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AR3735S12


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2. DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS
2.1.1 FRONT GRILLE                                               Figure 1
1. Disconnect the unit from the power source.
2. Remove the two knobs by pulling them off.
   Using a screwdriver, remove the screw that
   secures the front grille to control board.
   (See Figure 1)
3. Push the front grille up from the bottom.
   Pull the top of the front grille away from the
   cabinet as the top tabs lift out of their slots.
   (See Figure 2)
                                                                 Figure 2
4. Replace the grille by placing the tabs in the slots
   and push the grille until it snaps into place.




                                                                 Figure 3
2.1.2 CABINET
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 2.1.1)
3. Remove 6 screws that secure the cabinet to the
   base pan. (See Figure 3)
4. Lift the cabinet from the unit.
5. Re-install by referring to the procedures above.

                                                                 Figure 4
2.1.3 CONTROL BOARD
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 2.1.1)
3. Remove the cabinet. (Refer to Section 2.1.2)
4. Remove 2 screws that secure the control board to
   base pan and orifice. (See Figure 4)
5. Pull the control board toward yourself.

 NOTE : Controls, wires, and capacitor are now
        accessible for servicing. Discharge the
        capacitor before servicing.                              Figure 5


6. Disconnect one housing terminal and 3 wires for
   the fan motor and compressor. (See Figure 5)
7. Re-install components by referring to procedures
   above. (Refer to wiring diagram on page 20 in this
   manual or inside control board.)

                                                         --5--
2.2 AIR HANDLING PARTS                                          Figure 6
2.2.1 ORIFICE
 1. Disconnect the unit from the power source.
 2. Remove the front grille. (Refer to Section 2.1.1)
 3. Remove the cabinet. (Refer to Section 2.1.2)
 4. Remove the control board.
    (Refer to Section 2.1.3)
 5. Remove 2 screws that secure the orifice.
    (See Figure 6)
 6. Lift orifice upward.
 7. Re-install by referring to the procedures above.



                                                                Figure 7
2.2.2 BLOWER WHEEL, FAN AND SHROUD
 1. Disconnect the unit from the power source.
 2. Remove the front grille. (Refer to Section 2.1.1)
 3. Remove the cabinet. (Refer to Section 2.1.2)
 4. Remove the control board.
    (Refer to Section 2.1.3)
 5. Remove the orifice. (Refer to Section 2.2.1)
 6. Remove the screw that secures shroud and air
    guide. (Figure 7)
 7. Remove 2 screws that secure the base pan.
    (See Figure 8)
 8. Remove the screw that secures the shroud to                 Figure 8
    channel of condenser.
 9. Press the snap area of shroud with your thumbs.
    This allows you to remove it from the condenser.
10. Lift the compressor upward with the evaporator
    and condenser. (See Figure 8)
11. Remove the clamp springs which are clamped to
    the boss of fan and blower wheel by hand plier.
    (See Figure 9)
12. Pull the fan and blower wheel outward tilting it
    foward yourself.
13. Remove the shroud.
14. Re-install by referring to the procedures above.

                                                                Figure 9




                                                        --6--
2.2.3 AIR GUIDE AND MOTOR
 1. Disconnect the unit from the power source.                  Figure 10
 2. Remove the front grille. (Refer to Section 2.1.1)
 3. Remove the cabinet. (Refer to Section 2.1.2)
 4. Remove the control board.
    (Refer to Section 2.1.3)
 5. Remove the orifice. (Refer to Section 2.2.1)
 6. Remove the compressor, evaporator and
    condenser. (Refer to Section 2.2.2)
 7. Remove 2 screws that secure the motor to the air
    guide. (See Figure 10)
 8. Separate the motor by pulling it backward.
 9. Remove 2 screws that secure the air guide to the
    base fan. (See Figure 11)
10. Push the air guide backward and lift it upward.
    (See Figure 11)
11. Re-install by referring to the procedures above.
                                                                Figure 11




2.3 ELECTRICAL PARTS
2.3.1 OVERLOAD PROTECTOR
 1. Remove the cabinet. (Refer to Section 2.1.2)                Figure 12   Figure 13
 2. Remove the nut which fastens the terminal cover.
 3. Remove the terminal cover.
 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.
    (See Figure 12 and 13)




                                                        --7--
2.3.2 COMPRESSOR
1. Remove the cabinet. (Refer to Section 2.1.2)                 Figure 14
2. Discharge the refrigerant by using a refrigerant
   recovery system.
3. Remove the overload protector.
   (Refer to Section 2.3.1)
4. After discharging the unit completely, unbrace the
   suction and discharge pipes at the compressor
   connections.
5. Remove 3 nuts which fasten the compressor.
6. Remove the compressor.
7. Re-install by referring to the removal procedure
   above. (See Figure 14)


2.3.3 CAPACITOR
1. Remove the cabinet. (Refer to Section 2.1.2)
2. Remove the control board.
   (Refer to Section 2.1.3)
3. Discharge the capacitor by placing a 20 K                    Figure 15
   resistor across the capacitor terminals.
4. Remove the screw which fastens the capacitor
   clamp. (See Figure 15)
5. Remove all the leads of capacitor terminals.
6. Remove the capacitor
7. Re-install the components by referring to the
   removal procedure above.



2.3.4 THERMOSTAT
1. Remove the cabinet. (Refer to Section 2.1.2)
2. Remove the control board.
                                                                Figure 16
   (Refer to Section 2.1.3)
3. Remove 2 screws which fasten the thermostat.
   (See Figure 16)
4. Remove all the leads of the thermostat terminals.
5. Remove the thermostat.
6. Re-install the components by referring to the
   removal procedure above.


2.3.5 ROTARY SWITCH
1. Remove the cabinet. (Refer to Section 2.1.2)                 Figure 17
2. Remove the control board.
   (Refer to Section 2.1.3)
3. Remove 2 screws which fasten the rotary switch.
   (See Figure 17)
4. Remove all the leads of the rotary switch
   terminals.
5. Remove the rotary switch.
6. Re-install the components by referring to the
   removal procedure above.

                                                        --8--
2.3.6 FAN MOTOR
 1. Disconnect the unit from the power source.                  Figure 18
 2. Remove the front grille. (Refer to Section 2.1.1)
 3. Remove the cabinet. (Refer to Section 2.1.2)
 4. Remove the control board.
    (Refer to Section 2.1.3)
 5. Remove the orifice. (Refer to Section 2.2.1)
 6. Remove the compressor, evaporator, and
    condenser. (Refer to Section 2.2.2)
 7. Remove the fan and blower wheel.
    (Refer to section 2.2.2)
 8. Remove the motor. (Refer to Section 2.2.3)
 9. Remove the air guide. (Refer to Section 2.2.3)
10. Re-install by referring to procedures above.




                                                                Figure 19
2.3.7 POWER CORD
 1. Disconnect the unit from the power source.
 2. Remove the front grille. (Refer to Section 2.1.1)
 3. Remove the cabinet. (Refer to Section 2.1.2)
 4. Remove 2 screws that secure control board to
    base pan and orifice (Refer to Section 2.1.3).
 5. Pulls the control board toward you.
 6. Disconnect the 2 receptacles and remove the
    grounding screw.
 7. Remove a screw securing the clip with cord to the
    control board. (See Figure 19)
 8. Pull the power cord.
 9. Re-install by referring to procedures above.



                                                                Figure 20

2.4 REFRIGERANT CYCLE
2.4.1 CONDENSER
 1. Remove the cabinet. (Refer to Section 2.1.2)
 2. Discharge the refrigerant by using a refrigerant
    recovery system.
 3. Remove 2 screws which fasten the condenser.
    (See Figure 20)
 4. After discharging the refrigerant completely,
    unbraze the interconnecting tube at the
    condenser connections.
 5. Remove the condenser.
 6. Re-install by referring to the procedures above.




                                                        --9--
2.4.2 EVAPORATOR
1. Remove the cabinet. (Refer to Section 2.1.2)                6-3. Operate the vacuum pump for 20 to 30 minutes,
2. Discharge the refrigerant by using a refrigerant                  until 600 micron vacuum is obtained.
   recovery system.                                                  Close valves A and B and observe vacuum
3. Remove the orifice. (Refer to Section 2.2.1)                      gauge for a few minutes.
4. After discharging the refrigerant completely,                     A rise in pressure would indicate a possible leak
   unbraze the interconnecting tube at the evaporator                or moisture remains in the system.
   connections.                                                      With valves A and B closed, stop the vacuum
5. Remove the evaporator.                                            pump.
6. Re-install by referring to the procedures above.            6-4. Remove the hose from the vacuum pump and
                                                                     place it on the charging cylinder. See figure 23B.
2.4.3 CAPILLARY TUBE                                                 Open valve C.
1. Remove the cabinet. (Refer to Section 2.1.2)                      Discharge the line at the manifold connection.
2. Discharge the refrigerant by using a refrigerant            6-5. The system is now ready for final charging.
   recovery system.                                            7. Recharge as follows :
3. Remove the orifice. (Refer to Section 2.2.1)                7-1. Rotary compressor systems are charged from
4. After discharging the refrigerant completely,                     the high-side. If the total charge cannot be put in
   unbraze the interconnecting tube of the capillary                 the high-side, the balance will be put in the
   tube.                                                             suction line through the access valve which is
5. Remove the capillary tube.                                        installed as the system is opened.
6. Re-install by referring to the procedures above.            7-2. Connect the charging cylinder as shown in figure
                                                                     21B. With valve C open, discharge the hose at
NOTES                                                                the manifold connection.
                                                               7-3. Open valve A and allow the proper charge to
Replacement of the refrigeration cycle.
                                                                     enter the system. Valve B is still closed.
                                                               7-4. If more charge is required, the high-side will not
1. When replacing the refrigerating cycle, be sure to
                                                                     take it. Close valve A.
   discharge the refrigerant by using a refrigerant
                                                               7-5. With the unit running, open valve B and add the
   recovery system.
                                                                     balance of the charge.
2. After discharging the unit completely, remove the
                                                                  a. Do not add the liquid refrigerant to the low-side.
   desired components, and unbraze the pinch-off
                                                                  b. Watch the low-side gauge, allow pressure to rise
   tubes.
                                                                     to 30 lbs.
3. Solder service valves into the pinch-off tube ports,
                                                                  c. Turn off valve B and allow the pressure to drop.
   leaving the valves open.
                                                                  d. Repeat steps B and C until the balance of the
4. Solder the pinch-off tubes with service valves.
                                                                     charge is in the system.
5. After doing the above procedures, the valve must
                                                               7-6. When the unit is operating correctly, use the
   be closed and left in place on the system for any
                                                                     pinch-off tool with the unit still running and the
   subsequent procedures.
                                                                     clamp on the pinch-off tube. Using a tube cutter,
6. Evacuate as follows:
                                                                     cut the pinch-off tube about 2 inches from the
6-1. Connect the vacuum pump, as illustrated figure
                                                                     pinch-off tool. Use sil-fos solder and solder the
      21A.
                                                                     pinch-off tube closed. Turn off the unit, allow
5-2. Start the vacuum pump. Slowly open manifold
                                                                     setting for a while and then test the leakage of
      valves A and B with two full turns counterclock-
                                                                     the pinch-off connection.
      wise and leave the valves closed.
      The vacuum pump is now pulling through valves
      A and B up to valve C by means of manifold and
      the 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 counter-clock-
     wise. This will keep oil from foaming and being
     drawn into the vacuum pump.

                                                          --10--
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, service valve.




                                                                COMPOUND GAUGE

                                                                            MANIFOLD
                                                                              GAUGE
                                                                                          B           A




       CONDENSER
       (HIGH PRESSURE SIDE)                                                          SEE INSETS
                                                                                       BELOW



                             COMPRESSOR



                                                                          EVAPORATOR
                                                                          (LOW PRESSURE SIDE)

                                                        CAPILLARY TUBE




                                                                    LO      HI   CHARGING CYLINDER


                             A
          B                                                     B                A
                          EXTERNAL VACUUM PUMP




                                                                                                  C


                Figure 21A-Pulling Vacuum                                Figure 21B-Charging




                                                  --11--



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