parts. -Replace the components. Measures Remarks

Problems

Causes

No power on

- Power cord cut.

outlet.

- Faulty connector insertion.
- Faulty connection between plug
and adapter. - Check the fuse with tester or visually. - Check the input volt are with tester (between power cord and products). - Replace with rated fuse. - Check the resistance of power cord with testerf (if it is 0, it is shorted). s If fuse blowns out frequently, reconfirm the cause and prevent. low voltage). problem(ex. short, high voltage, - Find and remove the cause of - Replace with rated fuse after confirming its specification.
Fuse blows out. - Short circuit by wrong connection.
- Low voltage products are
connected to high voltage.
- Short circuit by insects.

- Electricity leakage.

- High voltage.
- Short circuit of components
(tracking due to moisture and dust
- 70 Checks - Check the resistance. Vlaue: is defective. with new one. - If compressor assembly parts are normal(capacitor, PTC, OLP), apply power directly to the compressor to force operation.
Auxiliary winding Main winding Power

- Door opens.
- High temperature, high moisture,

and high load.

Problems - Check food storage conditions visually.(Check clogging at intake and discharging port of cooling air.) - Check food occupation ratio in volume(Less than 75%). - Check frost on the evaporator after dissembling shroud and fan grille. - Check icing at intake port of refrigerator compartment. - Check gasket attachment conditions. - Check door assembly conditions. - Refrigerator operates pull down. (Check if it is operated intermittently) - The Temperature of freezer compartment is satisfactory, but over freezing happens in the refrigerator compartment even though the notch is set at "weak". - Check frost on the evaporator after - Check parts related to defrosting. dissembling shroud and grille. - Check ice on the intake port in the refrigerator compartment. - Check food holds door open. - Check ice on the ice tray. - Check defrosting.(Check ice on the evaporator and pipes after forced defrosting.) - Be acquainted with how to use. -Replace defective parts. conditions and replace it. - Door assembly and replacement. - Correct the gasket attachement - Replace when it can not be repaired. defrosting). the faulty defrosting. evaporator and pipes after forced problem is caused by - Check defrost (Check ice on the to defrosting if the - Be acquainted with how to use. - Check the parts related
Ice in the freezer 1) Bad cooling air circulation.
- Intake port is colgged in the freezer

- Surface of fan

grille.
- Discharging port is Clogged.
- Wall of freezer - Too much food is stored.

- Cool air

discharging port.

- Basket(rack)

- Food surface. 2) Bad freezer compartment door

- Icing in the

- Faulty gasket

shute.

- Faulty assembly
3) Over freezing in the freezer

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- Faulty MICOM.

4) Bad defrosting.

- Faulty defrost sensor.

- Defrosting cycle

5) User is not familiar with how to
- High moisture food(water) is stored.

2-7. Sound

Checks 1.1 Check the level of the refrigerator. 1.2 Check the rubber seat conditions (sagging and aging). reduces noise in the pipe. 2.1 Check the level of pipes connected to the compressor and their interference. 2.2 Check rubber inserting conditions in pipes. 2.3 Touch pipes with hands or screw 7) Leve a clearance between -driver (check the change of sound). sound. 9) Leave a clearance if evaporator pipes and suction pipe touch freezer shroud. the structures. 8) Reassemble the parts which make blade damage. 3.2 Check the interference with structures. 3.3 Check fan motor. 3.4 Check fan motor rubber insertion and aging conditions. 4.1 Same as fan confirmation in the refrigerator. 4.2 Check drip tray leg insertion. 4.3 Check the screw fastening conditions at condenser and drip tray. interfering parts and seal gaps in bell mouth of the fan guide. 6) Adjust fan to be in the center of motor. 5) Replace defective fan and fan 4) Avoid pipe interference. 3) Insert rubber where hand contact are sagged and aged. 2) Replace rubber and seat if they 1) Maintain horizontal level. Measures Remarks

Drier High pressure side

Refrigent Intake
When replacing a drier: Weld and parts by blowing nitrogen(0.1~0.2kg/cm2) to high pressure side after assembling a drier. When replacing a compressor: Weld and parts by blowing nitrogen to the low pressure side. Note) For other parts, nitrogen blowing is not necessary because it does not produce oxidized scales inside pipe because of its short welding time. 3. Replacement of drier. * Unit : mm KEYPOINTING Be sure to check the inserted length of capillary tube when it is inserted. (If too much inserted, a capillary tube is clogged by a filter.)
12 Filter Inserting a capillary tube
Measure distance with a ruler and put a mark(12+3/-0)on the capillary tube. Insert tube to the mark, and weld it

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Items 4.Vacuum degassing.
Suction pipe Compressor Drier

Precautions

Evaporator
Low pressure Blue Yellow Red

High pressure

Vaccum Pump
Pipe Connection Connect a red hose to the high pressure side and a blue hose to the low pressure side. Vacuum Sequence Open , valves and evacuate for 40 minutes. Close valve. 5.Refrigerant charging. Charging sequence
KEYPOINTING - If power is applied during vacuum degassing, vacuum degassing shall be more effective. - Operate compressor while charging refrigerant. (It is easier and more certain to do like this.)
1) Check the amount of refrigerant supplied to each model after completing vacuum degassing. 2) Evacuate bombe with a vacuum pump. 3) Measure the amount of refrigerant charged. - Measure the weight of an evacuated bombe with an electronic scale. - Charge refrigerant into a bombe and measure the weight. Calculate the weight of refrigerant charged into the bombe by subtracting the weight of an evacuated bombe. Indicate the weight of an evacuated bombe R134a KEYPOINTING - Be sure to charge the refrigerant at around 25C. - Be sure to keep -5g in the winer and +5g in summer Calculation of amount of refrigerant charged the amount of refrigerant charged= a weight after charging a weight before charging (a weight of an evacuated cylinder)

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Items Precautions Evaporator
Compressor Drier Condenser Bombe 4) Refrigerant Charging Charge refrigerant while operating a compressor as shown above. 5) Pinch a charging pipe with a pinch-off plier after completion of charging. 6) Braze the end of a pinched charging pipe with copper brazer and take a gas leakage test on the welded parts. 6. Gas-leakage test 7. Pipe arrangement in each cycle * Take a leakage test on the welded or suspicious area with an electronic leakage tester. Check each pipe is placed in its original place before closing a cover back-M/C after completion of work. Particularly control the size of Joint Drain Pipe Rubber

s Check if food is stored near the outlet of the cooling air. The temperature at cooling air outlet is always below the freezing point. Do not store food near the outlet of the cooling air as it block the air circulation. And do not block the outlet. If the outlet of the cooling air is blocked, the refrigerator compartment will not be cooled.

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4-3. Odor and Frost
Odor in the refrigerator compartment.
s Explain the basic principles of food odor. Each food has its own peculiar odor. Therefore it is impossible to prevent or avoid food odor completely when food is stored in the completely sealed refrigerator compartment. Deodorizer can absorb some portions of the odor but not completely. The intensity of odor depends on refrigerator conditions and environments.
s Check the temperature control button and set at strong. Clean inside of the refrigerator with detergent and remove moisture. Dry inside the refrigerator by opening the door for about 3 or 4 hours and then set the temperature control button at strong.
Frost in the freezer compartment
s Explain the basic principles of frost formation. The main causes for frosting: - Door was left open. - Air penetration through the gasket - Too frequent door opening. (parties. etc.) - Hot foods are stored before they are cooled down. The temperature of freezer is -19C. if temperature is set at MID. If hot air comes into the refrigerator, fine frost forms as cold air mixes with hot air. If this happens quite often, much frost forms inside of the refrigerator. If the door is left open in Summer, ice may form inside of the refrigerator.

Frost in ice tray.

s Explain basic principles of frost formation. When ice tray with full of water is put into a freezer compartment, the water evaporates. If cool air fan operates, the moisture attached to the jaw (protruded part) of ice mold shall freeze and form frost. If warm water was put into the ice mold, the situation will become worse.

- 97 -

4-5. Others
The refrigerator case is hot.
s Explain the principles of radiator. The radiator pipes are installed in the refrigerator case and partition plate between the refrigerator and the freezer compartment in order to prevent condensation formation. Particularly in summer or after installation of refrigerator, it may feel hot but it is normal. If there is no enough space to dissipate heat, it can be hotter due to lack of heat radiation. Please install a refrigerator in a well-ventilated place and leave a clearance between refrigerator and wall: s Explain that the hole is for releasing gas. A small hole in the door liner is for releasing gas during insulation materials lining work. With a releasing hole, forming can be easily done. s Check the use conditions. Too frequent door opening and hot food storing cause the compressor to operate continuously and hence increase the electric consumption and bills. s Explain how to store foods Condensation forms when refrigerator is installed at damp area, door is frequently opened, and wet foods are not stored in the air tight container or wrapped. Be sure to store wet foods in the air tight container or in the wrap. s When should the power be connected ? You can connect the power right after the installation. But if the refrigerator was laid flat during transportation for a long period of time and the refrigerant and compressor oils are mixed up, then this will affect badly the performance of a refrigerator. Be sure to connect the power 2~3 hours after refrigerator is installed. s Refrigerator compartment door does not open properly. When the door is open, warm open air comes into the compartment and is mixed up with cool air. This mixed air shall be compressed and increase the internal pressure when door is closed. This causes the door sticked closely to the refrigerator in a moment. (If the refrigerator is used for a long time, it will then open smoothly.) s When the refrigerator compartment door is open and close, the freezer compartment door moves up and down. When the refrigerator compartment door is open and close, fresh air comes into the freezer compartment and moves up and down the freezer compartment door. s Door opens too easily. There is a magnet in the gasket rubber so that it is ok. if door is securely closed without a gap. It can be open easily if the foods in the refrigerator or freezer compartments hold the door open. s A door does not close properly. If the rear side of the refrigerator is raised higher than front side, door shall not be easily closed. Adjust the level of refrigerator with levelling screws.

* 147B*

232A 234A 205F

243A 206B 240A 205A 264B 205C 402B 266A 262A 261A 264C 260A 265A 267A 205B

205D 240B 267A

266C 240C 265A

266B 263A

231A 233A

- 106 -

Ref No. : GR-L247, GR-L207, GR-B247, GR-B207, GR-B197

206D 241B 236A

232A 234A

240C 205B 205C

- 107 -

FREEZER COMPARTMENT

271B 271A 137A
136C 403A 136C 136B 136A 135A
400A 401A 302A 130A 128C 408B

320C 320A 120B 320A

272A 103A 320B 408A 120B

120A 105B 135B

- 108 -

REFRIGERATOR COMPARTMENT

140A 101B 146A 270B 271B 271A 626C

116A 410A

141D 115A 171B 141C 115B 170C 171A

402A 170B 151C

151E 401A

170A 140D

162B 272B 145A 166B
166A 165C 103A 165A 160D 160B or 165B

160A 160C 160D 160B

- 109 -

ICE & WATER PART

622A 618A 616E 616F

623A or 623B

620A 620B

612A 612C 600A

605A 616A 616C 611A
616A 603B 510B 603A 601A 615A 617A 613A 404B 616B

- 110 -

MACHINE COMPARTMENT

407A 407B 505A

500A 502B 303B 303C 304A

303D 313A

300A 307A 307A

306C 301A

317A 317B

306D 104A

308B 309A 309B 403B 309B 310A 306C

305A 305B 305C

105E 305B

105D 105C

- 111 -

DISPENSER PART

278C 402C 275A 278F 278E 405A 275D 278D 276B 276A

401C 275C 275B

501A 281A

280C 280B

280A 279A 207A

- 112 -

P/No. 3828JD8545H
OCT., 2003 Printed in Korea

EXPLODED VIEW

FREEZER DOOR PART: GR-P247, GR-P207, GR-L247, GR-L207

202A 206A

205A 205C

205D 210B

210C 205C

205B 210C

201A 203A 206E

- 104 -

FREEZER DOOR PART: GR-C247, GR-C207, GR-B247, GR-B207, GR-B197

210B 205C

210C 201A 203A 206E

- 105 -

Ref No. : GR-P247, GR-P207, GR-C247, GR-C207

REFRIGERATOR DOOR PART

* : Optional part

241A 206D 241B

* 147B*

232A 234A 205F

243A 206B 240A 205A 264B 205C 402B 266A 262A 261A 264C 260A 265A 267A 205B

243A 205D

266C 240C 265A

266B 263A

231A 233A

- 106 -

Ref No. : GR-L247, GR-L207, GR-B247, GR-B207, GR-B197

206D 241B 236A

232A 234A

240C 205B 205C

- 107 -

FREEZER COMPARTMENT

271B 271A 137A
136C 403A 136C 136B 136A 135A
400A 401A 302A 130A 128C 408B

320C 320A

120B 320A 272A 103A 320B 408A

120A 105B 135B

- 108 -

REFRIGERATOR COMPARTMENT

140A 101B 146A 270B 271B 271A 626C

116A 410A

141D 115A 171B 141C 115B 170C 171A

402A 170B 151C

151E 401A

170A 140D

162B 272B 145A 166B
166A 165C 103A 165A 160D 160B or 165B

160A 160C 160D 160B

- 109 -

ICE & WATER PART

622A 618A 616E 616F

616D 623A

623A or 623B

620A 620B

612A 612C 600A

605A 616A 616C 611A

616A 603B 510B 603A 601A 615A 617A 613A 404B 616B

- 110 -

MACHINE COMPARTMENT

407A 407B 505A

303A 303B 303C 304A

500A 502B

303D 313A

300A 307A 307A

306C 301A

317A 317B

306D 104A
308B 309A 309B 403B 309B 310A 306C

305A 305B 305C

105E 305B

105D 105C

- 111 -

DISPENSER PART

278C 402C 275A 278F 278E 405A 275D 278D 276B 276A

401C 275C 275B

501A 281A

280C 280B

280A 279A 207A

- 112 -