Internal Use Only
http://biz.lgservice.com
Room Air Conditioner
SVC MANUAL(Exploded View)
MODEL : R1003A3
R-8000AY3
CAUTION
Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.
CONTENTS
1. PREFACE |
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3. INSTALLATION |
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1.1 SAFETY PRECAUTIONS................................ |
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3.1 SELECT THE BEST LOCATION................... |
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1.2 INSULATION RESISTANCE TEST ................. |
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3.2 CHECK OF INSTALLATION.......................... |
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1.3 SPECIFICATIONS........................................... |
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3.3 HOW TO DRAIN............................................ |
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1.4 FEATURES...................................................... |
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3.4 HOW TO INSTALL ........................................ |
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1.5 CONTROL LOCATIONS ................................. |
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3.5 HOW TO USE THE REVERSIBLE INLET GRILLE... |
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2. DISASSEMBLY INSTRUCTIONS |
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4. TROUBLESHOOTING GUIDE |
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2.1 MECHANICAL PARTS .................................... |
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4.1 OUTSIDE DIMENSIONS ............................... |
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2.1.1 FRONT GRILLE ..................................... |
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4.2 PIPING SYSTEM........................................... |
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2.1.2 CABINET ................................................ |
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4.3 TROUBLESHOOTING GUIDE ...................... |
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2.1.3 CONTROL BOX ..................................... |
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5. SCHEMATIC DIAGRAM |
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2.2 AIR HANDLING PARTS |
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5.1 CIRCUIT DIAGRAM |
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2.2.1 AIR GUIDE AND BLOWER |
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6. EXPLODED VIEW |
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2.2.2 FAN AND SHROUD ............................... |
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2.3 ELECTRICAL PARTS...................................... |
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2.3.1 OVERLOAD PROTECTOR .................... |
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2.3.2 COMPRESSOR...................................... |
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2.3.3 CAPACITOR........................................... |
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2.3.4 POWER CORD ...................................... |
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2.3.5 THERMOSTAT....................................... |
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2.3.6 ROTARY SWITCH ................................. |
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2.3.7 MOTOR .................................................. |
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2.4 REFRIGERATION CYCLE .............................. |
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2.4.1 CONDENSER......................................... |
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2.4.2 EVAPORATOR....................................... |
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2.4.3 CAPILLARY TUBE ................................. |
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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 |
1.2 INSULATION RESISTANCE TEST |
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.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.
Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 2 - |
Only for training and service purposes |
LGE Internal Use Only |
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1.3 SPECIFICATIONS
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MODELS |
R10003A3 |
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R-8000AY3 |
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ITEMS |
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POWER SUPPLY |
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1ø, 115, 60Hz |
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COOLING CAPACITY |
(Btu/h) |
10,000 |
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8,000 |
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INPUT |
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(W) |
1,020 |
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820 |
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RUNNING CURRENT |
(A) |
9.2 |
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7.6 |
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E.E.R |
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(BTU/W.h) |
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9.8 |
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OPERATING |
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INDOOR (°C) |
26.7(DB)* |
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19.4(WB)** |
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CONDITION |
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OUTDOOR (°C) |
35(DB)* |
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23.9(WB)** |
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REFRIGERANT (R-22) CHARGE |
460g(16.2oz) |
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260g(9.2oz) |
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EVAPORATOR |
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3 ROW 14 STACKS, SLIT-FIN TYPE |
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CONDENSER |
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2 ROW 16 STACKS, L-BENDED TYPE |
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FAN, INDOOR |
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TURBO FAN |
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FAN, OUTDOOR |
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PROPELLER TYPE FAN WITH SLINGER-RING |
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FAN SPEEDS, FAN/COOLING |
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2/3 |
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FAN MOTOR |
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6 POLES |
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OPERATION CONTROL |
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ROTARY SWITCH |
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ROOM TEMP. CONTROL |
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THERMOSTAT |
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AIR DIRECTION CONTROL |
VERTICAL LOUVER (RIGHT & LEFT) |
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HORIZONTAL LOUVER (UP & DOWN) |
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CONSTRUCTION |
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SLIDE IN-OUT CHASSIS |
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PROTECTOR |
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COMPRESSOR |
OVERLOAD PROTECTOR |
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FAN MOTOR |
INTERNAL THERMAL PROTECTOR |
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POWER CORD |
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(3 WIRE WITH GROUDING) |
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ATTACHMENT PLUG (CORD-CONNECTED TYPE) |
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DRAIN SYSTEM |
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DRAIN PIPE OR SPLASHED BY FAN SLINGER |
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NET WEIGHT |
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(lbs/kg) |
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70/32 |
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OUTSIDE DIMENSION |
(inch) |
181/2 x 137/8 x 2011/16 |
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(W x H x D) |
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(mm) |
470 x 353 x 525 |
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* DB:Dry Bulb ** WB:Wet Bulb
Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 3 - |
Only for training and service purposes |
LGE Internal Use Only |
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1.4 FEATURES
•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.
•Built-in adjustable THERMOSTAT
•Washable one-touch filter
•Compact size
•Reliable and efficient rotary compressor is equipped.
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 (the right side of arc) for a cooler temperature in the room. The temperature is selected by positioning the knob to the desired position.
The 5 or 6 position (the middle position of arc) is a normal setting for average conditions.
• OPERATION
OFF |
: Turns the air conditioner to off. |
MED FAN |
: Permits the medium fan speed |
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operation without cooling. |
LOW FAN |
: Permits the low fan speed operation |
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without cooling. |
HIGH COOL : Permits cooling with the high fan speed operation.
MED COOL : Permits cooling with the medium fan speed operation.
LOW COOL : Permits cooling with the low fan speed operation.
CLOSE 
VENT 
OPEN
Thermostat |
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Operation |
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5 |
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Off |
4 |
6 |
Med |
High |
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Fan |
Cool |
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1 |
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Low |
Med |
Fan |
Cool |
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Low Cool
Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 4 - |
Only for training and service purposes |
LGE Internal Use Only |
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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 or downward.
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)
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 2
2.1.3 CONTROL BOX
1. |
Disconnect the unit from the power source. |
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2. |
Remove the front grille. (Refer to section 2.1.1) |
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3. |
Remove the cabinet. (Refer to section 2.1.2) |
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4. |
Remove the screw which fastens the control box |
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cover. |
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5. |
Remove the housing which connects motor wire |
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in the control box. |
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6. |
Remove the 3 leads from the compressor. |
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(Refer to section 2.3.1) |
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7.Discharge the capacitor by placing a 20,000 |
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ohmresistor across the capacitor terminals. |
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8. |
Remove the 2 screws which fasten the control |
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box.(See Figure 3) |
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9. |
Pull the control box forward completely. |
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10. Re-install the components by referring to the |
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removal procedure, above. (See Figure 3) |
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(Refer to the circuit diagram found on page 24, |
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in this manual or on the control box.) |
Figure 3 |
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Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 5 - |
Only for training and service purposes |
LGE Internal Use Only |
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2.2 AIR HANDLING PARTS
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 3 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.Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 5)
10.Remove the clamp with a hand plier which secures the turbo fan.
11.Remove the turbo fan.
12.Remove the 4 screws which fasten the air guide from the barrier.
13.Move the air guide backward, pulling out from the base pan.
14.Re-install the components by referring to the removal procedure, above.
Figure 4
Figure 5
2.2.2 FAN AND SHROUD
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace (Refer to section 2.2.1)
3. Remove the screw which fastens the cover cond.
4. Remove the 5 screws which fasten the condenser.
5. Move the condenser to the left carefully.
6. Remove the clamp with a hand plier which secures the fan.
7. Remove the fan and then pull out the shroud. (See Figure 6)
8. Re-install the components by referring to the removal procedure.
Figure 6
Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 6 - |
Only for training and service purposes |
LGE Internal Use Only |
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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 7)
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 7
2.3.2 COMPRESSOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant system using a FreonTM 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.
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 Figure 8 connections.
5.Remove the 3 nuts and the 3 washers which fasten the compressor.
6.Remove the compressor. (See Figure 8)
7.Re-install the components by referring to the removal procedure, above.
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 is located in the front. 4. Open the bottom side of control box.
5. Remove the screw and the clamp which fasten the capacitor.
6. Disconnect all the leads of capacitor terminals. 7. Re-install the components by referring to the removal procedure, above. (See Figure 9)
Figure 9
Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 7 - |
Only for training and service purposes |
LGE Internal Use Only |
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2.3.4 POWER CORD
1. |
Remove the control box. (Refer to section 2.1.3) |
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2. |
Open the control box. (Refer to section 2.3.3) |
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3. |
Disconnect the grounding screw from the control |
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box. |
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4. |
Disconnect the 2 receptacles. |
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5. |
Remove a screw which fastens the clip cord. |
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(See Figure 10) |
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6. |
Remove the power cord. |
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7. |
Re-install the component by referring to the above |
Figure 10 |
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removal procedure, above. |
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(Use only one ground-marked hole |
for ground |
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connection.) |
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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.)
2.3.5 THERMOSTAT
1. |
Remove the control box. (Refer to section 2.1.3) |
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2. |
Open the control box. (Refer to section 2.3.3) |
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3. |
Remove the 2 screws which fasten the thermostat. |
Figure 11 |
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 11)
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 12)
Figure 12
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 housing of the motor in the control box. (Refer to section 2.1.3)
7. Remove the 2 screws which fasten the motor from the mount motor. (See Figure 13)
8. Remove the motor.
9. Re-install the components by referring to the removal procedure, above.(See Figure 13)
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Figure 13 |
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Copyright ©2007 LG Electronics. Inc. All right reserved. |
- 8 - |
Only for training and service purposes |
LGE Internal Use Only |
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