Goldstar M1203r Service Manual

Room Air Conditioner

SVC MANUAL(Exploded View)

CAUTION

Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.

Internal Use Only

http://biz.lgservice.com

MODEL : R1203, M1203R, R1203H, R1403 M1003L, M1203L, LWC1213AAG/ACG WR-1210, WM-1211

CONTENTS

1. PREFACE

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

1.2 INSULATION RESISTANCE TEST .................2

1.3 SPECIFICATIONS...........................................3

1.4 FEATURES......................................................6

1.5 CONTROL LOCATIONS .................................6

2.

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS ....................................9

2.1.1 FRONT GRILLE .....................................9

2.1.2 CABINET ................................................9

2.1.3 CONTROL BOX .....................................9

2.2 AIR HANDLING PARTS ................................10

2.2.1 AIR GUIDE AND BLOWER ..................10

2.2.2 FAN ......................................................10

2.2.3 SHROUD ..............................................11

2.3 ELECTRICAL PARTS....................................11

2.3.1 OVERLOAD PROTECTOR ..................11

2.3.2 COMPRESSOR....................................11

2.3.3 CAPACITOR.........................................12

2.3.4 POWER CORD ....................................12

2.3.5 THERMOSTAT.....................................12

2.3.6 ROTARY SWITCH ...............................12

2.3.7 MOTOR ................................................13

2.4 REFRIGERATION CYCLE ............................13

2.4.1 CONDENSER.......................................13

2.4.2 EVAPORATOR.....................................13

2.4.3 CAPILLARY TUBE ...............................14

3.

INSTALLATION

3.1 SELECT THE BEST LOCATION...................16

3.2 CHECK OF INSTALLATION..........................16

3.3 HOW TO DRAIN............................................16

3.4 HOW TO INSTALL ........................................17

3.4.1 WHEN USING GASKET.......................17

3.4.2 WHEN USING INSTALLATION KITS...17

4.

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS ...............................20

4.2 PIPING SYSTEM...........................................21

4.3 TROUBLESHOOTING GUIDE ......................22

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM ......................................34

5.2 ELECTRONIC CONTROL DEVICE...............38

5.3

COMPONENTS LOCATION(FOR MAIN P.C.B ASM)

5.4

COMPONENTS LOCATION(FOR DISPLAY P.C.B ASM)

..40

...41

6. EXPLODED VIEW ..................................42

1. PREFACE

This

SERVICE MANUAL provides various service information, including the mechanical and electrical

parts etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SAFETY PRECAUTIONS

1. When servicing the unit, set the ROTARY SWITCH or POWER SWITCH to OFF and unplug the power cord.

2. Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

3. After servicing the unit, make an insulation resistance test to protect the customer from being exposed to shock hazards.

1.2

INSULATION RESISTANCE TEST

1. Unplug the power cord and connect a jumper between 2 pins (black and white).

2. The grounding conductor (green) is to be open.

3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all the positions (except OFF) of the ROTARY SWITCH.

4. The value should be over 1MΩ.

- 2 -

LGE Internal Use Only

1.3 SPECIFICATIONS

1.3.1 FOR R1203/M1203R/R1403/WR-1210/WM-1211

MODELS

ITEMS

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (BTU/W.h)

OPERATING

CONDITION

INDOOR (°C)

OUTDOOR (°C)

REFRIGERANT (R-22) CHARGE

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

OPERATION CONTROL

R1203/WR-1210 M1203R/WM-1211 R1403

1ø, 115, 60Hz

12,000 14,000

1,220 1,380

11.0 12.0

9.8 10.1

26.7(DB)*

35(DB)*

19.4(WB)**

23.9(WB)**

530g (18.7 oz) 550g (19.4 oz)

2 ROW 16 STACKS, SLIT-FIN TYPE

2 ROW 17 STACKS, LOUVERED-FIN TYPE

2 ROW 13 STACKS, LOUVERED-FIN TYPE

2 ROW 17 STACKS, L-BENDED TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

2/3 3/3 2/3

6 POLES

ROTARY SWITCH

REMOTE CONTROLLER

ROTARY SWITCH

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

PROTECTOR

COMPRESSOR

FAN MOTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

OUTSIDE DIMENSION (inch)

(W x H x D) (mm)

* DB:Dry Bulb **

WB:Wet Bulb

THERMOSTAT THERMISTOR THERMOSTAT

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

(3 WIRE WITH GROUDING)

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

95/43 93/42

235/

8 x 14

31

/

32 x 22

5

/

16

600 x 380 x 567

- 3 -

LGE Internal Use Only

1.3.2 FOR R1203H

MODELS

ITEMS

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (BTU/W.h)

HEATING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

OPERATING CONDITION

INDOOR (°C)

OUTDOOR (°C)

REFRIGERANT (R-22) CHARGE

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

R1203H

1ø, 208/230V, 60Hz

11,500/12,000

1,250/1,220

6.2/5.5

9.8

9,200/11,200

2,900/3,500

14/15.3

26.7(DB)

35(DB)

* 19.4(WB)**

* 23.9(WB)**

555g (19.5 oz)

2 ROW 13 STACKS LOUVERED-FIN TYPE

2 ROW 17 STACKS, LOUVERED-FIN TYPE

BLOWER

PROPELLER TYPE FAN WITH SLINGER-RING

FAN SPEEDS, FAN/HEATING/COOLING

FAN MOTOR

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

ELECTRIC HEATER

COMPRESSOR

PROTECTOR FAN MOTOR

ELECTRIC HEATER

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

OUTSIDE DIMENSION (inch)

(W x H x D) (mm)

1/2/2

6 POLES

ROTARY SWITCH OR ROCKER SWITCH

THERMOSTAT

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

SLIDE IN-OUT CHASSIS

3.5KW, 230V

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

FUSE LINK, BIMETAL THERMOSTAT

(3 WIRE WITH GROUDING)

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

97/44

235/

8 x 14

31

/

32 x 22

5

/

16

600 x 380 x 567

* DB:Dry Bulb **

WB:Wet Bulb

- 4 -

LGE Internal Use Only

1.3.3 FOR M1003L/M1203L/LWC1213AAG

MODELS

ITEMS

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (BTU/W.h)

OPERATING

CONDITION

REFRIGERANT (R-22) CHARGE

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

OPERATION CONTROL

INDOOR (°C)

OUTDOOR (°C)

M1003L M1203L LWC1213AAG/ACG

1ø, 115, 60Hz

9,800 12,000 12,000

890 1,110 1,220

8.2 10.2 11.0

11.0 10.8 9.8

26.7(DB)*

35(DB)*

470g (16.6 oz) 525g (18.5 oz) 530g (18.7 oz)

2 ROW 13 STACKS, LOUVERED-FIN TYPE

2 ROW 17 STACKS, LOUVERED-FIN TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3 3/3 2/3

REMOTE CONTROLLER

19.4(WB)**

23.9(WB)**

2 ROW 16 STACKS, SLIT-FIN TYPE

2 ROW 17 STACKS,LOUVERED-FIN TYPE

6 POLES

ROTARY SWITCH

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

PROTECTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

OUTSIDE DIMENSION (inch)

(W x H x D) (mm)

* DB:Dry Bulb **

WB:Wet Bulb

COMPRESSOR

FAN MOTOR

THERMISTOR THERMOSTAT

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

(3 WIRE WITH GROUDING)

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

92/42 95/43

235/8 x 1431/32 x 225/16

600 x 380 x 567

- 5 -

LGE Internal Use Only

1.4 FEATURES

CLOSE VENT OPEN

Thermostat

Warmer Cooler

BEFORE RESTARTING WAIT THREE MINUTES

Operation

1

Thermostat Operation

2

3

4

9

8

7

6

5

Off

Med Fan

Low Fan

High Cool

Med Cool

Low Cool

Auto Swing

Off On

• Designed for COOLING ONLY.

• Powerful and whispering cooling.

• Slide-in and slide-out chassis for the simple installation and service.

• Side air-intake, side cooled-air discharge.

1.5 CONTROL LOCATIONS

1.5.1 COOLING ONLY MODEL

• VENTILATION

The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When a fresh air is necessary in the room, set the ventilation lever OPEN position. The damper is opened and room air is exhausted.

• THERMOSTAT

Thermostat will automatically control the temperature of the room. Select a higher number for a cooler temperature in the room. The temperature is selected by positioning the knob to the desired position. The 5 or 6 position is a normal setting for average conditions.

• Built-in adjustable THERMOSTAT

• Washable one-touch filter

• Compact size

• Reliable and efficient rotary compressor is equipped.

• OPERATION

Off - Turns air conditioner off.

Med Fan - Med speed fan operation without cooling.

Low Fan - Low speed fan operation without cooling.

High Cool - Cooling with high speed fan operation.

Med Cool - Cooling with med speed fan operation.

Low Cool - Cooling with low speed fan operation.

• OPERATION

Off Low Fan

Low Cool

( ) : ( ) :

Turns the air conditioner off. Permits the low fan speed operation

without cooling (heating).

( ) :

Permits cooling with the low fan speed operation.

High Cool

( ) :

Permits cooling with the high fan speed operation.

Low Heat

( ) :

Permits heating with the low fan speed operation.

High Heat

( ) :

Permits heating with the high fan speed operation.

• Auto Swing (For R1403/WR1210)

On: Air Swing is operated while operation knob is set to

the Cool position

Off: Stops the operation of air swing.

- 6 -

A slight heat odor may come from the unit when first switching to HEAT after the cooling season is over. This odor, caused by fine dust particles on the heater, will disappear quickly.

LGE Internal Use Only

1.5.2 COOLING ONLY MODEL WITH REMOTE CONTROL AND TOUCH TYPE

6

7

8

9

■ M1203R DISPLAY

32

9

6

5

1

Fan Speed

■ WM-1211

54

3

2

3

Timer Mode

Energy

Saver

6

9

6

1

54

Precaution: The Remote Control unit will not function properly if strong light strikes the sensor window of the air

conditioner or if there are obstacles between the Remote Control unit and the air conditioner.

7

REMOTE CONTROL

Powe r

1

Temp

4

Auto

Swing

2

Powe r

1

Temp

5

Fan Speed

4

8

Sleep Mode

Energy

Auto

Saver

Swing

6

2

7

POWER BUTTON

To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons.

OPERATION MODE SELECTION BUTTON

Every time you push this button, it will toggle COOL, FAN and DRY.

ON/OFF TIMER BUTTON

Everytime you push this betton, timer is set as follows.(1Hours ➔2Hours➔ 3Hours➔ 4Hours➔ 5Hours➔ 6Hours➔ 7Hours➔ 8Hours➔ 9Hours➔ 10Hours➔ 11Hours➔ 12Hours➔ Cancel)

FAN SPEED SELECTOR

Everytime you push this button, it is set as follows. ( High [

FF33

] ➔ Low[

FF11

] ➔ Med[

FF22

]➔ High[

FF33

]... )

ROOM TEMPERATURE SETTING BUTTON

This button can automatically control the temperature of the room. The temperature can be set within a range of 16˚C to 30˚C by 1˚C. Select the lower number for lower temperature of the room.

ENERGY SAVER

The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will tern on and check the room air to determine if cooling is needed.

AUTO SWING

This button can automatically control the air flow direction.

SLEEP MODE BUTTON

Press the sleep mode button to set the time you want the unit to turn off automatically. The timer is programmed in one hour increment by pressing the button. Every time you push this button, the remaining time will be set as follows.(1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 0Hour ➔ 1Hour➔ 2Hours➔... ) Note: The Sleep Mode will be operated at low fan speed for quiet sleeping. The temperature will automatically rise by 1°C

over the next 30 minutes and by 2°C in 1 hour for comfortble sleeping.

REMOCON SIGNAL RECEIVER

- 7 -

LGE Internal Use Only

■ M1003L/M1203L

6

7

8

9

DISPLAY

13 9

REMOTE CONTROL

Powe r

1

Temp

3

Fan Speed

4

2

4

7

8

Sleep Mode

Energy

Auto

Saver

Swing

2

6

8 6 7 5

Precaution: The Remote Control unit will not function properly if strong light strikes the sensor window of the air

conditioner or if there are obstacles between the Remote Control unit and the air conditioner.

POWER BUTTON

To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons.

OPERATION MODE SELECTION BUTTON

Every time you push this button, it will toggle between COOL, FAN and DRY as follows.

ROOM TEMPERATURE SETTING BUTTON

This button can automatically control the temperature of the room. The temperature can be set within a range of 60°F to 86°F by 1°F. (16°C to 30°C by 1°C) Select the lower number for lower temperature of the room.

FAN SPEED SELECTOR

Every time you push this button, it is set as follows. (Hi ➔ Low ➔ Mid ➔ Hi ➔ Low ➔...)

ON/OFF TIMER BUTTON

You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating, this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time you push this button, the remaining time will be set as follows.

- Stopping operation (1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 8Hours ➔ 9Hours ➔ 10Hours ➔ 11Hours ➔ 12Hours ➔ 0Hour ➔ 1Hour ➔ 2Hours ➔... )

- Starting operation (1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 8Hours ➔ 9Hours ➔ 10Hours ➔ 11Hours ➔ 12Hours ➔ off ➔ 1Hour ➔ 2Hours ➔ ... )

AUTO SWING

This button can automatically control the air flow direction.

SLEEP MODE BUTTON

Press the sleep mode button to set the time you want the unit to turn off automatically. The timer is programmed in one hour increment by pressing the button. Every time you push this button, the remaining time will be set as follows.(1Hour ➔ 2Hours ➔ 3Hours ➔ 4Hours ➔ 5Hours ➔ 6Hours ➔ 7Hours ➔ 0Hour ➔ 1Hour➔ 2Hours➔... ) Note: The Sleep Mode will be operated at low fan speed for quiet sleeping. The temperature will automatically rise by 1°C

over the next 30 minutes and by 2°C in 1 hour for comfortble sleeping.

ENERGY SAVER

If you push this button, the fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and check the room air temperature to determine if cooling is necessary.

REMOCON SIGNAL RECEIVER

- 8 -

LGE Internal Use Only

1

T

h

er

m

o

sta

t

O

p

e

ratio

n

2

3

4

9

8

7

6

5

O

ff

M

e

d

Fa

n

L

ow F

a

n

H

ig

h

C

o

l

M

e

d

C

o

l

L

o

w

C

o

ol

1

T

h er

m

os

ta

t

O

pe

r atio

n

2

3

4

9

8

7

6

5

O

f f

M ed F a

n

L ow Fa

n

H ig

h C oo

l

M e

d C oo

l

Lo

w Co

ol

1

Therm

ostat

Operation

2

3

4

9

8

7

6

5

O

f f

Med

Fan

Low

Fan

High Cool

Med Cool

Low Cool

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the lnlet grille upward .

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille.

5. Re-install the component by referring to the removal procedure, above.(See Figure 1)

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove the 2 screws which fasten the cabinet at both sides.

2. Remove the 2 screws which fasten the cabinet at back.

3. Pull the base pan forward. (See Figure 2)

4. Remove the cabinet.

5. Re-install the component by referring to the removal procedure, above.

Figure 1

Figure 2

2.1.3 CONTROL BOX

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the 2 screws which fasten the control box cover.

4. Remove two housings which connect compressor wire and motor wire in the control box.

5.Discharge the capacitor by placing a 20,000 ohmresistor across the capacitor terminals.

6. Remove the 2 screws which fasten the control box.

7. Pull the control box forward completely.

8. Re-install the components by referring to the removal procedure, above. (See Figure 3) (Refer to the circuit diagram found on pages 34~37 in this manual and on the control box.)

- 9 -

Figure 3

LGE Internal Use Only

2.2 AIR HANDLING PARTS

1

Thermo

s tat

Oper

ation

2

3

4

9

8

7

6

5

O ff

M e

d F a

n

L o

w F a

n

H i g

h C o

o

l

M e

d C o

o

l

L o

w C o

o l

2.2.1 AIR GUIDE AND BLOWER

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the control box. (Refer to section 2.1.3)

4. Remove the 4 screws which fasten the brace.

5. Remove the brace.

6. Remove the 2 screws which fasten the evaporator.

7. Move the evaporator forward and pulling it upward slightly. (See Figure 4)

8. Move the evaporator to the left carefully.

9. Remove the 2 terminals carefully. (See Figure 5, at Electric heater Model)

10. Remove the 3 screws which fasten the Heater

Cover. (See Figure 5, at Electric Heater Model)

11. Remove the Heater cover. (See Figure 5, at

Electric Heater Model)

12. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 6)

13. Remove the clamp with a hand plier which

secures the blower.

14. Remove the blower.

15. Remove the 4 screws which fasten the air guide

from the barrier.

16. Move the air guide backward, pulling out from the

base pan.

17. Re-install the components by referring to the

removal procedure, above.

Figure 4

Figure 5

2.2.2 FAN

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the brace (Refer to section 2.2.1)

3. Remove the 4 screws which fasten the condenser.

4. Move the condenser to the left carefully.

5. Remove the clamp which secures the fan.

6. Remove the fan. (See Figure 7)

7. Re-install by referring to the removal procedure.

- 10 -

Figure 6

Figure 7

LGE Internal Use Only

2.2.3 SHROUD

1. Remove the fan. (Refer to section 2.2.2)

2. Remove the screw which fastens the shroud.

3. Remove the shroud. (See Figure 8)

4. Re-install the component by referring to the

removal procedure, above.

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover. (See Figure 9)

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

6. Re-install the component by referring to the

removal procedure, above.

Figure 8

2.3.2 COMPRESSOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Discharge the refrigerant system using a Freon

Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the Freon servicing the system.

3. Remove the overload protector. (Refer to section

2.3.1)

4. After purging the unit completely, unbraze the

suction and discharge tubes at the compressor connections.

5. Remove the 3 nuts and the 3 washers which

fasten the compressor.

6. Remove the compressor. (See Figure 10)

7. Re-install the components by referring to the

removal procedure, above.

TM

. Leave the valve in place after

Figure 9

TM

Figure 10

- 11 -

LGE Internal Use Only

2.3.3 CAPACITOR

1. Remove the control box. (Refer to section 2.1.3)

2. Remove the knobs and the screw which fasten control panel from control box.

3. Remove the screw which located in the front.

4. Open the bottom side of control box.

5. Remove the screw and the clamp which fastens the capacitor.

6. Disconnect all the leads of capacitor terminals.

7. Re-install the components by referring to the removal procedure, above. (See Figure 11)

2.3.4 POWER CORD

1. Remove the control box. (Refer to section 2.1.3)

2. Open the control box. (Refer to section 2.3.3)

3. Disconnect the grounding screw from the control box.

4. Disconnect the 2 receptacles.

5. Remove a screw which fastens the clip cord. (See Figure 12)

6. Remove the power cord.

7. Re-install the component by referring to the above removal procedure, above. (Use only one ground-marked hole for ground connection.)

8. If the supply cord of this appliance is damaged, it must be replaced by the special cord. (The special cord means the cord which has the same specification marked on the supply cord attached at the unit.)

Figure 11

Figure 12

2.3.5 THERMOSTAT

1. Remove the control box. (Refer to section 2.1.3)

2. Open the control box. (Refer to section 2.3.3)

3. Remove the 2 screws which fasten the thermostat.

4. Disconnect 2 leads of thermostat terminals.

5. Remove the thermostat.

6. Re-install the components by refereing to the above removal procedure. (See Figure 13)

2.3.6 ROTARY SWITCH

1. Remove the control box. (Refer to section 2.1.3)

2. Open the control box. (Refer to section 2.3.3)

3. Remove the 2 screws which fasten the rotary switch.

4. Disconnect all the leads of the rotary switch terminals.

5. Remove the rotary switch.

6. Re-install the components by referring to the above removal procedure. (See Figure 14)

Figure 13

Figure 14

- 12 -

LGE Internal Use Only

2.3.7 MOTOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the evaporator. (Refer to section 2.2.1)

3. Remove the orifice. (Refer to section 2.2.1)

4. Remove the blower. (Refer to section 2.2.1)

5. Remove the fan. (Refer to section 2.2.2)

6. Remove the control box cover and disconnect 5 or 4 wires of motor housing. (Refer to section 2.1.3)

7. Remove the 2 or 4 screws which fasten the motor from the mount motor. (See Figure 15)

8. Remove the motor.

9. Re-install the components by referring to the removal procedure, above.(See Figure 15)

2.4 REFRIGERATING CYCLE

CAUTION

Discharge the refrigerant system using a FreonTMRecovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system.

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the 4 screws which fasten the brace.(Refer to section 2.2.1)

3. Remove the 5 screws which fasten the condenser and shroud.

4. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

5. Remove the condenser.

6. Re-install the component by referring to notes. (See Figure 16)

Figure 15

Figure 16

2.4.2 EVAPORATOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the 2 screws which fasten the evaporator.

3. Move the evaporator sideways carefully. (Refer to section 2.2.1)

4. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections.

5. Remove the evaporator.

6. Re-install the component by referring to notes. (See Figure 17)

- 13 -

Figure 17

LGE Internal Use Only

2.4.3 CAPILLARY TUBE

1. Remove the cabinet. (Refer to section 2.1.2)

2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above)

NOTES

— Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a Freon recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system.

2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes.

3. Solder service valves into the pinch-off tube ports, leaving the valves open.

4. Solder the pinch-off tubes with Service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated figure

18A.

2) Start the vacuum pump, slowly open manifold

valves A and B with two full turns counterclockwise and leave the valves open. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold

and entire system.

CAUTION

If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.

3) Operate the vacuum pump for 20 to 30 minutes,

until 600 microns of vaccum is obtained. Close valves A and B, and observe vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop

the vacuum pump.

4) Remove the hose from the vacuum pump and

place it on the charging cylinder. See figure 18B. Open valve C. Discharge the line at the manifold connection.

5) The system is now ready for final charging.

TM

3. Remove the capillary tube.

4. Re-install the component by referring to notes.

6. Recharge as follows :

1) Refrigeration cycle systems are charged from the High-side. If the total charge cannot be put in the High-side, the balance will be put in the suction line through the access valve which you installed as the system was opened.

2) Connect the charging cylinder as shown in figure 18B. With valve C open, discharge the hose at the manifold connection.

3) Open valve A and allow the proper charge to enter the system. Valve B is still closed.

4) If more charge is required, the high-side will not take it. Close valve A.

5) With the unit running, open valve B and add the balance of the charge.

a. Do not add the liquid refrigerant to the Low-

side.

b. Watch the Low-side gauge; allow pressure to

rise to 30 lbs. c. Turn off valve B and allow pressure to drop. d. Repeat steps b. and c. until the balance of the

charge is in the system.

6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

- 14 -

LGE Internal Use Only

Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable

A

COMPOUND GAUGE

EVAPORATOR (LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER (HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

B

A

B

EXTERNAL VACUUM PUMP

A

CHARGING CYLINDER

LOW

HI

B

C

of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve.

Figure 18A-Pulling Vacuum

- 15 -

Figure 18B-Charging

LGE Internal Use Only