Amana AAC081SRA Service User manual

Servi
This manual is to be used by qualified appliance
technicians only. Maytag does not assume any
responsibility for property damage or personal
injury for improper service procedures done by
an unqualified person.
Sli e
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|
Air C e
This Base Manual covers general information
Refer to individual Technical Sheet
for information on specific models
This manual includes, but is
not limited to the following:
Amana
AAC081SRA
AAC101SRA
AAC121SRA
AAC141SRA
AAC182SRA
AAC202SRA
AAC242SRA
16022061
May 2003

important information
important Notices for Servicers and Consumers
Maytag will not be responsible for personal injury or property damage from improper service procedures. Pride and
workmanship go into every product to provide our customers with quality products. It is possible, however, that
during its lifetime a product may require service. Products should be serviced only by a qualified service technician
who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts,
testing instruments and the appropriate service information. IT IS THE TECHNICIANS RESPONSIBLITY TO
REVIEWALL APPROPRIATE SERVICE INFORMATION BEFORE BEGINNING REPAIRS.
_lb WARNING I
To avoid risk of severe personal injury or death, disconnect power before working!servicing on appliance to avoid
electrical shock.
To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this
product. For further assistance, please contact:
Customer Service Support Center
CAIR Center
Web Site Telephone Number
WWW.AMANA.COM ............................................... 1-800-843-0304
WWW.JENNAIR.COM ............................................ 1-800-536-6247
WWW.MAYTAG.COM ............................................. 1-800-688-9900
CAIR Center in Canada .......................................... 1-800-688-2002
Amana Canada Product .......................................... 1-866-587-2002
Recognize Safety Symbols, Words, and Labels
I _, DANGER
DANGER--Immediate hazards which WILL result in severe personal injury or death.
I _ WARNING I
WARNING--Hazards or unsafepracticeswhich COULD resultinseverepersonalinjuryordeath.
I _ll CAUTION I
CAUTION--Hazards or unsafe practices which COULD result in minor personal injury, product or property
damage.
2 16022061 Rev. 0 ©2003 MaytagAppliancesCompany

important Safety information
General Information
This Service Manual describes the operation,
disassembly, troubleshooting, and repair of Amana
Room Air Conditioners. it is intended for use by
authorized servicers who troubleshoot and repair these
units.
NOTE: It is assumed that users of this manual are
familiar with the use of tools and equipment used
to troubleshoot and repair electrical, mechanical,
and refrigeration systems; and understand the
terminology used to describe and discuss them.
Maytag urges you read and follow all safety precautions
and warnings contained in this manual. Failure to comply
with safety information may result in severe personal
injury or death.
Related Publications
This is a base service manual, covering a range of
[ ill WARNING J
To avoidriskofpersonalinjuryordeathdue toelectrical
shock, grounding wires and wires colored like grounding
wires are NOT to be used as current carrying
conductors. The standard accepted color coding for
ground wires is green or green with a yellow stripe.
Electrical components such as the compressor and fan
motor are grounded through an individual wire attached
to the electrical component and to another part of the air
conditioner. Grounding wires should not be removed
from individual components while servicing, unless the
component is to be removed and replaced. It is
extremely important to replace all removed grounding
wires before completing service.
[WARNING J
To avoid risk of heat exposure, which may cause death
or severe illness, air conditioner must be monitored
similar models. It is intended to be used in conjunction when malfunctions or shuts down.
with the Parts Manual and Technical Sheet covering
specific model being serviced.
General Precautions and Warnings
WARNING ]
To avoid risk of personal injury or death due to electrical
shock, disconnect electrical power to unit before
attempting to service the unit.
WARNING ]
To avoid risk of personal injury or death due to electrical
shock, DO NOT, under any circumstances, alter the
grounding plug. Air conditioner must be grounded at all
times. Do not remove warning tag from power cord. If a
two-prong (non-grounding) wall receptacle is
encountered, contact a qualified electrician and have
the receptacle replaced with a properly grounded wall
receptacle in accordance with the National Electrical
Code.
©2003 Maytag Appliances Company 16022061 Rev. 0 3

Table of Contents
Important Information .................................................. 2
Important Safety Information ........................................ 3
Product Identification .................................................... 5
Troubleshooting Information ......................................... 6
Testing Procedures ..................................................... 13
Low Voltage ........................................................... 13
High Voltage ......................................................... 13
Testing Capacitors ................................................ 13
Checking Overload Protectors ............................. 13
Checking Compressor Windings .......................... 13
Ground Test ......................................................... 14
Compressor Burnout ............................................ 14
Fan Motor ............................................................. 14
Leak Testing ......................................................... 14
Brazing ................................................................. 15
Restriction Testing ................................................ 15
Evacuation ........................................................... 15
Charging .............................................................. 16
Refrigerant Precautions ....................................... 17
Using Line Piercing Valves ................................... 17
Open Lines ........................................................... 17
Disassembly Procedures ............................................ 18
Air Filter Removal ................................................. 18
Insert Removal ..................................................... 18
Front Frame Removal .......................................... 19
Front Frame Clips Removal ................................. 19
Chassis Removal ................................................. 19
Rotary Control Assembly Removal ....................... 20
Fan MotorAssembly and Disassembly ................ 21
Condenser Removal ............................................ 21
Compressor Overload Protector Removal ............ 22
Compressor Removal .......................................... 22
Evaporator (Indoor Coil) Removal ........................ 23
Appendix A
Owner's Manual .................................................... A-1
4 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Product identification
Every Amana ® Room Air Conditioner has an
identification plate showing the model number, P
(manufacturing part) number, serial number of unit.
Identification plate is located on side of unit. Use plate to
positively identify specific model of unit being serviced.
Design information
Many design features are incorporated into all Amana ®
model Room Air Conditioners. Basic concepts of balance
in refrigeration and air handling components are used in
all models.
The outer case of unit, regardless of style, is designed to
help circulate air across evaporator, condenser,
compressor and fan motor. It must be in place to ensure
maximum efficiency of unit, to prevent overheating of
components, and to maintain system balance and
capacity.
Structural components of room air conditioners are
heavy, zinc-coated steel that is further treated with zinc
phosphate. Exterior parts are hot-dipped galvanized steel
that is chemically pretreated, then primed with electro-
coated primer, and finished with a baked-on polyester top
coat.
Modular design allows easier and faster disassembly
and assembly.
Acoustical and thermal insulation, used on partition panel
and in side air discharge plenum, reduce noise and
increase efficiency.
Large evaporator and condenser coils are designed to
provide maximum heat transfer. Coils are manufactured
from rifled copper tubing and embossed aluminum fins to
achieve maximum heat transfer. Thermal mastic is
placed on refrigeration tubes to dampen and isolate
system vibrations.
Fan motors are sealed to prevent moisture and dirt
contamination of motor windings. Motor bearings are
permanently lubricated. Large blower wheels and
condenser fans reduce noise levels.
Condenser fans contain a slinger ring for condensate
removal. The slinger ring picks-up condensate and
sprays it against the condenser, increasing condenser
evaporative cooling. In extreme humidity conditions,
excess condensate drains from base pan.
The following diagram explains how to interpret Amana
Room Air model numbers. Model numbers contain
information about cooling capacity, configuration, chassis
type, power requirements and series index for unit.
Brand
Product Type
Configuration
Cooling Capacity
123456789
-_ Series Index
_Controt Type
Chassis Type
--Voltage
3 Configuration
C= Cooling
4-5 BTU cooling Capacity
05= 5,000 BTU
08= 8,000 BTU
10= 10,000 BTU
12= 12,000 BTU
20= 20,000 BTU
6 Voltage
1= 115 Volt
2= 230 Volt
7 Chassis Type
F= Fixed
S= Slide Out
8 Control Type
R= Rotary Knob
T= Electronic control
9 Series Index
@2003 Maytag Appliances Company 16022061 Rev. 0 5

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
CAUTION
Units covered in this manual are polarized. Reversing polarity of a unit or any of its components will cause
damage. To avoid reversing polarity, any wires disconnected or removed during service must be reconnected to
the same location. To ensure wires are reconnected to the proper location, tag or otherwise mark the wires
before disconnecting or removing.
Tools and Equipment
Accurate diagnosis and repair of malfunctioning air
conditioners requires proper tools and equipment. In
addition to standard hand tools (screw drivers, pliers,
sockets, etc.), the following equipment is required:
Multimeter (combination voltmeter, ammeter, and
ohmmeter) for reading current loads during start-up
and normal operation, verifying voltage levels, and
testing various components for continuity.
,, Accurate leak detector, to check for refrigerant leaks.
,, Vacuum pump capable of removing all non-
condensables in sealed system.
,, Charging manifold and related equipment to determine
and replenish exact refrigerant charges.
Recovery cylinder and related equipment to recover
and store refrigerant charge in sealed system.
Additional tools and equipment may be required.
Troubleshooting Table
Troubleshooting table on the following pages contains
symptoms that may be seen in a malfunctioning air
conditioner. Each group of symptoms is accompanied by
one or more possible causes. Each possible cause is
accompanied by a remedy, or a test to determine if
suspect component(s) are working properly.
6 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Corrective Action
Symptom
Fan motor will not operate.
Possible Causes
No power supplied to unit.
Wire(s) disconnected or loose.
Fan motor capacitor faulty.
Check fuse box/circuit
breaker for blown fuse or
tripped breaker. Replace/reset.
Check power cord for opens.
Replace cord if faulty.
Ensure all connections are
tight and secure.
Check capacitor for open/
short. Replace if faulty.
NOTE: Discharge capacitor
before testing.
Fan motor faulty. Check fan motor windings for
shorts/opens. Replace if
faulty.
Fan hitting shroud or blower wheel hitting scroll.
Fan blade will not rotate.
Wire(s) disconnected or loose.Fan motor operates intermittently.
Cycling on motor protector.
Check fan blade!blower wheel
for proper alignment on motor
shaft. Reposition if necessary.
Check fan motor for proper
position, ensure mounting
nuts/bracket tight and secure.
Ensure all connections are
tight and secure.
Replace motor.
@2003 Maytag Appliances Company 16022061 Rev. 0 7

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Corrective Action
Symptom
Fan motor noisy.
Compressor does not run,
fan motor operates normally.
Possible Causes
Outside coil fan blade or inside
coil blower wheel loose or improperly aligned.
Worn fan motor bearings.
Fan motor mounting hardware!bracket
loose.
Wire(s) disconnected or loose.
Compressor capacitor faulty.
Compressor faulty.
Check fan blade!blower wheel
for proper position. Reposition
if necessary.
Ensure hardware attaching
fan blade/blower wheel to
motor shaft is tight. Tighten if
loose, replace if stripped.
Replace motor.
Check mounting bolts/bracket
for tightness. Tighten if
necessary.
Ensure all connections are
tight and secure. Correct as
required.
Check capacitor for short.
Replace if faulty,
NOTE: Discharge capacitor
before testing.
Check compressor motor
windings for open /shorts.
Replace compressor if
faulty.
8 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Corrective ActionPossible Causes
Overload protector open.
Rotary control faulty.
Wire(s) disconnected or loose.
Supply voltage out of specification.
Symptom
Compressor does not run,
fan motor operates normally.
Overload protector open.
Compressor cycles on and off.
Fan motor faulty.
Restricted air flow.
Compressor capacitor faulty.
Sealed refrigerant system fault.
Check protector for continuity.
If open, replace.
Ensure all control connections
are tight and secure. Check
control for proper operation
and installation. Replace if
faulty.
Ensure all connections are
tight and secure.
Check input voltage for proper
levels. Take appropriate
action if voltage levels out of
specification.
Check protector for continuity.
If open, replace.
Check fan motor for proper
operation. Replace if faulty.
Inspect air filter, indoor/
outdoor coil for dirt. Clean as
required. Check fins on coils
for damage. Straighten fins if
bent, attempt other repairs as
necessary. Replace coil if
repairs cannot be made.
Check capacitor for
short. Replace if faulty.
NOTE: Discharge capacitor
before testing.
Test sealed system for proper
charge, leaks, and restrictions.
@2003 Maytag Appliances Company 16022061 Rev. 0 9

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Possible Causes Corrective Action
Symptom
Insufficient cooling.
Excessive noise.
Low refrigerant charge.
Restricted air flow.
Unit undersized for area/room.
Outside coil fan blade or inside coil
blower wheel loose or improperly aligned.
Compressor mounting hardware loose or
grommets worn.
Free parts, loose screws causing or allowing
excessive vibration.
Worn fan motor bearings.
Test sealed system for proper
charge. Ensure system is free
of leaks.
Inspect air filter, indoor/
outdoor coil for dirt. Clean as
required. Check fins on coils
for damage. Straighten fins if
bent, attempt other repairs as
necessary. Replace coil if
repairs cannot be made.
Reduce area being cooled or
replace unit with larger
capacity model.
Check fan blade!blower wheel
for proper position. Reposition
blade or bower wheel.
Ensure hardware attaching fan
blade/blower wheel to motor
shaft is tight.
Check mounting bolts for
tightness. Tighten if
necessary. Don't overtighten.
Inspect grommets for wear.
Inspect unit for parts that may
have worked free, loose/
missing screws, other
)roblems that
may cause excessive
vibration.
Replace motor
10 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Corrective Action
Symptom
Excessive noise.
No cooling.
Possible Causes
Fan motor mounting hardware!
bracket loose.
Copper tubing improperly routed.
Compressor internal noise.
No refrigerant charge in sealed system.
Restriction in sealed system.
Compressor faulty.
Rotary Control faulty.
Undercharged, restricted strainer or plugged
capillary tube.
Wattage slowly decreases below
minimum specification.
Check mounting bolts/bracket
for tightness. Tighten if
necessary.
Inspect copper tubing for
excessive vibration. Secure
tubing.
Inspect compressor for proper
operation. Replace.
Test sealed system for leak.
Recharge unit.
Evacuate sealed system.
Remove restriction, recharge
unit.
Check compressor motor
windings for open /shorts.
Replace compressor.
Ensure all control connections
are tight and secure. Check
control for proper operation
and installation. Replace if
faulty.
Test sealed system for proper
charge. Ensure system is free
of leaks/restriction. Repair
Evacuate & recharge
sealed system.
@2003 MaytagAppliancesCompany 16022061 Rev. 0 11

Troubleshooting information
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Corrective Action
Symptom
Wattage decreases immediately.
Wattage continuously high.
Evaporator coil partially frosted.
Evaporator completely iced.
Possible Causes
No refrigerant.
Compressor faulty.
Refrigerant overcharge.
Insufficient air flow.
System low on refrigerant.
Restricted capillary tube.
Insufficient air flow.
Low outside temperature.
Restricted capillary tube.
Insufficient air flow.
Test sealed system for proper
charge. Ensure system is free
of leaks. Repair as required.
Check compressor motor
windings for open/shorts.
Replace compressor if
faulty.
Test sealed system for proper
charge.
Inspect air filter, indoor!
outdoor coil for dirt. Clean as
required. Check fins on coils
for damage. Straighten fins if
bent, attempt other repairs as
necessary. Replace coil if
repairs cannot be made.
Test sealed system for proper
charge. Ensure system is free
of leaks. Repair as required.
Replace capillary tube.
Inspect air filter, indoor/
outdoor coil for dirt. Clean as
required. Check fins on coils
for damage. Straighten fins if
bent, attempt other repairs as
necessary. Replace coil if
repairs cannot be made.
Turn unit off.
(Consumer education)
Replace capillary tube.
Inspect air filter, indoor/
outdoor coil for dirt. Clean as
required. Check fins on coils
for damage. Straighten fins if
bent, attempt other repairs as
necessary. Replace coil if
repairs cannot be made.
12 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Testing Procedures
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
Low Voltage
Low voltage can result in one or more of the following
problems:
Unit will not operate.
Compressor motor cycling.
Premature failure of overload protector.
Frequent blown fuses or tripped circuit breakers.
Premature failure of compressor or fan motor.
Noticeable dimming of lights when unit is operating.
Common causes for low voltage include inadequate
supply circuit wiring; use of extension cords; and
loose fuses or connections in fuse box, circuit
breaker, or distribution panel.
NOTE: A good indication of voltage problems caused
by inadequate or faulty wiring is voltage
levels that do not remain constant under load
(supply voltage fluctuates).
A less common cause for low voltage is voltage from
local electric utility is low (sometimes called "brown
outs"). If this is the case, have consumer contact
local electric utility for assistance.
All units should operate normally if power stays within
specifications (refer to Technical Sheet for unit under
test). Test for low voltage using voltmeter. Verify
voltage level at circuit breaker/distribution panel for
unit under test, and at electrical outlet serving unit.
Take initial voltage readings with air conditioner
turned off. Take additional readings during start-up of
unit, and again while unit is operating. All readings
should be within specifications and remain constant.
NOTE: Supply voltage may drop momentarily during
initial start-up and when compressor first
starts, but should always remain within
specifications.
High Voltage
High voltage causes motors to overheat, cycle on
their protectors, or break down electrically. This
problem can only be solved by local electric utility.
@2003 Maytag Appliances Company
Testing Capacitors
Compressors in these units use permanent split
capacitor type motors, eliminating need for start
capacitors and relays. A low capacitance
"compressor run capacitor" assists during start, and
remains in system during operation. See directions
on capacitor, and wiring diagram (on Technical
Sheet) for unit under test.
Capacitors are also used on permanent split
capacitor (PSC) fan motors.
To test capacitors:
1. Disconnect power to unit.
2. Discharge capacitor by shorting capacitor
terminals through a 10,000 ohm resistor.
Disconnect leads attached to capacitor terminals.
3. Set ohmmeter on highest scale. Attach ohmmeter
leads to capacitor and observe ohmmeter display:
•Good condition--indicator swings to zero and
slowly returns toward infinity.
•Shorted--indicator swings to zero and remains.
•Open--indicator does not move.
4. Reverse ohmmeter leads on capacitor and repeat
step 3.
Checking Overload Protectors
Overload protectors protect compressor from current
and temperature overloads by removing power from
compressor before it is damaged.
To check overload protector:
1. Disconnect power to unit.
2. Remove overload lead from compressor terminal.
3. Use ohmmeter to test continuity between overload
terminals. If open, replace overload.
Checking Compressor Windings
Resistance Test
1. Disconnect power to unit.
2. Remove leads from compressor terminals.
3. Set ohmmeter to lowest scale.
4. Attach ohmmeter to compressor terminals C and
S. Note reading.
5. Attach ohmmeter to compressor terminals C and
R. Note reading. If either compressor winding
reads open (infinite or very high resistance) or
dead short (0 ohms), replace compressor.
16022061 Rev. 0 13

Testing Procedures
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures
require power to be connected. Ensure all ground wires are connected before certifying unit as repaired
and/or operational.
NOTE: Motor windings typically have very little
resistance. When checking windings for
shorts, ensure ohmmeter is set on lowest
scale. Good windings may indicate as little
as 2 ohms of resistance.
Ground Test
1. Disconnect power to unit.
2. Remove leads from compressor terminals.
3. Set ohmmeter to highest scale.
4. Attach one lead of ohmmeter to body of
compressor. Ensure connection point is clean,
and makes good contact with compressor.
5. Attach remaining lead on ohmmeter to C, then S,
then R terminals on compressor. If ohmmeter
indicates continuity between compressor case
and any terminal, replace compressor.
Compressor Burnout
To avoid personal injury, do not allow sludge or oil
from compressor to contact skin. Severe burns may
result.
NOTE: Before opening any refrigeration system, EPA
regulations require refrigerant in system to be
captured for safe disposal.
NOTE: Do not use captured or recycled refrigerant in
Amana units. Captured or recycled refrigerant
voids all Amana and/or compressor manufacturer's
warranties.
When a compressor burns out, high temperature
causes the refrigerant, oil, and motor insulation to
decompose, forming acids and sludge.
If a compressor is suspected of burning out:
1. Replace Compressor.
Fan Motor
1. Disconnect power to unit.
2. Discharge capacitor by shorting capacitor
terminals through a 10,000 ohm resistor.
3. Disconnect fan motor leads from selector switch
and respective capacitor.
4. Check for continuity between each motor lead with
ohmmeter.
5. Check for ground by attaching one lead of
ohmmeter to motor frame (ground). Attach
remaining ohmmeter lead to each fan motor lead,
one at a time.
NOTE: Ensure contact point between ohmmeter lead
and motor frame is clean.
Replace fan motor if windings test open (very high or
infinite resistance), or if any continuity is indicated
between motor frame and windings.
Leak Testing
I & DANGER
To preventseriousinjuryordeathfrom violent
explosions, NEVER use oxygen or acetylene for
pressure testing or cleanout of refrigeration
systems. Free oxygen will explode on contact with
oil. Acetylene will explode spontaneously when put
under pressure.
It is important to check sealed system for refrigerant
leaks. Undetected leaks can lead to repeated service
calls and eventually result in system contamination,
restrictions, and premature compressor failure.
Refrigerant leaks are best detected with electronic
leak detectors.
Testing Systems Containing a Refrigerant Charge
1. Stop the operation (turn air conditioner off).
2. Holding leak detector exploring tube as close to
system tubing as possible, check all piping, joints,
and fittings.
NOTE: Use soap suds on areas leak detector cannot
reach or reliably test.
Testing Systems Containing No Refrigerant
Charge
1. Connect cylinder of nitrogen, through gauge
manifold, to process tube of compressor and
liquid line strainer.
2. Open valves on nitrogen cylinder and gage
manifold. Allow pressure to build within sealed
system.
14 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Testing Procedures
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
3. Check for leaks using soap suds.
If a leak is detected in a joint, do not to attempt to
repair by applying additional brazing material. Joint
must be disassembled, cleaned and rebrazed.
Capture refrigerant charge (if system is charged),
unbraze joint, clean all parts, then rebraze. If leak is
detected in tubing, replace tubing. If leak is detected
in either coil, replace coil.
[ CAUTION ]
To reduce risk of personal injury or property
damage, take necessary precautions against
high temperatures required for brazing.
Satisfactory results require cleanliness, experience,
and use of proper materials and equipment.
Connections to be brazed must be properly sized
and cleaned.
Generally accepted brazing materials are:
-Copper to copper joints: SIL-FOS (alloy of 15
percent silver, 80 percent copper, and 5 percent
phosphorous). Use without flux. Recommended
brazing temperature is approximately 1400°F.
DO NOT USE FOR COPPER TO STEEL
CONNECTION.
•Copper to steel joints: SILVER SOLDER (alloy of
30 percent silver, 38 percent copper, 32 percent
zinc). Use with fluoride based flux. Recommended
brazing temperature is approximately 1200°F.
•If temperature of condenser tubing drops at any
point, tubing is restricted at point of temperature
drop (if restriction is severe, frost may form at point
of restriction and extend down in direction of
refrigerant flow in system). Go to step 4.
3. Turn unit off and time how long it takes high and
low pressure gauges to equalize:
•If pressure equalization takes longer than 7
minutes, a restriction exists in the capillary tube/
strainer. Go to step 4.
•If pressure equalization takes less than 7 minutes,
system is not restricted. Check for other possible
causes of malfunction.
4. Recover refrigerant in sealed system.
NOTE: Before opening any refrigeration system,
capture refrigerant in system for safe
disposal.
5. Remove power from unit.
CAUTION 1
To reduce risk of personal injury or property
damage, take necessary precautions against
high temperatures required for brazing.
6. Remove and replace restricted device.
7. Evacuate sealed system.
8. Charge system to specification.
NOTE: Do not use captured or recycled refrigerant in
units. Captured or recycled refrigerant voids
all and!or compressor manufacturer's
warranties.
Restriction Testing
Restrictions in sealed system generally occur in
capillary tube, but can exist anywhere in the system.
To determine if a restriction exists:
1.Attach gauge and manifold between suction and
discharge sides of sealed system.
2. Turn unit on, and allow pressure on each side to
stabilize. Inspect condenser side of system. Tubing
on condenser should be warm and temperature
should be equal throughout (no sudden drops at any
point along tubing):
•If temperature of condenser tubing is consistent
throughout, go to step 3.
Evacuation
l CAUTION J
To avoid risk of fire, sealed refrigeration system
must be air free. To reduce risk of air
contamination follow evacuation procedures
exactly.
@2003 MaytagAppliancesCompany 16022061 Rev. 0 15

Testing Procedures
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures
require power to be connected. Ensure all ground wires are connected before certifying unit as repaired
and/or operational.
NOTE: Before opening any refrigeration system, EPA
regulations require refrigerant in system to
be captured for safe disposal.
Proper evacuation of sealed refrigeration system is
an important service procedure. Usable life and
operational efficiency of air conditioner greatly
depends upon how completely air, moisture and
other non-condensables are evacuated from sealed
system.
Air in sealed system causes high condensing
temperature and pressure, resulting in increased
power requirements and reduced performance.
Moisture in sealed system chemically reacts with
refrigerant and oil to form corrosive hydrofluoric and
hydrochloric acids. These acids attack motor
windings and parts, causing Restriction /Burnout
condition.
Equipment required to evacuate sealed system
includes:
,, High vacuum pump, capable of producing a
vacuum equivalent to 25 microns.
,, Thermocouple vacuum gauge capable of providing
true readings of vacuum in system.
l CAUTION J
To avoid damage to compressor motor, never
use air conditioner compressor as a vacuum
pump or run compressor when system is under
high vacuum.
To evacuate sealed refrigeration system:
1. Connect vacuum pump, vacuum tight manifold set
with high vacuum hoses, thermocouple vacuum
gauge and charging cylinder as shown in
illustration.
2. Connect low side line to compressor process tube.
3. Connect high side line to process tube of liquid line
strainer.
NOTE: If a compression or flare fitting cannot be
attached to process tube(s) and still leave
room for a pinch-off, swage tube(s) and
braze on an additional length of tubing.
4. Start vacuum pump and open shut off valve to high
vacuum gauge manifold only.
5. After compound gauge (low side) drops to
approximately 29 inches gauge, open valve to
vacuum thermocouple gauge.
6. Ensure vacuum pump will blank-off to a maximum
of 25 microns.
NOTE: A high vacuum pump can only produce a
good vacuum if oil in pump is not
contaminated.
7. If vacuum pump is working properly, close valve to
vacuum thermocouple gauge.
8. Open high and low side valves of high vacuum
manifold set. With valve on charging cylinder
closed, open manifold valve to cylinder.
9. Evacuate system to at least 29 inches gauge.
Open valve to thermocouple vacuum gauge.
10.Continue to evacuate to a maximum of 250
microns. Close valve to vacuum pump and watch
rate of rise:
•If vacuum does not rise above 1500 microns in
three minutes, system can be considered properly
evacuated.
•If thermocouple vacuum gauge continues to rise,
then levels off above 5000 microns, moisture and
non-condensables are still present. Re-evacuate.
•If gauge continues to rise above 5000 microns, a
leak is present. Locate, repair, and re-evacuate.
11. When system is properly evacuated, close valve
to thermocouple vacuum gauge and vacuum
pump. Shut off pump and prepare to charge
system.
Charging
NOTE: Do not use captured or recycled refrigerant in
units. Captured or recycled refrigerant
voids all and/or compressor manufacturer's
warranties.
NOTE: Charge system with exact amount of
refrigerant. SeeTechnical Sheet or refer to
unit nameplate for correct refrigerant charge.
Inaccurately charged system will cause
future problems.
16 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Testing Procedures
WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.
To charge system:
NOTE: When using ambient compensated calibrated
charging cylinder, allow liquid refrigerant to
enter high side only.
1. With no power applied to unit, allow liquid
refrigerant to flow into system until no more
refrigerant can be added.
2. Close valve on high side of manifold.
3. Start (apply power to) system and charge to
specification through low side. Do not charge
through low side in a liquid form.
4. Close low side valve on manifold and pinch-off
both process tubes. Remove manifold set, crimp
shut open ends of process tubes and braze.
5. Recheck for refrigerant leaks.
Refrigerant Precautions
To avoid personal injury, do not allow refrigerant to
contact eyes or skin.
To avoid risk of property damage, do not use
refrigerant other than that shown on unit serial
number identification plate.
NOTE: All precautionary measures recommended by
refrigerant manufacturers and suppliers
apply and must be observed.
Using Line Piercing Valves
Line piercing valves can be used for diagnosis, but
are not suitable for evacuating or charging due to
holes pierced in tubing by valves.
NOTE: Do not leave line piercing valves on system.
Connection between valve and tubing is not
hermetically sealed. Leaks will occur.
Open Lines
During any processing of refrigeration system, never
leave lines open to atmosphere. Open lines allow
water vapor to enter system, making proper
evacuation more difficult.
@2003 MaytagAppliancesCompany 16022061 Rev. 0 17

Disassembly Procedures
[ WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures
require power to be connected. Ensure all ground wires are connected before certifying unit as repaired
and/or operational.
]
The following paragraphs describe how to
disassemble the unit. Disassembly to some extent is
required to install unit, to perform troubleshooting
procedures, and to remove and replace faulty
corn ponents.
Component names used throughout disassembly
procedures are the same as those used in Parts
Manuals.
For quicker reassembly, disassemble unit under test
only to extent necessary to troubleshoot and repair.
Unless noted, reassembly is opposite of disassembly.
[ WARNING
To avoid risk of personal injury or death due to
electrical shock, ground wires and wires colored
like ground wires are NO'[" to be used as current
carrying conductors. The standard accepted
color coding for ground wires is green or green
with a yellow stripe. Electrical components
such as the compressor and fan motor are
grounded through an individual wire attached to
the electrical component and to another part of
the air conditioner. Ground wires should not be
removed from individual components while
servicing, unless the component is to be
removed and replaced. It is extremely important
to replace all removed ground wires before
completing service.
Swing filter cover to the
left to expose filter
Press two buttons
to release cover.
Air Filter Removal
To remove air filter:
1. Press two buttons on front air filter cover to
release tabs.
2. Swing air filter cover open to expose filter, then
pull filter out and away from front frame.
NOTE: If air filter is dirty, clean with vacuum, or
hand wash. Ensure filter is completely dry
before reinstalling in unit
Grill Front (Insert) Removal
1. Remove Front Frame ( see Front Frame
Removal).
2. Press two buttons on front air filter cover to
release tabs.
3. On back side of the hinged insert press bottom
hinge out to release top hinge from Front Frame.
18 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Disassembly Procedures
[WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures
require power to be connected. Ensure all ground wires are connected before certifying unit as repaired
and/or operational.
Front Frame Removal Chassis Removal
To remove front frame:
1. Remove 2 screws securing front frame to air
conditioner chassis.
2. Remove screw from behind air filter cover.
3. Pull front frame out and away from air conditioner.
To remove Chassis:
1. Remove Front Frame (See Front Frame Removal)
2. Remove one screw securing clip to case from
chassis. Remove one screw in back of unit
holding
case to chassis.
3. Remove chassis by sliding out of outer case.
Screws
Clips Screw Screw
Front Frame Clips Removal
1. Remove Front Frame (see Front Frame Removal).
2. Press two buttons on front air filter cover to release
tabs.
3. Swing Air Filter Cover open to expose back side of
Air Filter Cover.
4. On back side of Front Frame push Insert Grill Front
Clips through Front Frame.
5. To reinstall Air Filter Clips push clips into openings
in the front side of the Front Frame.
@2003 MaytagAppliancesCompany 16022061 Rev. 0 19

Disassembly Procedures
[ WARNING ]
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures
require power to be connected. Ensure all ground wires are connected before certifying unit as repaired
and/or operational.
Rotary Control Assembly Removal
To remove Rotary Control Assembly:
1. Remove Front Frame (see Front Frame Removal)
2. Remove control knobs.
3. Remove cover plate
4. Remove 2 screws holding Rotary Control
Assembly to chassis.
5. Remove temperature sensing bulb from bulb
retainer in evaporator.
6. Slide Rotary Control Assembly out to expose
switches and wiring.
7. Discharge capacitor through 10,000 ohm resistor.
8. Disconnect fan motor and compressor wires
attached to capacitor.
9. Disconnect fan motor and compressor wires
attached to selector switch.
NOTE: Before disconnecting or removing wires,
always note position or location of wires.
Ensure all disconnected wires are
reconnected to proper location.
10.Reverse procedure to reinstall Rotary Control
Assembly.
Rotary Control Assembly Removal
20 16022061 Rev. 0 @2003 MaytagAppliancesCompany