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18 Room Air Conditioner

Disassembly

Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable
of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve.

B

A

B

A

B

A

COMPOUND GAUGE

SEE INSETS

BELOW

CAPILLARY TUBE

EVAPORATOR
(LOW PRESSURE SIDE)

COMPRESSOR

CONDENSER
(HIGH PRESSURE SIDE)

EXTERNAL VACUUM PUMP

LO HI CHARGING CYLINDER

MANIFOLD

GAUGE

C

Figure 31A-Pulling Vacuum

Figure 31B-Charging

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Summary of Contents for HBLG5004

Page 1: ...m Air Conditioner SERVICE MANUAL MODELS HBLG5004 HBLG5004T4 CAUTION website http www lgservice com BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL ...

Page 2: ...t Some Models 10 How to Secure the Drain Pipe 11 Operation 12 Features 12 Insulation Resistance Test 12 About the Controls on the Air conditioner 12 Disassembly 13 Mechanical Parts 13 Air Handling Parts 14 Electrical Parts 15 Refrigerating Cycle 16 Schematic Diagram 19 Wiring Diagram 19 Troubleshooting Guide 20 Piping System 20 Troubleshooting Guide 21 Room Air Conditioner Voltage Limits 23 Explod...

Page 3: ...death or serious injury This symbol indicates the possibility of injury or damage to property only Be sure not to do Be sure to follow the instruction Gasolin WARNING Installation Always install the expansion panel s Improper assembly or installation may cause incorrect operation including injury fire and electric shock hazards Do not place the power cord near a heater It may cause fire and electr...

Page 4: ...d length It will cause electric shock or fire Use the air conditioner on a single outlet circuit See page 7 Do not share the outlet with other appliances It will cause electric shock or fire Always plug into a grounded outlet No grounding may cause electric shock Unplug the unit if strange sounds odors or smoke come from it Otherwise it will cause fire and electric shock accident Do not use the so...

Page 5: ...out of the window creating a safety hazard Close all doors windows and other outside openings to the room The air conditioner must be operated in a enclosed area to be most effective Ventilate before operating air conditioner when gas goes out It may cause explosion fire and burn Installation CAUTION Do not clean the air conditioner with water It will cause electric shock or failure of machine If ...

Page 6: ...Operation without filters will cause failure Use a soft cloth to clean Do not use wax thinner or a strong detergent The appearance of the air conditioner may deteriorate change color or develop surface flaws Do not drink water drained from air conditioner Do not direct airflow at room occupants only It is not sanitary and could cause illness or personal injury hazard Be cautious not to touch the s...

Page 7: ...83 11 1 8 D mm inch 326 12 13 16 Model Dimension All Model Outside Dimensions This symbol alerts you to the risk of electric shock This symbol alerts you to hazards that could cause harm to the air conditioner This symbol indicates special notes NOTICE Symbols Used in this Manual ...

Page 8: ...T AMP 4 8 REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE R 22 200g 7 0 Oz 225g 7 9 Oz INSIDE FAN TURBO OUTSIDE FAN ROPELLER FAN WITH SLINGER RING AIR DISCHARGE 2 WAY RIGHT AND LEFT CHASSIS TOP DOWN PROTECTOR TEMPERATURE CONTROL THERMOSTAT ROCKER SWITCH 1 2 POSITIONS POWER ON POWER OFF ROCKER SWITCH 2 2 POSITIONS HI FAN LOW FAN FAN MOTOR 6 POLES OVERLOAD PROTECTOR FOR COMPRESSOR INTERNAL PRO...

Page 9: ...IP MOUNTED ON TOP OF INNER SILL is more than 1 two of wood strip are not necessary NOTICE Installation Installation Select the Best Location How to Install This air conditioner is designed with a button down chassis so it can be easily installed in a window 1 To prevent vibration and noise make sure the unit is installed securely and firmly 2 Install the unit where the sun does not shine directly ...

Page 10: ... with pencil on the center of the inner sill as shown in Figure 6 2 Attach L Bracket a Install the L brackets behind the inner window sill with the short side of bracket as shown Use the 2 screws TYPE A provided b The bracket helps to hold unit securely in place Be sure to place bracket edge flush against back of inner sill See Figure 7 HARDWARE TYPE F 1EA SASH SEAL Not adhesive backed TYPE E 1EA ...

Page 11: ...ng 2 screws TYPE B 2 screws TYPE C to secure them as shown in Figure 10 5 Install the Sash Seal and Sash Lock a Cut the sash seal TYPE F to the window width Stuff the sash seal between the glass and the window to prevent air and insects from getting into the room as shown in Figure 10 b Fasten the L bracket using a TYPE A screw as shown in Figure 10 6 Window installation of room air conditioner is...

Page 12: ... operation with cooling or not Normal Fan 1 Turn the FAN speed mode switch to the HI or the LOW setting 2 Set the thermostat control to the temperature mark Fan Only Normal cooling 1 Turn the FAN speed mode switch to the HI or the LOW setting 2 Set the thermostat control to the desire temperature the mid point is a good starting position If the room temperature is not satisfactory after a reasonab...

Page 13: ...re 15 4 Lift the cabinet from the unit 5 Re install by referring to the procedures above 3 CONTROL PANEL 1 Disconnect the unit from the power source 2 Remove the front grille Refer to Section 1 3 Remove the cabinet Refer to Section 2 4 Remove 2 screws that secure the control panel to control box and base pan See Figure 16 5 Pull the control board toward yourself Controls wires and capacitor are no...

Page 14: ... the control panel Refer to Section 3 5 Remove the air guide upper Refer to Section 4 6 Remove 2 screws that secure the condenser to the base pan 7 Remove the screw that secures the shroud to channel of condenser 8 Press the snap area of shroud with your thumbs This allows you to remove it from the condenser 9 Remove 1 screw that secure the evaporator to the base pan See Figure 19 10 Remove the or...

Page 15: ...r Refer to Section 6 8 Remove 2 screws that secure the shroud to the base pan See Figure 23 9 Lift air guide lower and shroud upward See Figure 23 10 Re install by referring to the procedures above 8 OVERLOAD PROTECTOR 1 Remove the front grille and cabinet Refer to Section 1 2 2 Remove the nut which fastens the terminal cover 3 Remove the terminal cover 4 Remove all the leads from the overload pro...

Page 16: ...ontrol board Refer to Section 3 3 Remove all the leads of the rotary switch terminals 4 Remove the rocker switch See Figure 28 5 Re install the components by referring to the removal procedure above 13 POWER CORD 1 Disconnect the unit from source of power 2 Remove the front grille Refer to Section 1 3 Remove the cabinet Refer to Section 2 4 Remove a screw that secures control panel to control box ...

Page 17: ... few minutes then open slowly with the two full turns counter clockwise This will keep oil from foaming and being drawn into the vacuum pump 6 3 Operate the vacuum pump for 20 to 30 minutes until 600 micron vacuum 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 clos...

Page 18: ...f making a vapor proof seal leak detector tubing cutter hand tools to remove components and service valve B A B A B A COMPOUND GAUGE SEE INSETS BELOW CAPILLARY TUBE EVAPORATOR LOW PRESSURE SIDE COMPRESSOR CONDENSER HIGH PRESSURE SIDE EXTERNAL VACUUM PUMP LO HI CHARGING CYLINDER MANIFOLD GAUGE C Figure 31A Pulling Vacuum Figure 31B Charging ...

Page 19: ...L LO BK RD BK BK GN YL GL GN YL GL RD OR BR OR BR BK RD BL YL CAPACITOR F C H MOTOR COMP OLP THERMOSTAR YL 2 2 3 R S C 1 1 Ribbed MODEL HBLG5004 HBLG5004T4 DESCRIPTION NAME POWER CORD ASSY FAN MOTOR COMPRESSOR ROCKER SWITCH 1 ROCKER SWITCH 2 THERMOSTAT CAPACITOR OVERLOAD PROTECTOR Q TY 1 1 1 1 1 1 1 1 REF NO 1 2 3 4 5 6 7 8 ...

Page 20: ...cycle COOLED AIR HOT DISCHARGED AIR MOTOR COMPRESSOR ROOM AIR HEAT LOAD CAPILLARY TUBE LIQUID REFRIGERANT LIQUID OUTLET VAPOR INLET COMPLETE LIQUID BOIL OFF POINT SUCTION LINE COOL LOW PRESSURE VAPOR LIQUID PRESSURE DROP DISCHARGE LINE NOT HIGH PRESSURE VAPOR OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH EVAPORATOR COILS CONDENSER COILS ROOM AIR CONDITIONER CYCLE OF REFRIGERATION HIGH PRESSURE ...

Page 21: ...perature difference of inlet outlet air 44 50 F 7 10 C Replacement of unit if the unit is beyond repair Check outdoor coil heat exchanger and fan operation Check heat load increase Check cold air circulation for smooth flow Check gas leakage Clean condenser Not on separate circuit Check inside gas pressure Adjust refrigerant charge Malfunction of compressor Replacement of compressor Check clogging...

Page 22: ... start Defect of compressor capacitor Replacement of compressor Motor damaged Irregular motor insulation Ω Irregular motor resistance Ω Check of circuit breaker and fuse Gas leakage of feeler bulb of thermostat Check control switch Fan only fails to start Improper wiring Defect of fan motor capacitor Replacement of fan motor Regular but fails to start Replacement of compressor Locking of piston me...

Page 23: ...e terminal Capacitor Discharge Test capacitor capacitor before testing Replace if not within 10 of manufacturer s rating Replace if shorted open or damaged Will not rotate Fan blade hitting shroud or blower wheel hitting scroll Re align assembly Units using slinger ring condenser fans must have 0 22 0 25 inch clearance to the base If necessary shim up the bottom of the fan motor with mounting scre...

Page 24: ...h Check for continuity refer to the wiring diagram for terminal identification Replace the switch if the circuit is open Thermostat Check the position of knob If not at the coldest setting advance the knob to this setting and restart the unit Check the continuity of the thermostat Replace the thermostat if the circuit is open Capacitor discharge Check the capacitor capacitor before Replace if not ...

Page 25: ...res will increase causing the compressor to cycle Straighten the fins or replace the coil Capacitor Test the capacitor Wiring Check the terminals If loose repair or replace Refrigeration system Check the system for a restriction Insufficient cooling Air filter If restricted clean or replace Unit undersized Determine if the unit is properly sized for the area to be cooled Excessive noise Turbo Fan ...

Page 26: ... 2 266002 1 149410 352115 349480 352113 35211A 567502 554160 550140 137215 W0CZZ 264110 354210 130410 W48602 148000 130910 359011 552102 554030 159830 147582 1 147582 2 352380 1 352380 2 135312 249950 359012 149980 346811 731273 W48602 269310 552113 35211A 238310 749740 ...

Page 27: ...ORATOR IN 35211A TUBE ASSEMBLY SUCTION SINGLE 352380 1 AIR GUIDE 352380 2 AIR GUIDE 352410 EVAPORATOR ASSEMBLY FIRST 359012 FAN TURBO 550140 ISOLATOR COMPRESSOR 554030 CONDESER ASSEMBLY FIRST 554160 COMPRESSOR 559010 FAN AXIAL 567502 O L P W0CZZ CAPACITOR DRAWING W48602 CLAMP SPRING LOCATION NO PART NO REMARK DESCRIPTION 3041A10040A 3091A10055A 3531A11008A 3720A30090A 4800A30012A 4941A30024A 4998A...

Page 28: ...P No 3828A20472B February 2004 Printed in China ...

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