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LG Electronics M8004R manual

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Table of contents for the manual

  • Page 1

    LG Room Air Conditioner SERVICE MANUAL LG CAUTION website http://www.lgservice.com • BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. • ONLY FOR AUTHORIZED SERVICE PERSONNEL. MODEL: HBLG8004R,HBLG8004RA4,HBLG8004RB4, HBLG1004R, CL8000ER,M8004R, M8004RY4, M1004R,L8004R , L8004RY4,L1004R [...]

  • Page 2

    2 Room Air Conditioner Air Conditioner Ser vice Manual T ABLE OF CONTENTS Safety Precautions ..........................................................................................................................................3 Dimensions ..........................................................................................................[...]

  • Page 3

    Ser vice Manual 3 Saf ety Precautions Safety Precautions T o pre v ent injury to the user or other people and proper ty damage, the f ollowing instructions must be f ollowed. ■ Incorrect operation due to ignoring instruction will cause har m or damage. The seriousness is classified by the f ollowing indications . ■ Meanings of symbols used in t[...]

  • Page 4

    4 Room Air Conditioner Saf ety Precautions Plug in the power plug properl y . • Otherwise , it will cause electric shock or fire. Do not operate or stop the unit by inserting or pulling out the power plug. • It will cause electric shock or fire. Do not damage or use an unspecified power cor d. • It will cause electric shock or fire. Do not mo[...]

  • Page 5

    Ser vice Manual 5 If water enters the pr oduct, turn off the the power switc h of the main body of appliance . Contact ser- vice center after taking the power -plug out from the socket. • It will cause electric shock or f ailure of machine. Do not clean the air conditioner with water . • W ater ma y enter the unit and degrade the insula- tion. [...]

  • Page 6

    6 Room Air Conditioner Dimensions Dimensions Outside Dimensions This symbol alerts you to the risk of electric shoc k. This symbol alerts you to hazar ds that could cause harm to the air conditioner . This symbol indicates special notes. NOTICE Symbols Used in this Manual 497 (19 9 / 16 ") 492 (19 3 / 8 ") 315 (12 3/8 ") 30 (1 3 / 16[...]

  • Page 7

    Specfications Pr oduct Specifications POWER SUPPLY CAPACITY POWER SUPPLY POWER SUPPLY (BTU/h) CAPACITY CAPACITY INPUT (BTU/h) (BTU/h) POWER SUPPLY (W) INPUT INPUT CAPACITY COOLING (W) (W) (BTU/h) RUNNING CURRENT COOLING COOLING INPUT (A) RUNNING CURRENT RUNNING CURRENT (W) E.E.R (A) (A) COOLING (BTU/W.h) E.E.R E.E.R RUNNING CURRENT INDOOR ( (BTU/W.[...]

  • Page 8

    8 Room Air Conditioner Installation Installation Select the Best Location Installation Chec k How to Secure the Drain Pipe 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 on the unit. 3. The outside of the cabinet must extend outward for at least 12&qu[...]

  • Page 9

    Ser vice Manual 9 Installation How to Install Window Requirements All supporting parts should be secured to firm wood, masonry, or metal. 1. This unit is designed for installation in standard double hung windows with actual opening widths of 22" to 36". The upper and lower sash must open sufficiently to allow a clear vertical opening of 1[...]

  • Page 10

    10 Room Air Conditioner Installation BEFORE INST ALLA TION 1. Insert the guide panels into the guides of the air conditioner. Fasten the curtains to the unit with screws (TYPE A) as shown Figure. 5. 2. Cut the adhesive-backed seal strip (TYPE D) to the window width. Remove the backing from the seal strip and attach the seal strip to the underside o[...]

  • Page 11

    Ser vice Manual 11 Installation 4. SECURE THE GUIDE PANELS Extend the guide panels (TYPE F) to fill the window opening using 4 screws (TYPE B) to secure them, as shown in Figure. 11. 5. INSTALL THE SASH SEAL AND SASH LOCK a. Cut the sash seal (TYPE E) to the window width. Stuff the sash seal between the glass and the window to prevent air and insec[...]

  • Page 12

    12 Room Air Conditioner Operation Operation • Designed for COOLING ONLY. • Powerful and quiet cooling. • Top-down chassis for the simple instal- lation and service. • Low air-intake, top cooled-air discharge. • Built-in adjustable Thermistor • Washable one-touch filter • Compact size • Equipped with reliable and efficient rotary com[...]

  • Page 13

    Ser vice Manual 13 Disassembly Disassembl y Mechanical P ar ts — Before the following disassembly, set the CONTROL BOX to OFF and disconnect the power cord. 1. Front Grille 1. Open the lnlet grille downward and remove the air filter. 2. Remove the screw that fastens the front grille.(See Figure 12) 3. Pull the front grille from the right side. 4.[...]

  • Page 14

    14 Room Air Conditioner Disassembly Figure 1 5 Figure 1 6 Figure 1 7 Figure 18 4. Air Guide and T urbo Fan 1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the control box. (Refer to section 3) 4. Remove the 4 screws that fasten the brace. 5. Remove the brace. 6. Remove the 2 screws that fasten [...]

  • Page 15

    7. Overload Protector 1. Remove the cabinet. (Refer to section 2) 2. Remove the nut that fastens the terminal cover. 3. Remove the terminal cover. (See Figure 19 ) 4. Remove all the leads from the overload protec- tor. 5. Remove the overload protector. 6. Re-install the components by referring to the removal procedure, above. 8. Compressor 1. Remov[...]

  • Page 16

    16 Room Air Conditioner Disassembly 10. P ower Cor d 1. Remove the control box. (Refer to section 3) 2. Open the top cover from the control box. (Refer to section 9) 3. Disconnect the front panel from the control box. (See Figure 22) 4. Disconnect two leads from the capacitor and relay. 5. Pull out the power cord. 6. Re-install the component by ref[...]

  • Page 17

    Ser vice Manual 17 Disassembly 12. Condenser CA UTION: Dischar g e the refrigerant system using a Freon TM Recovery System. If there is no valve to attac h the recovery system, install one (such as a W A TCO A-1) before venting the Freon TM . Leave the v alve in place after servicing the system. 1. Remove the cabinet. (Refer to section 2) 2. Remove[...]

  • Page 18

    18 Room Air Conditioner Disassembly — Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a Freon TM recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the Freon TM . Leave the valve in place after se[...]

  • Page 19

    Ser vice Manual 19 Disassembly Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve. A COMPOUND GAUGE EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR CAPILLARY TUBE CONDENSER (HIGH PRESSURE SIDE) [...]

  • Page 20

    20 Room Air Conditioner Schematic Dia gram 33 22 11 HVB 5V b c R04P X O O X 5V R04P 8 EEPROM Model 1 EEPROM A0 5V S7136 IC01A 3.6V 2 1 R01A 20K 3 + 10V 1uF C02A CAT93C46 Vcc Auto Restart Non Auto Restart 20K R03P 20K 5 7 6 R02P Q03G 1K R04P A101S Q01G A101S Q02G SW03G D03G SW06G D06G TEMP UP D02G D05G SW02G MODE SW05G TEMP DOWN ON/OFF D01G D04G FAN[...]

  • Page 21

    Ser vice Manual 21 Schematic Diagram Wiring Diagram MOTOR ASSY CAPACITOR COMPRESSOR OVERLOAD PROTECTOR DC PCB ASSEMBLY AC PCB ASSEMBLY THERMISTOR PLASMA FILTER ASSY 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 S S S S S S S S LOCATION NO. DESCRIPTION REMARKS Q'TY PER SET MO TOR COMP . CAP A CITOR DC PCB ASSEMBL Y THERMIST OR AIR FIL TER ASSEMBL Y A C PCB A[...]

  • Page 22

    22 Room Air Conditioner Schematic Diagram Components Location 1. MAIN P .C.B ASSEMBL Y R01T CN-HVB C03T Q03T Q04T C04D C05D C01D C02D D02D D03D D04D D05D IC01D HEA T SINK QIC02DT J5 Q01T CN-TELE CN-TH2 CN-PWR CN-MOT OR ZNR01J CN-4W A Y C01J R01J E03J E04J POWER TRANS FUSE 250V/T3.15A R Y -COMP E05J E02J J8 E01J J6 J2 J3 RY - HI PCB:6870A90068D?[...]

  • Page 23

    Ser vice Manual 23 T roubleshooting Guide T r oubleshooting Guide Piping System Figure 26 is a brief description of the important components and their function in what is called the refrigeration system. This will help you to understand the refrigeration cycle and the flow of the refrigerant in the cooling cycle. MOTOR COMPRESSOR OIL (LIQUID REFRIG[...]

  • Page 24

    24 Room Air Conditioner T roubleshooting Guide T roub leshooting Guide In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused from an electrical defect, and the other is ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application. Unit runs but poor cooli[...]

  • Page 25

    Ser vice Manual 25 T roubleshooting Guide Fails to Start Check circuit breaker and fuse. Gas leakage of feeler bulb of thermostat Check of control switch. Fan only fails to start. Improper wiring. Defect of fan motor capacitor . Irregular motor resistance ( ). Irregular motor insulation ( ). Replacement of fan motor . Regular but fails to start. Re[...]

  • Page 26

    26 Room Air Conditioner T roubleshooting Guide • Check the Fuse. • Check the wiring diagram. Is the Trans input power AC 115V? Is the Trans output power about AC 14V? Is shorted the Trans. output? Is output Voltage of IC01D DC 12V? Is output Voltage of IC02D DC 5V? Is the voltage No.18 of Micom DC 5V? Replace AC PCB Ass'y. Is the connectio[...]

  • Page 27

    Ser vice Manual 27 T roubleshooting Guide Possible Trouble 2 The compressor does not operate. Possible Trouble 3 The compressor always operate. Is setting Temp. set lower than Room Temp.-0.5 ° C? Is the voltage No.10 of IC01M 0V? • Replace IC01M. • Select the setting Temp. to lower Number. • Wait 3 Minutes. Does the Unit delay for 3 minutes?[...]

  • Page 28

    28 Room Air Conditioner T roubleshooting Guide Possible Trouble 4 FAN does not operate. Possible Trouble 5 The function of Energy Saver does not operate. • Replace IC01M. • Replace IC01M. Is the voltage NO.1 or 2 or 4 of IC01M DC 12V? Is the voltage NO.16 or 15 or 13 of IC01M 0V? • Check the RY-Hi or RY-Med or RY-Lo. • Check the wiring diag[...]

  • Page 29

    Ser vice Manual 29 T roubleshooting Guide Possible Trouble 6 Remote controller does not operate. Possible Trouble 7 It displays abnormally on DC PCB Ass ’ y. NO NO NO NO YES YES YES Is IC01G good? Is the connection of CN-AC/DC OK? • Replace the DC PCB Ass'y. • Replace IC01G. • Replace IC03G (Q01G, Q02G, Q03G for Delux Model). • Conne[...]

  • Page 30

    30 Room Air Conditioner T roubleshooting Guide • Check the Fuse. • Check the wiring diagram. Is the Trans input power AC 115V? Is the Trans output power about AC 14V? Is shorted the Trans. output? Is output Voltage of IC01D DC 12V? Is output Voltage of IC02D DC 5V? Is the voltage No.40 of Micom DC 5V? Replace AC PCB Ass'y. Is the connectio[...]

  • Page 31

    Ser vice Manual 31 T roubleshooting Guide Possible Trouble 2 The compressor does not operate. Possible Trouble 3 The compressor always operate. Is desired Temp. set lower than Room Temp.-0.5 ° C? Is the voltage No.10 of IC01M 0V? • Replace IC01M. • Select the desired Temp. to lower Number. • Wait 3 Minutes. Is the Unit for 3 minutes delay? ?[...]

  • Page 32

    32 Room Air Conditioner T roubleshooting Guide Possible Trouble 4 FAN does not operate. Possible Trouble 5 Remote controller does not operate. • Replace IC01M. • Replace IC01M. Is the voltage NO.1 or 2 or 4 of IC01M DC 5V? Is the voltage NO.16 or 15 or 13 of IC01M 0V? • Check the RY-Hi or RY-Med or RY-Lo. • Check the wiring diagram. NO NO Y[...]

  • Page 33

    Ser vice Manual 33 T roubleshooting Guide Possible Trouble 6 It displays abnormally on DC PCB Ass ’ y. NO NO NO NO YES YES YES Are IC01G and IC02G OK? Is the connection of CN-AC/DC OK? • Replace the DC PCB Ass'y. • Replace IC01G, IC02G. • Replace IC03G. • Connect connector to CN-AC/DC exactly. Does the IC03G operate normally on AC PC[...]

  • Page 34

    34 Room Air Conditioner T roubleshooting Guide COMPLAINT CAUSE REMEDY Check voltage at outlet. Correct if none. Check voltage to Control Box. If none, check power supply cord. Replace cord if circuit is open. Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal. Test capacitor. Replace if not within ±[...]

  • Page 35

    Ser vice Manual 35 T roubleshooting Guide COMPLAINT CAUSE REMEDY Check the TEMP control. If not at the lowest number, set TEMP control to this setting and restart the unit. Check the continuity of the thermistor. Replace the thermistor if the circuit is open. Check the capacitor. Replace if not within ±10% of manufacturers rating. Replace if short[...]

  • Page 36

    Room Air Conditioner Exploded View Exploded Vie w 130910 149980 346811 359012 W48602 349001-2 268711-2 268711-1 238310 W0CZZ 135500 249950 147581 147582-1 559011 349480 552113 352113 352115 567480 237200 W48602 3523 8 0 148000 354210 267110 159830 264110 130410 550140 35211A 554160 567502 135312 135303 554030 e n w O r' a M s n l a u 147582-2 [...]

  • Page 37

    Ser vice Manual 37 Replacement P ar ts List Replacement P ar ts List L8004R HBLG8004R M8004R 130410 BA SE ASSEMBLY,WELD[SINGLE] 3041A10041H 3041A10041H 3041A10041H R 130910 CA BINET ASSEMBLY,SINGLE 3091A10056A 3091A10056A 3091A10056A R 135312 GRILLE A S SEMBLY,FRONT(SINGLE) 3531A24016A 3531A24017A 3531A24020A R 135303 GRILLE,INLET 3530A10238A 3530A[...]

  • Page 38

    Replacement P ar ts List R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R DESCRIPTION PART NO. REMARK LOCATION NO . 130410 130910 135312 135313 135500 147581 147582-1 147582-2 148000 159980 152302 237200 249950 268712 238310 268714 263230 264110 346811 349001-1 349001-2 349480 352115 35211A 352113 552111 552102 352390 35421[...]

  • Page 39

    Replacement P ar ts List R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R DESCRIPTION PART NO. REMARK LOCATION NO . 130410 130910 135312 135313 135500 147581 147582-1 147582-2 148000 159980 152302 237200 249950 268712 238310 268714 263230 264110 346811 349001-1 349001-2 349480 352115 35211A 352113 552111 552102 352390 35421[...]

  • Page 40

    P/NO:3828A20472A February, 2004 Printed in China[...]