Whirlpool of India Limited SERVICE AND PARTS MANUAL Document No. WOI/GNF/………………….
CONTENTS Introduction Safety precautions & warnings Special Features Technical Specifications Care & Cleaning GNF Refrigerator Parts Identification Energy-Saving Tips Refrigerator Sounds Trouble-shooting General Changing Control Settings RI 34a Service Consideration 3 4-5 6 6 7 8 9 9-10 10 10-11 11 Service Instructions 12-17 (1) Procedure for R134a Sealed System (1) R134a Sealed System Service (2) Sweep Charging Procedure (3) Contaminated R134a Sealed System Repairs (4) Freezer Compartment (5) Refriger
INTR0DUCTI0N CFC Free Manufacturing of a refrigerator includes certain operations like foaming, gas charging of the sealed system etc. This involves the use of certain refrigerants, which are released in the atmosphere, that contain chlorine. These are termed as CFCs (Chlorofluorocarbon). CFC's when released in the atmosphere affect the ozone layer. It leads to the depletion of the Ozone layer.
Safety Precautions & Warnings 4
SPECIAL FEATURES The special features of these refrigerators compared to the existing refrigerators are as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
GNF - REFRIGERATOR PARTS IDENTIFICATION 8
ENERGY - SAVING TIPS You can help your refrigerator use less electricity by 1. 2. 3. 4. 5. Making sure the gaskets are clean and are making good contact with the cabinet. Opening the refrigerator and freezer doors as little as possible. Keep food well organized and remove all of what you need at one time. Not overfilling the compartments so that air cannot circulate properly. Not setting the refrigerator and freezer sections to at temperature higher than necessary.
CLICKING OR SNAPPING - caused by thermostat when the refrigerator stops on starts operating. The defrost timer will click when the defrost cycle begins and ends. WATER SOUNDS / GURGLING NOISE - caused by liquid settling in the tubing when the refrigerator stops operating. You may also hear defrost water dripping into the defrost water pan. TROUBLE SHOOTING - GENERAL HEAVY WARM LOAD - The amount of warm food placed in the refrigerator affects running time and power consumption.
4. If ICE isn't made fast enough 5. If both sections are too warm Heavy ice usage Very cold room temperature Door opened often Large amount of food added Very warm or very cold room temperature R134a SERVICE CONSIDERATIONS R134a systems cannot tolerate (compared to other refrigerants) even trace amounts of foreign substances, chemical contamination or moisture.
SERVICE INSTRUCTIONS The GNF refrigerators 285L, 250L, and 220L all are clean back refrigerators. A clean back refrigerator incorporates the following parts foamed between the main liner and the cabinet. 1. 2. 3. 4. 5. The skin condenser - The condenser assembly is placed on the three sides of the cabinet. Heat loop - The heat loop is placed along the front side of the cabinet. Suction & Capillary - The suction & capillary is placed on the backside of the cabinet.
iii) iv) v) vi) vii) moisture and keeps them plugged with the right plug till it is required to be used in the repair. Do not use lubricating oil or refrigerant from chlorine based sealed system into R134a system. Use sweep charging method (explained in detail in the next section) for charging of R134a based systems after repair as it is more effective in removing the contaminants from the sealed system.
CONTAMINATED R134a SEALED SYSTEM REPAIRS NOTE: Always replace the filter - drier during ANY repair on R134a sealed system. COMPRESSOR BURN OUT 1. 2. 3. 4. 5. Purge refrigerant from the system. Flush the system Replace the filter-drier. Replace the compressor. Leak check, sweep and recharge the system. RESTRICTION IN THE SYSTEM 1. 2. 3. 4. 5. 6. Purge refrigerant from the system. Determine location of restriction and repair if possible. Flush the system. Replace the filter-drier.
3. 4. 5. 6. Pull out the defrost heater from the evaporator clips holding the heater. Install the new heater to the clips. Make sure that the defrost heater leads are routed properly, and plug the connector into the wiring harness. Now proceed mounting the evaporator cover. Repairing / Replacing Evaporator NOTE: It may be helpful to remove the freezer door if it is hinged on the same side as the evaporator heat exchanger entrance. 1. 2. 3. Purge the refrigerant from the system.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove the bottom cover of the freezer compartment. Remove the evaporator cover with fan motor. Remove the defrost heater and the bimetal switch from the evaporator. Disconnect the main wiring harness plug from the cabinet connector. Unwrap the sound deadening material from the evaporator inlet. Keep it in one piece. It will need to be reinstalled later.
REFRIGERATOR COMPARTMENT The refrigerator compartment comprises of the following parts: 1. 2. 3. 4. Shelves and crisper Thermostat Bulb holder and bulb Timer motor All the shelves and trays come out by carefully pulling outwards. The electrical parts like thermostat, bulb holder, bulb and timer motor are fixed to a common control box which is fixed on top back of the refrigerator compartment. For replacement of the parts in the control box, the procedure is as follows: 1. 2. 3. 4. 5.
SEALED SYSTEM DIAGNOSIS REVIEW Entering and properly processing the sealed refrigeration system requires special equipment and time consuming, therefore a system should not be entered until it is determined that it is at fault. There are four conditions that make entering the sealed system necessary. They are: 1. 2. 3. 4. Incorrect amount of refrigerant Restriction of refrigerant flow Refrigerant leak Compressor not operating correctly INCORRECT AMOUNT OF REFRIGERANT 1.
SEALED SYSTEM SCHEMATIC LAYOUT 24
ASSEMBLY DRAWINGS CABINET 34
SHELVES 35
CONTROL BOX DRAIN CUP BODY-AIR DIFFUSER-REAR THERMOSTAT ASSY WIRE ASSY.
COMPRESSOR SERVICE DRIER TRAY EVAPORATINGMATSHUSHITA COMP.
PARTS LIST S.No.
36 A201084000E 37 A201224000E 38 A201012000A 39 A201001000F 40 A201008000G 41 A201034000E 42 A201178000B 43 A201232000E 44 A201021000F 45 A201391000C 46 A201139000A 47 A201331000C 48 A201084000E 49 A208690550A 50 A208691550A 51 A208692550A 52 A208693550A 53 A208857000A 54 A208856000A 55 A208689000A 56 A2087890000 57 A2087900000 58 A2087910000 59 A208687000B 60 A2088325500 61 A2088315400 62 A211018000C 63 A2110190000 64 A208673550A 65 A208728000A 66 A201356000B 67 A201358000E 68 A201670000A 69 A201361000B 70
84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 A2117520000 A201135000E A201472000A A2014490000 A201594000H A201593000J A201616000B A201616000A A2113990000 A2087720000 A211098000B A211357000B A2114390000 A2014280000 A208614000B A201429000A A201471000A A2019250000 A201633000A A2089840000 A2035020000 A2089850000 A2080070000 A2089600000 A2089610000 A2089620000 X01A41992K2 A2211090000
132 A2084290000 133 A208168000C 134 A2081860000 135 A208171000A 136 A208172000A 137 A2087480000 138 A208666000B 139 A2086590000 140 A208685000A 141 1111000023 142 A2086950000 143 A201996000A 144 11153180000 145 A2119060000 146 21495450000 147 1111000024 148 2153908000 149 A2018890000 150 A2117300000 151 A208697000D 152 A2118770000 153 21539110000 154 84233900000 155 A201077550P 156 A211808550C 157 A201170000B 158 A201235000L 159 A201370000L 160 A201080000L 161 A211727000B 162 A211726000B 163 A211725000B 164