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2. DISASSEMBLY INSTRUCTIONS
-- Before disassembling, turn the POWER SWITCH to OFF and disconnect the power cord.

2.1 MECHANICAL PARTS
2.1.1 FRONT GRILLE
1. Open the INLET GRILLE upward and remove the
air filter.
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 above
removal procedure. (See figure 1)

Figure 1

2.1.2 CABINET
1. After disassembling the FRONT GRILLE, remove
two screws which fasten the CABINET at both
sides.
2. Remove two screws which fasten the CABINET at
back.
3. Pull the BASE PAN forward. (See figure 2)

9
8 1

2
7 MED F A N 0 CO
O
L

6 3 LOW HIGH
4
R

5
LE

THER CO
O LOW
MO
STA
T
OPER
ATION

Figure 2

2.1.3 CONTROL BOX
1. Remove the front grille. (Refer to section 2.1.1)
2. Romove 3 screws which fasten the CONTROL BOX.
3. Pull the CONTROL BOX forward about 10-
15cm(1/2").
4. Discharge the CAPACITOR by placing a 20,000
ohm resistor across the capacitor terminals.
5. Remove two wire housings in the control box.
6. Pull the control box forward completely. 8

7
9
1

2
ME FAN 0 C
D O
O
L

7. Re-install the components by referring to the above
6 3 LOW
HIGH
4
R

5
LE

THE O
RM CO LOW
OS
TAT

removal procedure. (See figure 3)
OP
ERAT
ION

(Refer to the CIRCUIT DIAGRAM found on pages Figure 3
31~36 in this manual and on the control box.)

--9--
2.2 AIR HANDLING PARTS
2.2.1 AIR GUIDE
1. Remove the front grille. (Refer to section 2.1.1)
2. Remove the cabinet. (Refer to section 2.1.2)
3. Pull the cover E.P.S upward.
4. Remove 3 screws which fasten the UPPER AIR
GUIDE.
5. Push two hooks which fasten the UPPER AIR
GUIDE and remove the UPPER AIR GUIDE.
6. Re-install the components by referring to the above
removal procedure. (See figure 4 and 5)

Figure 4

9
8 1

2
7 MED FAN 0 CO
O
L

2.2.2 BLOWER
6 3 LOW HIGH
4
R

5
LE

THE CO
O LOW
RM
OSTAT

OPER
ATION

1. Remove the air guide. (Refer to section 2.2.1) Figure 5
2. Move the evaporator sideward carefully.
3. Remove the clamp which secures the blower with a
hand plier. (See figure 6)
4. Remove 2 screws which fasten the MOTOR
MOUNT.
5. Pull the BLOWER forward by dragging the motor
mount upward carefully.
6. Remove the BLOWER.
7. Re-install the components by referring to the
removal procedure, above. (See figure 7) Figure 6

Figure 7

--10--
2.2.3 FAN, SHROUD
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove 4 screws which fasten the condenser.
3. Move the condenser sideward carefully.
4. Remove the clamp which secures the FAN with a
hand plier.
5. Remove the FAN.
6. Remove the SHROUD.
7. Re-install by referring to the above removal
procedure.(See figure 8 and 9))

Figure 8

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.
4. Remove all the leads from the OVERLOAD
PROTECTOR. Figure 9
5. Remove the overload protector.
6. Re-install the component by referring to the above
removal procedure. (See figure 10 and 11)

2.3.2 COMPRESSOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the regrigerant system using a FreonTM
Recovery System.
If there is no valve to attach the recovery system, Figure 11
Figure 10
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, detach the suction
tube and the discharge tubes at the compressor
connections.
5. Remove 3 nuts and 3 bracket washers which fasten
the compressor.
6. Remove the compressor.
7. Re-instll the components by referring to the above
removal procedure. (See figure 12)

Figure 12

--11--
2.3.3 CAPACITOR
1. Remove the control box. (Refer to section 2.1.3)
2. Remove the screw and the clamp which fastens the
CAPACITOR.
3. Disconnect all the leads of capacitor terminals.
4. Re-install the components by referring to the
removal procedure, above. (See figure 13)

2.3.4 POWER CORD Figure 13
1. Remove the control box. (Refer to section 2.1.3)
2. Disconnect the grounding screw from the control
box.(See figure 14)
3. Disconnect 2 receptacles.
4. Remove the screw which fastens the CLIP CORD.
5. Pull the power cord. (See figure 15)
6. Re-install the components by referring to the above
removed procedure.
(Use only one ground-maked hole for ground
connection.)

2.3.5 THERMOSTAT Figure 14 Figure 15
1. Remove the control box. (Refer to section 2.1.3)
2. Remove the screw which fasten the display panel.
3. Remove two knobs.
4. Remove the display panel.
5. Remove 2 screws which fasten the thermostat.
6. Disconnect all the leads of thermostat terminals.
7. Remove the THERMOSTAT.
8. Re-install the components by referring to the
above removal procedure. (See figure 16)

2.3.6 ROTARY SWITCH
1. Remove the control box. (Refer to section 2.1.3)
2. Remove the screw which fastens the display panel.
3. Remove two knobs.
4. Remove the display panel. Figure 16
5. Remove 2 screws which fasten the rotary switch.
6. Disconnect all the leads of the rotary switch
terminals.
7. Remove the rotary switch.
8. Re-install the components by referring to the
above removal procedure. (See figure 17)

Figure 17

--12--
2.3.7 MOTOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the upper air guide. (Refer to section 2.2.1)
3. Remove the blower. (Refer to section 2.2.2)
4. Remove the fan. (Refer to section 2.2.3)
5. Remove the shroud. (Refer to section 2.2.3)
6. Remove the control box. (Refer to section 2.1.3)
7. Remove 2 screws which fasten the motor.
8. Remove the motor.
9. Re-install the components by referring to the
above removal procedure. (See figure 18)
Figure 18

2.4 REFRIGERATION CYCLE
2.4.1 CONDENSER
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 4 screws which fasten the condenser.
4. After discharging the refrigerant completely, detach
the interconnecting tube at the condenser
connections.
5. Remove the condenser. Figure 19
6. Re-install the component by referring to notes.
(See figure 19)

2.4.2 EVAPORATOR
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 cover E,P.S and the upper air guide
(Refer to section 2.2.1)
4. After discharging the refrigerant completely, detach
the interconnecting tube at the evaporator
connections.
5. Remove the evaporator.
6. Re-install the component by referring to notes.
(See figure 20)

Figure 20

--13--
2.4.3 CAPILLARY TUBE
1. Remove the cabinet. (Refer to section 2.1.2) 4. After discharging the refrigerant completely, detach
2. Remove the upper air guide. (Refer to section the interconnecting tube at the CAPILLARY TUBE.
2.2.1) 5. Remove the CAPILLARY TUBE.
3. Discharge the refrigerant system using a FreonTM 6. Re-install the component by referring to notes.
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
servicing the system.

NOTES

-- Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, discharge 4) Remove the hose from the vacuum pump and
the refrigerant system using a FreonTM Recovery place it on the charging cylinder. See figures
System. 21A and 21B. Open valve C.
If there is no valve to attach the recovery system, Discharge the line at the manifold connection.
install one (such as a WATCO A-1) before venting 5) The system is now ready for final charging.
the FreonTM. Leave the valve in place after
servicing the system. 6. Recharge as follows :
2. After discharging the unit completely, remove the 1) Refrigeration cycle systems are charged from the
desired component, and detach the pinch-off High-side. If the total charge connot be put
tubes. in the High-side, the balance will be put in the
3. Solder service valves into the pinch-off tube ports, suction line through the access valve which you
leaving the valves open. install as the system was opened.
4. Solder the pinch-off tubes with care. 2) Connect the charging cylinder as shown in figure
5. Evacuate as follows. 21B.
1) Connect the vacuum pump, as illustrated Figure With valve C open, discharge the hose at the
21A. manifold connection.
2) Start the vacuum pump, slowly open manifold 3) Open valve A and allow proper charge to
valves A and B with two full turns enter the system. Valve B is still closed.
counterclockwise and leave the valves open. 4) If more charge is required, the high-side does not
The vacuum pump is now pulling through valves take it. Close valve A.
A and B up to valve C by means of the manifold 5) With the unit running, open valve B and add the
and entire system. balance of the charge.
a. Do not add the liquid refrigerant to the Low-
CAUTION
side.
If high vacuum equipment is used, just crack b. Watch the Low-side gauge; allow pressure to
valves A and B for a few minutes, then open rise to 30 lbs.
slowly with two full turns counterclockwise. This c. Turn off valve B and allow pressure to drop.
will keep oil from foaming and being drawn into d. Repeat steps b and c until the balance of the
the vacuum pump. charge is in the system.
6) When satisfied the unit is operating correctly,
3) Operate the vacuum pump for 20 to 30 minutes, use the pinch-off tool with the unit still running
until 600 microns of vaccum is obtained. Close and the clamp on to the pinch-off tube. Using a
valves A and B, and observe vacuum gauge for tube cutter, cut the pinch-off tube about 2 inches
a few minutes. A rise in pressure would from the pinch-off tool. Use sil-fos solder and
indicate a possible leak or moisture remaining in solder pinch-off tube closed. Turn off the unit,
the system. With valves A and B closed, stop allow it to set for a while, and then test the
the vacuum pump. leakage of the pinch-off connection.

--14--
Equipment needed: Vacuum pump, FreonTM Recovery System, 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.

CONDENSER COMPOUND GAUGE
(HIGE PRESSURE SIDE)
MANIFOLD
GAUGE
B A

CAPILLARY TUBE

SEE INSETS
BELOW

EVAPORATOR
(LOW PRESSURE SIDE)

COMPRESSOR

LO HI

A
B B A
EXTERNAL
VACUUM PUMP CHARGING
CYLINDER

Figure 21A-Pulling Vacuum Figure 21B-Charging

--15--

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