website http://www.lgservice.com LG LG Room Air Conditioner SERVICE MANUAL MODEL: HBLG8004R,HBLG8004RA4,HBLG8004RB4, HBLG1004R, CL8000ER,M8004R, M8004RY4, M1004R,L8004R,L8004RY4,L1004R CAUTION • BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. • ONLY FOR AUTHORIZED SERVICE PERSONNEL.
Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions..........................................................................................................................................3 Dimensions .....................................................................................................................................................6 Outside Dimensions ...........................................................................................................................
Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. ■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications. WARNING This symbol indicates the possibility of death or serious injury. CAUTION This symbol indicates the possibility of injury or damage to property only. ■ Meanings of symbols used in this manual are as shown below.
Safety Precautions Plug in the power plug properly. • Otherwise, it will cause electric shock or fire. Do not operate or stop the unit by inserting or pulling out the power plug. Do not damage or use an unspecified power cord. • It will cause electric shock or fire. • It will cause electric shock or fire. ON ON Do not modify power cord length. • It will cause electric shock or fire. Do not use the socket if it is loose or damaged. • It may cause fire and electric shock.
Safety Precautions If water enters the product, turn off the the power switch of the main body of appliance. Contact service center after taking the power-plug out from the socket. • It will cause electric shock or failure of machine. Do not clean the air conditioner with water. • Water may enter the unit and degrade the insulation. It may cause an electric shock. CAUTION Never touch the metal parts of the unit when removing the filter. • They are sharp and may cause injury.
Dimensions Dimensions Symbols Used in this Manual This symbol alerts you to the risk of electric shock. This symbol alerts you to hazards that could cause harm to the air conditioner. NOTICE This symbol indicates special notes. Outside Dimensions 30 (1 3/16") 492 (19 3/8 ") 42 (1 21/32") 497 (19 9/16") 42 (1 21/32") 100.3 (3 15/16") 27.5 (1 3/32") Cool F1 LOW F2 MED F3 HIGH Energy Saver 'F Fan Dry TEMP Timer TIMER FAN SPEED POWER 12 (0.4 1/16") 347 (13 21/32") 315 (12 3/8") MODE 22.
Specfications Product Specifications MODELS HBLG8004R(A4/B4) L8004R(Y4)/M8004R(Y4) ITEMS POWER SUPPLY HBLG1004R L1004R/M1004R 1ø, 115V, 60Hz CAPACITY COOLING CL8000ER (BTU/h) 8,000 8,000 10,000 (W) 820 740 1,020 RUNNING CURRENT (A) 7.3 7.0 9.4 E.E.R 9.8 10.8 9.8 INPUT (BTU/W.h) OPERATING INDOOR ( C) 26.7(DB)* 19.4(WB)** CONDITION OUTDOOR ( C) 35(DB)* 23.9(WB)** REFRIGERANT (R-22) CHARGE 420g(14.8 oz) 410g(14.3 oz) 480g(16.
Installation Installation Select the Best Location CAUTION: All side louvers of the cabinet must remain exposed on the outdside of the structure. OUTSIDE FENCE AWNING HEAT RADIATION 30"-60" 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 INSIDE unit. 3.
Installation How to Install INNER SILL Window Requirements NOTICE 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 13" from the bottom of the sash to the window stool. 2.
Installation BEFORE INSTALLATION 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 of the bottom window. (Figure. 6) Type A Type A Figure 5 NOW START INSTALLATION SEAL STRIP (TYPE D) 1.
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 insects from getting into the room, as shown in Figure. 11. b. Fasten the L bracket using a (TYPE A) screw, as shown in Figure. 11.
Operation Operation • Designed for COOLING ONLY. • Powerful and quiet cooling. • Top-down chassis for the simple installation 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 compressor.
Disassembly Disassembly — Before the following disassembly, set the CONTROL BOX to OFF and disconnect the power cord. Mechanical Parts 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. Remove the front grille.(There are 4 hooks.) 5. Re-install the components by referring to the removal procedure, above. 2. Cabinet Figure 12 1.
Disassembly Air Handling Parts 4. Air Guide and Turbo 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 the air guide upper. 7. Remove the air guide upper.(See Figure 15) 8. Remove the 2 screws that fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 16) 10.
Disassembly Electrical Parts 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 protector. 5. Remove the overload protector. 6. Re-install the components by referring to the removal procedure, above. Figure 19 8. Compressor 1. Remove the cabinet. (Refer to section 2) 2. Discharge the refrigerant system using a FreonTM Recovery System.
Disassembly 10. Power Cord 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 referring to the above removal procedure, above. (Use only one ground-marked hole for ground connection.) 7.
Disassembly Refrigerating Cycle 12. Condenser CAUTION: 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. 1. Remove the cabinet. (Refer to section 2) 2. Remove the 4 screws that fasten the brace.(Refer to section 4) 3. Remove the 5 screws that fasten the condenser and shroud. 4.
Disassembly NOTICE — Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to 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. 2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes. 3.
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.
MAIN POWER FAN COMP HERM C CAPACITOR FAN MOTOR S/V4WAY HVB SW1 SW2 PIPE-TH 1 2 1 2 7 7 3 1 3 1 9 5 9 3 1 1 5 1 1 3 3 3 1 1 3 2 3 2 3 3 1 1 2 1 1 2 2 2 YW396-03AV CN-PWR YW396-09AV 250VT3.15A FUSE RY-COMP G4A-1A-E-LG CN-MOTOR YW396-03AV(YL) CN-12V J5 C01T 5V 0.
Schematic Diagram Wiring Diagram CAPACITOR F C RD H WH(BL) (Ribbed) FUSE 250V/T3.15A C 4 4 S BL OLP WIRING DIAGRAM 6 SWITCH DC12V CN-12V CN-HVB 3 R COMP. THERMISTOR CN-PWR BK(BR) (Plain) 3 CN-TH1 7 POWER TRANS OR(BR) BK GN/YL (GN) DC PCB ASSEMBLY YL ZNR01J 2 RY-HI MOTOR CN-AC/DC 5 RY-LOW GN/YL (GN) CN-AC/DC CN-MOTOR BK BL RD YL OR RY-MED 1 H.V. ASSEMBLY RY-COMP BK RD AC PCB ASSEMBLY 8 AIR FILTER ASSEMBLY S: Service Parts N: Non Service Parts LOCATION NO.
Schematic Diagram Components Location 1. MAIN P.C.B ASSEMBLY Q03T J7 Q04T J3 J2 IC01D C02D C04D CN-PWR CN-4WAY ZNR01J C01J R01J C05D RY-LOW D05D D04D D03D QIC02DT RY-MED HEAT SINK J1 D02D CN-TH2 PCB:6870A90068D C03T CN-TELE RY-HI CN-12V CN-HVB CN-AC/DC CN-MOTOR J6 J5 D01T C02T J4 Q02T CN-CON R01T Q01T E03J C01D RY-4WAY ASSEMBLY:6871A20417C FUSE 250V/T3.15A 2. DISPLAY P.C.B.
Troubleshooting Guide Troubleshooting Guide Piping System CONDENSER COIL FAN CAPILLARY TUBE MOTOR COMPRESSOR TURBO FAN EVAPORATOR COIL 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.
Troubleshooting Guide Troubleshooting 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 cooling. Ineffective Cooling Check cold air circulation for smooth flow. Check outdoor coil (heat exchanger) & the fan operation. Dirty indoor coil (Heat exchanger) Check gas leakage.
Troubleshooting Guide Fails to Start Check of power source. Check circuit breaker and fuse. Check of control switch setting. Gas leakage of feeler bulb of thermostat Check of control switch. Compressor only fails to start. Fan only fails to start. Improper wiring. Drop of power voltage. Improper thermostat setting. Defect of compressor capacitor. Loose terminal connection. Capacitor check. Improper wiring. Defect of fan motor capacitor. Irregular motor resistance ( ).
Troubleshooting Guide Electrical Parts Troubleshooting Guide Possible Trouble 1 The unit does not operate. Is the Trans input power AC 115V? NO •• Check Check the the Fuse. Fuse. •• Check the Check thewiring wiringdiagram. diagram. YES Is the Trans output power about AC 14V? NO YES Is output Voltage of IC01D DC 12V? Is shorted the Trans. output? YES NO NO • Check the Main PCB pattern. • Replace the Trans. • Replace D02D~D05D. • Replace IC01D.
Troubleshooting Guide Possible Trouble 2 The compressor does not operate. Is setting Temp. set lower than Room Temp.-0.5°C? NO • Select the setting Temp. to lower Number. YES NO Is the voltage No.10 of IC01M 0V? Is the voltage N0.9 of IC01M DC 12V? YES YES • Check the RY-COMP. • Check the wiring Diagram. • Replace IC01M. NO Does the Unit delay for 3 minutes? NO YES • Wait 3 Minutes. • Replace MAIN PCB Ass'y. Possible Trouble 3 The compressor always operate.
Troubleshooting Guide Possible Trouble 4 FAN does not operate. Is the voltage NO.1 or 2 or 4 of IC01M DC 12V? NO • Replace IC01M. YES Is the voltage NO.16 or 15 or 13 of IC01M 0V? NO • Replace IC01M. YES • Check the RY-Hi or RY-Med or RY-Lo. • Check the wiring diagram. Possible Trouble 5 The function of Energy Saver does not operate. Is the mode key pushed once more from cool mode? NO • Set the mode key to Energy Saver mode. YES Is the voltage No.
Troubleshooting Guide Possible Trouble 6 Remote controller does not operate. Is the voltage of Battery over 2.3V? NO • Replace the battery. YES Is the voltage No.10 of CN-AC/DC on DC PCB Ass'y DC 5V? NO ••Check Checkthe thePCB PCBpattern. pattern. YES NO Is the connection of CN-AC/DC OK? • Connect connector to CN-AC/DC exactly. YES • Replace Receiver Ass'y. Possible Trouble 7 It displays abnormally on DC PCB Ass’y. NO Is IC01G good? • Replace IC01G.
Troubleshooting Guide Electrical Parts Possible Trouble 1 The unit does not operate. Is the Trans input power AC 115V? NO •• Check Check the the Fuse. Fuse. •• Check the Check thewiring wiringdiagram. diagram. YES Is the Trans output power about AC 14V? NO YES Is output Voltage of IC01D DC 12V? Is shorted the Trans. output? YES NO NO • Check the AC PCB pattern. • Replace the Trans. • Replace D02D~D05D. • Replace IC01D. YES Is output Voltage of IC02D DC 5V? NO • Replace IC02D.
Troubleshooting Guide Possible Trouble 2 The compressor does not operate. Is desired Temp. set lower than Room Temp.-0.5°C? NO • Select the desired Temp. to lower Number. YES NO Is the voltage No.10 of IC01M 0V? Is the voltage N0.9 of IC01M DC 12V? YES YES • Check the RY-COMP. • Check the wiring Diagram. • Replace IC01M. NO Is the Unit for 3 minutes delay? NO YES • Wait 3 Minutes. • Replace AC PCB Ass'y. Possible Trouble 3 The compressor always operate.
Troubleshooting Guide Possible Trouble 4 FAN does not operate. Is the voltage NO.1 or 2 or 4 of IC01M DC 5V? NO • Replace IC01M. YES Is the voltage NO.16 or 15 or 13 of IC01M 0V? NO • Replace IC01M. YES • Check the RY-Hi or RY-Med or RY-Lo. • Check the wiring diagram. Possible Trouble 5 Remote controller does not operate. Is the voltage of Battery over 2.3V? NO • Replace the battery. YES Is the voltage No.10 of CN-AC/DC on AC PCB Ass'y DC 5V? NO Check the •• Check thePCB PCBpattern.
Troubleshooting Guide Possible Trouble 6 It displays abnormally on DC PCB Ass’y. Are IC01G and IC02G OK? NO • Replace IC01G, IC02G. NO • Connect connector to CN-AC/DC exactly. YES NO Is the connection of CN-AC/DC OK? YES Does the IC03G operate normally on AC PCB Ass'y? NO • Replace IC03G. YES • Replace the DC PCB Ass'y.
Troubleshooting Guide COMPLAINT Fan motor will not run. CAUSE REMEDY No power Check voltage at outlet. Correct if none. Power supply cord Check voltage to Control Box. If none, check power supply cord. Replace cord if circuit is open. Wire disconnected or connection loose Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal. Capacitor (Discharge capacitor before testing.) Test capacitor. Replace if not within ±10% of manufacturer's rating.
Troubleshooting Guide COMPLAINT Compressor will not run, but fan motor runs. Compressor cycles on overload. Compressor cycles on overload. Compressor cycles on overload. Insufficient cooling or heating Excessive noise CAUSE REMEDY Thermistor 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. Capacitor (Discharge capacitor before servicing.
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Replacement Parts List Replacement Parts List LOCATION No.
Replacement Parts List Replacement Parts List LOCATION NO. DESCRIPTION PART NO.
Replacement Parts List Replacement Parts List LOCATION NO. PART NO.
P/NO:3828A20472A February, 2004 Printed in China