Page 1
website: http://www.lgservice.com
e-mail: http://www.lgeservice.com/techsup.html
ROOM AIR CONDITIONER
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
D
r
y
F
a
n
C
o
o
l
MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011,
LWJ0611PCG, LWC061JGMK1
Page 2
—2—
CONTENTS
1. PREFACE ................................................................ 2
1.1 FEATURES.................................................................. 2
1.2 SPECIFICATIONS ...................................................... 3
1.3 SAFETY PRECAUTIONS ........................................... 3
1.4 INSULATION RESISTANCE TEST ............................. 3
1.5 LOCATIONS OF CONTROLS .................................... 4
2. DISASSEMBLY INSTRUCTIONS ............. 6
2.1 MECHANICAL PARTS ............................................... 6
2.1.1 FRONT GRILLE ................................................. 6
2.1.2 CABINET............................................................ 6
2.1.3 CONTROL BOARD ............................................ 6
2.2 AIR HANDLING PARTS ............................................. 7
2.2.1 AIR GUIDE UPPER............................................ 7
2.2.2 ORIFICE, TURBO FAN AND FAN...................... 7
2.2.3 MOTOR .............................................................. 8
2.2.4 AIR GUIDE ......................................................... 8
2.3 ELECTRICAL PARTS ................................................. 8
2.3.1 OVERLOAD PROTECTOR ................................ 8
2.3.2 COMPRESSOR.................................................. 9
2.3.3 CAPACITOR ...................................................... 9
2.3.4 THERMISTOR.................................................... 9
2.3.5 CONTROL PANEL.............................................. 9
2.3.6 POWER CORD ................................................ 10
2.4 REFRIGERANT CYCLE ........................................... 10
2.4.1 CONDENSER .................................................. 10
2.4.2 EVAPORATOR ................................................. 10
2.4.3 CAPILLARY TUBE .......................................... 11
3. INSTALLATION .................................................. 13
3.1 SELECT THE BEST LOCATION .............................. 13
3.2 HOW TO INSTALL .................................................... 13
4. TROUBLESHOOTING GUIDE ..................
16
4.1 OUTSIDE DIMENSIONS........................................... 16
4.2 PIPING SYSTEM ..................................................... 17
4.3 TROUBLESHOOTING GUIDE ................................. 18
5. SCHEMATIC DIAGRAM ............................... 26
5.1 CIRCUIT DIAGRAM.................................................. 26
5.2 ELECTRONIC CONTROL DEVICE.......................... 27
5.3
COMPONENTS LOCATION(FOR MAIN P.W.B ASM)
........ 28
5.4
COMPONENTS LOCATION(FOR DISPLAY P.W.B ASM)
... 28
6. EXPLODED VIEW ............................................ 29
7. SERVICE PARTS LIST .................................. 30
1. PREFACE
This service manual provides various service information, including the mechanical and electrical parts, etc.
This room air conditioner was manufactured and assembled under a strict quality control system.
The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.
1.1 FEATURES
• DESIGNED FOR COOLING ONLY
• POWERFUL AND INCREDIBLE COOLING
• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE
• WASHABLE ONE-TOUCH FILTER
• COMPACT SIZE
Page 3
1.2 SPECIFICATIONS
• NOTE: Specifications are subject to minor change without notice for further improvement.
—3—
MODELS
ITEMS
COOLING CAPACITY (BTU/h) 5,300 5,200 5,200 6,000 6,000
POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ
INPUT (W) 530 470 610 620
OPERATING CURRENT (AMP.) 4.8 4.3 5.6 5.8
REFRIGERANT CONTROL CAPILLARY TUBE
REFRIGERANT CHARGE (R-22) 230g (8.1 Oz ) 330g(11.6 Oz) 335g (11.8 Oz)
235g (8.3 Oz)
INSIDE FAN TURBO
OUTSIDE FAN PROPELLER FAN WITH SLINGER RING
AIR DISCHARGE 2-WAY (RIGHT AND LEFT)
CHASSIS TOP-DOWN
PROTECTOR
TEMPERATURE CONTROL THERMISTOR
ROTARY SWITCH
5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)
FAN MOTOR
6 POLES, 16W
6 POLES, 21.3W 6 POLES, 24W 6 POLES,
21.4W
• OVERLOAD PROTECTOR FOR COMPRESSOR
• INTERNAL PROTECTOR FOR FAN MOTOR
M5403R M5203R M5203L
M6003R
WM-6011
LWJ0611PCG
LWC061JGMK1
1.3 SAFETY PRECAUTIONS
1. When servicing, set the POWER of CONTROL
BOARD to Off and unplug the power cord.
2. Observe the original lead dress.
If a short circuit is found, replace all parts which
have been overheated or damaged by the short circuit.
3. After servicing, make an insulation resistance test
to prevent the customer's exposure to shock
hazards.
1.4
INSULATION RESISTANCE TEST
1. Unplug the power cord and connect a jumper
between 2 pins (black and white).
2. The grounding conductor (green or green and yellow) is to be open.
3. Measure the resistance value with an ohm meter
between the jumpered lead and each exposed
metallic part on the equipment at all Mode [except
POWER OFF].
4. The value should be over 1 MΩ.
Page 4
—4—
1.5 LOCATIONS OF CONTROLS
1.5.1
CONTROLS
Dry Fan
Cool
ON/OFF TIMER
- STOPPING OPERATION
• Everytime you push this button, when the unit is operating,
timer is set as follows.
(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours
7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)
• The Setting Temperature will be raised by 2°F(1°C) 30min. later
and by 2°F(1°C) after another 30 min.
- STARTING OPERATION
• Everytime you push this button, when the unit is
not operating, timer is set as follow.
(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours
7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)
FAN/COOL/DRY
• Everytime you push this button, it will toggle between
COOL, FAN and DRY.
POWER
• To turn the unit ON, push the button. To turn the unit OFF,
push the button again.
• This button takes priority over any other buttons.
• When you first turn it on, the unit is on the High cool mode
and the temp. at 72°F(22°C).
TEMPERATURE SETTING
• This button can automatically control the temperature
of the room. The temperature can be set within a range of
60°F(16°C) to 86°F(30°C) by 1°F(1°C).
Select the lower number for lower temperature of the room.
FAN SPEED
• Everytime you push this button it is set as follows.
{High(F2) Low(F1) High(F2)...}.
ENERGY SAVER
The fan stops when the compressor stops cooling.
• Approximately every 3 minutes the fan will turn on and
check the room air to determine if cooling is needed.
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—5—
1.5.2 REMOTE CONTROLLER
How to Insert Batteries
1. Remove the cover from the back of the
remote controller
2. Insert two batteries.
• Be sure that the (+) and (-) directions
are correct.
• Be sure that both batteries are new.
3. Re-attach the cover.
• Do not use rechargeable batteries. Such batteries
differ from standard dry cells in shape, dimensions, and performance.
• Remove the batteries from the remote controller if the air conditioner is not going to be
used for an extended length of time.
Auto
Swing
Power
Temp
Fan Speed
Timer Mode
Energy
Saver
TEMPERATURE SETTING
ENERGY SAVER
The fan stops when the compressor stops cooling.
• Approximately every 3 minutes the fan will turn on and
check the room air to determine if cooling is needed.
FAN SPEED
• Everytime you push this button it is set as follows.
(High(F2) Low(F1) High(F2)...)
POWER
• To turn the Set ON, push the button. To turn the Set OFF, push the button again.
• This button takes priority over any other buttons.
• When you first turn it on, the Set is on the High cool mode and the temp. at 72°F(22°C).
COOL/FAN/DRY
ON/OFF TIMER
- STOPPING OPERATION
• Everytime you push this button, when the set is operating,
timer is set as follows.
(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours
7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)
• The Setting Temperature will be raised by 2°F(1°C) 30min.
later and by 2°F(1°C) after another 30 min.
- STARTING OPERATION
• Everytime you push this button, when the set is
not operating, timer is set as follow.
(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours
7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel)
• This button can automatically control the temperature of the room.
The temperature can be set within a range of
60°F(16°C) to
86°F(30°C) by 1°F(1°C).
Select the lower number for lower temperature of the room.
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2. DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS
2.1.1 FRONT GRILLE
1. Disconnect the unit from source of power.
2. 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)
4. Replace the grille by placing the tabs in the slots
and push the grille until it snaps into place.
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 7 screws that secure the cabinet to the
base pan and condenser. (See Figure 3)
4. Lift the cabinet from the unit.
5. Re-install by referring to the procedures above.
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 air guide. (See Figure 4)
5. Pull the control board toward yourself.
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 circuit diagram on page 26 in this
manual or inside control board.)
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
NOTE : Controls, wires, and capacitor are now
accessible for servicing. Discharge the
capacitor before servicing. See step
2.3.3 on page 8 for procedures.
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—7—
2.2 AIR HANDLING PARTS
2.2.1 AIR GUIDE UPPER
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 air guide upper
to air guide lower. (See Figure 6)
6. Lift air guide upper upward.
7. Re-install by referring to the procedures above.
2.2.2 ORIFICE, TURBO FAN AND FAN
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 air guide upper.
(Refer to Section 2.2.1)
6. Remove 2 screws that secure the base pan to
condenser. (See Figure 7)
7. Remove screw that secures the shroud to
channel of condenser.
8. Press the snap area of shroud with your thumbs.
This allows you to remove it from the condenser.
9. Lift the compressor upward with the evaporator
and condenser. (See Figure 7)
10. Remove the orfice by pushing the snap area of
the air guide blower. (See Figure 8)
11. Remove the clamp springs which are clamped to
the boss of fan and turbo fan by hand plier. (See
Figure 9)
12. Pull the fan and turbo fan outward.
13. Remove the shroud.
14. Re-install by referring to the procedures above.
Figure 6
Figure 7
Figure 8
Figure 9
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2.2.3 MOTOR
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 air guide upper.
(Refer to Section 2.2.1)
6.
Remove the compressor, turbo fan, fan and
shroud. (Refer to
Section
2.2.2)
7.
Remove 2 screws that secure the motor to the
motor. (See Figure 10)
8. Remove the motor.
9.
Re-install by referring to the procedures above.
2.2.4 AIR GUIDE
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 air guide upper.
(Refer to Section 2.2.1)
6.
Remove the compressor, turbo fan, fan and
shroud. (Refer to
Section
2.2.2)
7.
Remove the motor. (Refer to
Section
2.2.3)
8. Remove 2 screws that secure the air guide to the
base pan. (See Figure 11)
9. Push the air guide backward and lift it upward.
(See Figure 11)
10. Re-install by referring to the procedures above.
2.3 ELECTRICAL PARTS
2.3.1 OVERLOAD PROTECTOR
1. Remove the front grille and cabinet.
(Refer to Section 2.1)
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)
Figure 10
Figure 12
Figure 13
Figure 11
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—9—
2.3.2 COMPRESSOR
1. Remove the front grille and cabinet.
(Refer to Section 2.1.2)
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 KΩ
resistor across the capacitor terminals.
4. Pull the capacitor upward.
5. Remove all the leads of capacitor terminals.
6. Re-install the components by referring to the
removal procedure above. (See Figure 15)
2.3.4 THERMISTOR
1. Remove the cabinet. (Refer to Section 2.1.2)
2. Remove the control board.
(Refer to Section 2.1.3)
3. Disconnect the thermistor terminals from main
P.W.B assembly.
4. Remove the thermistor.
5. Re-install the components by referring to the
removal procedure above. (See Figure 16)
2.3.5 CONTROL PANEL
1. Remove the cabinet. (Refer to Section 2.1.2)
2. Remove the control board.
(Refer to Section 2.1.3)
3. Pull the control panel forward and pull out it.
4. Remove 2 lead wire terminals.
5. Re-install the components by referring to the
removal procedure above. (See Figure 17)
Figure 14
Figure 15
Figure 16
Figure 17
Page 10
—10—
2.3.6 POWER CORD
1. Disconnect the unit from source of power.
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.
5. Pulls the control board toward you.
6. Remove the grounding screw.
7. Remove a screw securing the clip with cord to the
control board.
8. Pull the power cord.
9. Re-install by referring to procedures above.
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 the air guide. (Refer to Section 2.2.1)
4. Remove 2 screws which fasten the condenser.
5. After discharging the refrigerant completely,
unbraze the interconnecting tube at the
condenser connections.
6. Remove the condenser.
7. Re-install by referring to the procedures above.
2.4.2 EVAPORATOR
1. Remove the cabinet.
2. Discharge the refrigerant by using a refrigerant
recovery system.
3. Remove the air guide upper. (Refer to Section
2.2.1)
4. After discharging the refrigerant completely,
unbraze the interconnecting tube at the condenser
connections.
5. Remove the evaporator.
6. Re-install by referring to the procedures above.
Figure 18
Figure19
Page 11
2.4.3 CAPILLARY TUBE
1. Remove the cabinet.
2. Discharge the refrigerant by using a refrigerant
recovery system.
3. Remove the air guide upper. (Refer to Section
2.2.1)
4. After discharging the refrigerant completely,
unbraze the interconnecting tube of the capillary
tube.
5. Remove the capillary tube.
6. Re-install by referring to the procedures above.
NOTES
Replacement of the refrigeration cycle.
1. When replacing the refrigerating cycle, be sure to
discharge the refrigerant by using a refrigerant
recovery system.
2. After discharging the unit completely, remove the
desired components, and unbraze the pinch-off
tubes.
3. Solder service valves into the pinch-off tube ports,
leaving the valves open.
4. Solder the pinch-off tubes with service valves.
5. After completing the above procedures, the valve
must be closed and left in place on the system for
any subsequent procedures.
6. Evacuate as follows:
6-1. Connect the vacuum pump, as illustrated in
figure 20A.
6-2. Start the vacuum pump. Slowly open manifold
valves A and B with two full turns counterclockwise 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-clockwise. This will keep oil from foaming and being
drawn into the vacuum pump.
6-3. Operate the vacuum pump for 20 to 30 min-
utes, until 600 micron vacuum is obtained.
Close valves A and B and observe vacuum
gauge for a few minutes.
A rise in pressure would indicate a possible
leak or moisture remaining in the system.
With valves A and B closed, stop the vacuum
pump.
6-4. Remove the hose from the vacuum pump and
place it on the charging cylinder. See figure
23B. Open valve C.
Discharge the line at the manifold connection.
6-5. The system is now ready for final charging.
7. Recharge as follows:
7-1. Rotary compressor systems are charged from
the high-side. If the total charge cannot be put
in the high-side, the balance will be put in the
suction line through the access valve which is
installed as the system is opened.
7-2. Connect the charging cylinder as shown in fig-
ure 21B. With valve C open, discharge the
hose at the manifold connection.
7-3. Open valve A and allow the proper charge to
enter the system. Valve B is still closed.
7-4. If more charge is required, the high-side will
not take it. Close valve A.
7-5. With the unit running, open valve B and add
the balance of the charge.
a. Do not add the liquid refrigerant to the low-
side.
b. Watch the low-side gauge, allow pressure to
rise to 30 lbs.
c. Turn off valve B and allow the pressure to
drop.
d. Repeat steps B and C until the balance of
the charge is in the system.
7-6. When the unit is operating correctly, use the
pinch-off tool with the unit still running and the
clamp on the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from
the pinch-off tool. Use sil-fos solder and solder
the pinch-off tube closed. Turn off the unit,
allow setting for a while and then test the leakage of the pinch-off connection.
—11—
Page 12
—12—
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 and service valve.
B
A
B
A
B
A
COMPOUND GAUGE
SEE INSETS
BELOW
CAPILLARY TUBE
EVAPORATOR
(LOW PRESSURE SIDE)
COMPRESSOR
CONDENSER
(HIGH PRESSURE SIDE)
EXTERNAL VACUUM PUMP
LO HI
CHARGING CYLINDER
MANIFOLD
GAUGE
C
Figure 20A-Pulling Vacuum Figure 20B-Charging
Page 13
—13—
3. INSTALLATION
This air conditioner is designed with a button-down
chassis so it can be easily installed in a window.
3.1 SELECT THE BEST LOCATION
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 10" and there should be no obstacles, such as a
fence or wall, within 20" from the back of the cabinet
because it will prevent heat radiation of the condenser.
Restriction of outside air will greatly reduce the cooling
efficiency of the air conditioner.
4. Install the unit slanted slightly so the back is slightly lower than the front (about 1/
4"). This will force
condensed water to the outside.
5. Install the unit with the bottom about 30"~60"
above the floor level.
3.2 HOW TO INSTALL
3.2.1 WINDOW REQUIREMENTS
NOTE: All suppor ting parts should be secured to fir m
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.If storm window presents interference, fasten a 2" wide
wood strip to the inner window sill across the full
width of the sill. The wood strip should be thick
enough to raise the height of the window sill so that
the unit can be installed without interference by the
storm window frame. See Figure. 23. Top of wood
strip should be approximately 3/4" higher than the
storm window frame (STORM WINDOW FRAME) or
wood strip (OUTDOORS) to help condensation to
drain properly to the outside.
3.
Install a second wood strip (approximately 6" long by
11/2" wide and same thickness as first strip) in the center of the outer sill flush against the back off the inner
sill. This will raise the L bracket as shown Figure. 23.
4. If the distance between STORM WINDOW FRAME
and WOOD STRIP MOUNTED ON TOP OF INNER
SILL is more than 1", two of wood strip are not necessary.
ABOUT / "
Over 20"
HEAT
RADIATION
FENCE
AWNING
OUTSIDE
INSIDE
COOLED AIR
30"-60"
1
4
Figure 21
Figure 22
Figure 23
All side louvers of the cabinet must remain
exposed on the outdside of the structure.
CAUTION
OUTDOORSINDOORS
INNER
SILL
OUTER
SILL
INNER
SILL
WOOD STRIP MOUNTED
ON TOP OF INNER SILL
WOOD STRIP
FOR
L
BRACKET
3/4"
CLEARANCE
1" MAX.
STORM
WINDOW
FRAME
OUTDOORSINDOORS
OUTER
SILL
Page 14
—14—
Installation
3.2.2 BEFORE INSTALLATION
1. Inser t the guide panels into the guides of the air condi-
tioner. Fasten the curtains to the unit with screws (TYPE
A) as shown Figure. 24.
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
. 25)
3.2.3 NOW START INSTALLATION
1. LOCATING UNIT IN WINDOW
Open the window and mark center line on the center of
the inner sill, as shown in Figure. 26.
2. ATTACH L BRACKET
a. Install the L brackets behind the inner window sill, with
the short side of bracket as shown.
Use the 2 screws (TYPE A) provided.
b. The bracket helps to hold unit securely in place. Be
sure to place bracket edge flush against back of inner
sill. See Figure. 26.
TYPE B: 4EA
(WOOD SCREW)
HARDWARE
TYPE A: 11EA
(SHORT SCREW)
TYPE C: 3EA
(L BACKET)
DRAIN PIPE
TYPE E: 1EA
(SASH SEAL)
(Not adhesive backed)
TYPE D: 1EA
(SEAL STRIP)
(Adhesive backed)
TYPE F: 2EA
(GUIDE PANEL)
10mm
16mm
During the following step, hold unit firmly until
window sash is lowered to top channel behind
side panel frames. Personal injury or property
damage may result if unit falls from window.
CAUTION
ROOM SIDE
CENTER LINE
INNER SILL
SEAL STRIP
(TYPE D)
TYPE A
TYPE C
Figure 24
Figure 25
Figure 26
Page 15
3. INST ALL THE AIR CONDITIONER IN THE WINDO W
a. Carefully lift the air conditioner and slide it into the
open window. Make sure the bottom guide of the air
conditioner drops into the notches of the
L bracket. See Figure. 27.
IMPORTANT :
When the air conditioner drops into the L bracket, the air
conditioner will be centered in window opening as shown in
Figure. 28.
b. While steadying the air conditioner, carefully bring the
window sash down behind the upper guide of the air
conditioner, as shown in Figure. 29.
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. 30.
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. 30.
b . Fasten the L bracket using a (TYPE A) screw, as
shown in Figure. 30.
6. Window installation of room air conditioner is now
completed. See ELECTRICAL DATA for attaching
power cord to electrical outlet.
3.2.4 How to Secure the Drain pipe
In humid weather, excess water may cause the BASE
PAN to overflow. To drain the water, remove the DRAIN
CAP and secure the DRAIN PIPE to the rear hole of the
BASE PAN. (Figure. 31)
—15—
OUTSIDE
INSIDE
L
BRACKET
OUTER SILL
SHORT SIDE
INNER SILL
TYPE A
8"
8"
CENTER LINE
CENTER LINE
SEAL
WINDOW FRAME
BOTTOM
GUIDE
ABOUT
1/4"
L
BRACKET
UPPER GUIDE
DRAIN PIPE
DRAIN CAP
hang push
SASH SEAL
(TYPE E)
L BRACKET
TYPE A
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
TYPE B
Page 16
—16—
REMOVAL FROM WINDOW
Tur n the air conditioner off, disconnect the power cord, remove the L bracket and the screws installed through the top and bottom of the guide panels, and save for reinstallation later. Close the guide panels. Keeping a firm gr ip on the air conditioner,
raise the sash, and carefully tilt the air conditioner backward, draining any condensate water. Lift the air conditioner from the
window and remove the sash seal from between the windows.
3.3 ELECTRICAL DATA
USE OF EXTENSION CORDS
Because of potential safety hazards, we strongly discourage the use of an extension cord. However, if you wish to use an extension
cord, use a CSA certified/UL-listed 3-wire (grounding) extension cord, rated 15A, 125V.
Do not under any
circumstances cut
or remove the
grounding prong
from the plug.
Line Cord Plug Use Wall Receptacle Power Supply
Power supply cord with
3-prong grounding plug
Standard 125V, 3-wire grounding
receptacle rated 15A, 125V AC
Use 15 AMP, time
delay fuse, or circuit
breaker.
4. TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS (unit: mm [in])
370 (14 9/16")
312 (12 1/4")
370 (14 9/16")
312 (12 1/4")
29 (1
5
/32")
120 (4 3/4")
27.5 (1
3
/32")
346 (13
5
/8")
472 (18 9/16")
42 (1 21/32")
42 (1 21/32")
155(6
3/32
")
12
(0.4
1/16
")
472 (18 9/16")
22.5(0.8
3/32
")
Page 17
—17—
4.2 PIPING SYSTEM
Following is a brief description of the important components and their function in what is called the refrigeration
system. Reference should be made to Figure 32 to follow the refrigerating cycle and the flow of the refrigerant in
the cooling cycle.
COOLED
AIR
HOT
DISCHARGED
AIR
MOTOR
COMPRESSOR
ROOM AIR HEAT LOAD
CAPILLARY TUBE
(LIQUID REFRIGERANT)
LIQUID OUTLET
VAPOR INLET
COMPLETE LIQUID
BOIL OFF POINT
SUCTION LINE
COOL LOW PRESSURE VAPOR
LIQUID
PRESSURE
DROP
DISCHARGE
LINE
NOT HIGH PRESSURE
VAPOR
OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH
EVAPORATOR COILS CONDENSER COILS
ROOM AIR CONDITIONER
CYCLE OF REFRIGERATION
HIGH PRESSURE VAPOR
LIQUID REFRIGERANT
LOW PRESSURE VAPOR
OIL
Figure 32
CONDENSER COILS
FAN
CAPILLARY
MOTOR
TUBE
TURBO FAN
EVAPORATOR
COILS
Page 18
—18—
4.3 TROUBLESHOOTING GUIDE
In general, possible trouble is classified in two kinds.
The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Con-
ditioning caused by a defect in the refrigeration circuit and improper application.
Unit is running but cooling is ineffective.
Ineffective Cooling
Satisfactory operation
with temperature
difference of inlet & outlet
air; 55~59°F (13~15°C)
Replacement of unit if
the unit is beyond repair.
Check outdoor coil
(heat exchanger) and
fan operation.
Check heat load
increase.
Check cold air
circulation for smooth
flow.
Check gas leakage.
Clean condenser.
Not on separate circuit
Check inside gas
pressure.
Adjust refrigerant
charge.
Malfunction of
compressor.
Replacement of
compressor.
Check clogging in refrigeration circuit.
Repair clogging in
refrigeration circuit.
Dirty indoor coil
(heat exchanger)
Repair gas leak.
Malfunction of fan.
Clogging of air filter.
Obstruction at air outlet.
Remove obstruction.
Page 19
—19—
Fails to Start
Improper thermistor
setting
Loose terminal
connection
Improper wiring
Check of power source.
Drop of power voltage.
Capacitor check.
Replacement.
Check of control panel
setting.
Compressor fails only to
start.
Defect of compressor
capacitor.
Replacement of compressor
(Motor damaged).
Irregular motor insulation (Ω)
Irregular motor resistance (Ω)
Check of circuit breaker
and fuse.
Check control panel.
Fan only fails to start.
Improper wiring.
Defect of fan motor
capacitor.
Replacement of fan motor.
Regular but fails to start.
Replacement of compressor.
(Locking of piston, metal.)
Irregular motor
resistance (Ω)
Irregular motor
insulation (Ω)
Page 20
—20—
Is the Trans output 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.20 of Micom
DC 5V?
Exchange Main P.W.B Ass'y.
Is the
connection between
Main and Display
all right?
Is the reset circuit all right?
(The No.16 of Micom
is 5V.)
•
Check the Fuse.
•
Check the wiring diagram.
•
Check the Main
P.W.B pattern.
• Exchange the Trans.
•
Exchange D02D~D05D.
• Exchange IC01D.
• Exchange IC02D.
• Exchange IC01A.
• Connect connector
exactly.
• Check the
P.W.B
pattern.
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
NO
YES
ELECTRIC PARTS TROUBLESHOOTING GUIDE:
Possible Trouble 1
• The unit does not operate.
Page 21
—21—
Is Temp.
setting set lower than Room
Temp.-0.5°C?
Is the voltage No.11
of IC01M 0V?
• Exchange IC01M.
• Set the Temp. setting to higher Temp.
• Wait 3 Minutes
Is the Unit for 3 minutes
delay?
• Exchange MAIN
P.W.B Ass'y.
Is the voltage N0.6 of
IC01M DC 5V?
• Check the RY-COMP.
• Check the wiring
Diagram.
NO
NO
NO NO
YES
YES
YES
YES
Possible Trouble 2
• The compressor does not operate.
Is the wire connection of
RY-COMP all right?
• Check the RY-COMP.
• Connect LEAD Wire to
RY-COMP again.
NO
YES
Possible Trouble 3
• The compressor always operate.
• Exchange IC01M.
• Exchange IC01M.
Is the voltage NO.2 or 4
of IC01M DC 5V?
Is the voltage NO.13 or 15
of IC01M 0V?
• Check the RY-Hi or
RY-Lo.
•
Check the wiring diagram.
NO
NO
YES
YES
Possible Trouble 4
• Fan does not operate.
Page 22
—22—
Is the voltage of Battery
about over 2.3V?
•
Exchange Receiver Ass'y.
Is the connection of
CN-DISP2 all right?
Is the voltage No.10
of CN-DISP2 on Main P.W.B
Ass'y DC 5V?
• Exchange the battery.
•
Check the P.W.B pattern.
• Connect connector to
CN-DISP2 exactly.
NO
NO
NO
YES
YES
YES
Possible Trouble 5
• Romote controller does not operate.
(only for M-5400, M-6000, M-7000)
NO
NO
NO
NO
YES
YES
YES
Is the IC01G all right?
Is the connection of
CN-DISP2 all right?
• Exchange the display
P.W.B Ass'y.
• Exchange IC01G.
• Exchange Q12G,
Q13G, Q14G
• Connect connector
to CN-DISP2 exactly.
Does the Q12G,
Q13G, Q14G operate normally
on main P.W.B Ass'y?
Possible Trouble 6
• It displays abnormally on Display P.W.B Ass'y.
Page 23
—23—
ROOM AIR CONDITIONER VOLTAGE LIMITS
NAME PLATE RATING MINIMUM MAXIMUM
115V ± 10% 103.5V 126.5V
COMPLAINT CAUSE REMEDY
Fan motor will not run. No power Check voltage at outlet. Correct if none.
Power supply cord Check voltage to rotary switch. If none, check
power supply cord. Replace cord if circuit is
open.
Rotary switch Check switch continuity. Refer to wiring diagram
for terminal identification. Replace switch if
defective.
Wire disconnected or Connect wire. Refer to wiring diagram for
connection loose terminal identification. Repair or replace loose
terminal.
Capacitor (Discharge Test capacitor.
capacitor before testing.) Replace if not within ±10% of manufacturer's
rating. Replace if shorted, open, or damaged.
Will not rotate Fan blade hitting shroud or blower wheel hitting
scroll. Re-align assembly.
Units using slinger ring condenser fans must
have 0.22~0.25 inch clearance to the base.
If necessary, shim up the bottom of the fan motor
with mounting screw(s).
Check fan motor bearings; if motor shaft will not
rotate, replace the motor.
Fan motor runs. Revolves on overload Check voltage. See limits on this page.
If not within limits, call an electrician.
Test capacitor.
Check bearings. Does the fan blade rotate
freely?
If not, replace fan motor.
Pay attention to any change from high speed to
low speed. If the speed does not change,
replace the motor.
Page 24
—24—
COMPLAINT CAUSE REMEDY
Fan motor noise. Fan If cracked, out of balance, or partially missing,
replace it.
Blower If cracked, out of balance, or partially missing,
replace it.
Loose set screw Tighten it.
Worn bearings If knocking sounds continue when running or
loose, replace the motor. If the motor hums or
noise appears to be internal while running,
replace motor.
Compressor will not run, Voltage Check voltage. See the limits on the preceding
fan motor runs. page. If not within limits, call an electrician.
Wiring Check the wire connections; if loose, repair or
replace the terminal. If the wires are discon-
nected, refer to wiring diagram for identification,
and replace the wires. Check the wire connections;
If not according to the wiring diagram, correct
the connections.
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 Check the capacitor.
capacitor before Replace if not within ±10% of manufacturer’s
servicing.) rating, replace if shorted, open, or damaged.
Compressor Check the compressor for open circuit or
ground. If open or grounded, replace the
compressor.
Overload
Check the compressor overload if externally mounted.
Replace if open. (If the compressor temperature is
high, remove the overload, cool, and retest.)
Compressor cycles on Voltage Check the voltage. See the limits on the
overload. preceding page. If voltage is not within these limits,
call an electrician.
Overload Check overload, if externally mounted.
Replace if open. (If the compressor temperature
is high, remove the overload, cool, and retest.)
Page 25
—25—
COMPLAINT CAUSE REMEDY
Compressor cycles on Fan motor If not running, determine the cause. Replace if
overload required.
Condenser air flow Remove the cabinet, inspect the interior surface
restriction of the condenser. If restricted, clean carefully
with a vacuum cleaner (do not damage fins) or
brush. Clean the interior base before
re-assembling.
Condenser fins If the condenser fins are closed over a large
(damaged) area on the coil surface, head pressures will
increase, causing the compressor to cycle.
Straighten the fins or replace the coil.
Capacitor Test the capacitor.
Wiring Check the terminals. If loose, repair or replace.
Refrigeration system Check the system for a restriction.
Insufficient cooling. Air filter If restricted, clean or replace.
Unit undersized Determine if the unit is properly sized for the
area to be cooled.
Excessive noise. Blower or fan Check the set screw, or clamp. If loose or miss-
ing, correct. If the blower or fan is hitting scroll
or barrier, rearrange the air handling parts.
Copper tubing Remove the cabinet and carefully rearrange the
tubing not to contact the cabinet,
compressor, shroud, and barrier.
Page 26
—26—
LOCATION
NO.
1
2
3
4
5
6
7
8
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM
• MODEL :
M5403R, M5203R, M5203L, M6003R, WM-6011, LWJ0611PCG, LWC061JGMK1
Q'TY
PER SET
1
1
1
1
1
1
1
1
DESCRIPTION
POWER CORD ASSEMBLY
FAN MOTOR
COMPRESSOR
DISPLAY P.W.B ASSEMBLY
MAIN P.W.B ASSEMBLY
THERMISTOR
CAPACITOR
OWERLOAD PROTECTOR
WH(BL)
POWER INPUT
BK(BR)
(Ribbed) (Plain)
GN(GN/YL)
THERMISTOR
BK BK
RDBLRD
CN-TH1
YL YL
OR(BR) OR(BR)
OR
SYNC
MOTOR
RY-L
RY-H
CN-WOR
CN-SYNC CN-DISP1 CN-DISP2
DISPLAY P.W.B ASM
RY-SYNC
FUSE 125V 2A
TRANS
FORMER
ZNR01J
RY-COMP
MAIN P.W.B ASM
CN-RD
CN-BK
BK
BK
WH
BK
RD
BL BL
OLP
BR
RD
MOTOR
CAPACITOR
F
R
S
COMP.
C
C
H
3854AR2330K
WIRING DIAGRAM
1
6
4
5
8
3
7
2
1
6
4
5
8
3
7
2
WH(BL)
POWER INPUT
BK(BR)
(Ribbed) (Plain)
GN/YL
(GN)
GN/YL(GN)
THERMISTOR
BK BK
BLRDBL
RD
CN-TH1
YL YL
OR(BR) OR(BR)
OR
SYNC
MOTOR
RY-LO
RY-HI
CN-WORK
CN-SYNC CN-DISP
DISPLAY P.W.B ASM
RY-SYNC
250V/T2A
(115V/T2A)
TRANS
FORMER
ZNR
43
RY-COMP
MAIN P.W.B ASM
BK
BK
WH
BK
RD
BL BL
OLP
RD
MOTOR
CAPACITOR
F
R
S
COMP.
C
C
H
3854A20022K
WIRING DIAGRAM
RY-MID
FUSE
Page 27
—27—
5.2 ELECTRONIC CONTROL DEVICE
Page 28
—28—
5.3 COMPONENTS LOCATION
(FOR MAIN P.W.B ASM)
5.4 COMPONENTS LOCATION
(FOR DISPLAY P.W.B ASM)
Page 29
—29—
6. EXPLODED VIEW
135313
352390
267110
152302
130410
359012
W48602
135312
354210
349480
352380
149980
559011
346811
554030
W48602
130910
264110
238310
W0CZZ
249950
268714
263230
550140
554160
567502
352115
552111
352113
35211A
237200
268712
Page 30
—30—
7. SERVICE PARTS LIST
LOCATION NO
DESCRIPTION
REMARKS
M5403R M5203R M5203L
130410 BASE ASSY, SINGLE 3041A10011E R
130910 CABINET ASSY ,SINGLE 3091A10020A R
135312 GRILLE ASSY, FRONT(SINGLE) 3531AR1644H 3531AR1644U R
135313 GRILLE ASSY, INLET 3530A10039A R
137215 PANEL, CONTROL 3720A20017A 3720A20111A R
149980 SHROUD 4998A10006A 4998A10008A R
152302 FILTER(MECH), A/C 5231AR2148A R
238310 ESCUTCHEON 3831A10001F 3831A10013A R
249950 CONTROL BOX ASSY, SINGLE 4995A20127D 4995A20127A 4995A20127G R
263230 THERMISTOR ASSY 6323A20003D R
264110 POWER CORD ASSY 2H00677P R
267110 REMOTE CONTROLLER ASSY 6711A20034A 6711A20034U R
268712 PWB(PCB) ASSY, DISPLAY 6871A20115B 6871A20142A R
268714 PWB(PCB) ASSY, MAIN 6871A10013M 6871A10013C 6871A10031B R
346811 MOTOR ASSY, SINGLE 4681A10002A 4681A10002F 4681A10002H R
349480 ORIFICE 4948A10007A R
352113 TUBE, DISCHARGE 5210A20252A 5210A20511A R
352115 TUBE ASSY, EVPORATOR IN 5211A10063A 5211A10063C R
35211A TUBE ASSY, SUCTION SINGLE 5211A10062A 5211A10062B R
352380 AIR GUIDE 5238A20004A 5238A20004B R
352390 AIR GUIDE ASSY 5239A30003A R
354210 EVAPORATOR ASSY, FIRST 5421A10008B 5421A20016H R
359012 FAN, TURBO 5900A20005A 5900A10005A R
550140 ISOLATOR, COMP 5040AR4195A R
552111 TUBE ASSY, CAPILLARY 5211A10065B 5211AR3332R R
554030 CONDENSER ASSY, FIRST 5403A20038D 5403A20009E R
554160 COMPRESSOR 2520UABC2EA 5416A20013M R
559011 FAN, PROPELLER 5900A20006A 5900A20017A R
567502 O.L.P 6750U-L050A 6750A30001F R
W0CZZ CAPACITOR, DRAWING 6120AR2359V R
W48602 CLAMP, SPRING 3H02932B R
PART NO
Page 31
—31—
M6003R WM-6011 LWJ0611PCG
LWC061JGMK1
130410 BASE ASSY, SINGLE 3041A10011E 3041A10011E 3041A10011E 3041A10011E R
130910 CABINET ASSY, SINGLE 3091A10020A 3091A10020A 3091A10020D 3091A10020D R
135312 GRILLE ASSY, FRONT(SINGLE) 3531AR1644H 3531AR1644T 3531AR1644T 3531AR1644T R
135313 GRILLE ASSY, INLET 3530A10039A 3530A10039A 3530A10039A 3530A10039A R
137215 PANEL, CONTROL 3720A20017A 3720A20017A 3720A20017A 3720A20017A R
149980 SHROUD 4998A10008A 4998A10008A 4998A10006A 4998A10006A R
152302 FILTER(MECH), A/C 5231AR2148A 5231AR2148A 5231AR2148G 5231AR2148G R
238310 ESCUTCHEON 3831A10001F 3831A10001G 3831A10001G 3831A10001G R
249950 CONTROL BOX ASSY, SINGLE 4995A20127D 4995A20127E 4995A20127E 4995A20127E R
263230 THERMISTOR ASSY 6323A20003D 6323A20003D 6323A20003D 6323A20003D R
264110 POWER CORD ASSY 2H00677P 2H00677P 2H00677P 2H00677P R
267110 REMOTE CONTROLLER ASSY 6711A20034A 6711A20034E 6711A20034E 6711A20034E R
268712 PWB(PCB) ASSY, DISPLAY 6871A20115B 6871A20115B 6871A20193B 6871A20193B R
268714 PWB(PCB) ASSY, MAIN 6871A10013M 6871A10013D 6871A20188Q 6871A20188Q R
346811 MOTOR ASSY, SINGLE 4681A10002C 4681A10002C 4681A10012G 4681A10012G R
349480 ORIFICE 4948A10007A 4948A10007A 4948A10007A 4948A10007A R
352113 TUBE, DISCHARGE 5210A20511A 5210A20511A 5210A20252A 5210A20252A R
352115 TUBE ASSY, EVPORATOR IN 5211A10063C 5211A10063C 5211A10063E 5211A10063E R
35211A TUBE ASSY, SUCTION SINGLE 5211A10062B 5211A10062B 5211A10062D 5211A10062D R
352380 AIR GUIDE 5238A20004B 5238A20004B 5238A20005B 5238A20004B R
352390 AIR GUIDE ASSY 5239A30003B 5239A30003A 5239A30003A 5239A30003A R
354210 EVAPORATOR ASSY, FIRST 5421A20016G 5421A20016G 5421A20016G 5421A20016G R
359012 FAN, TURBO 5900A10005A 5900A10005A 5900A10005A 5900A10005A R
550140 ISOLATOR, COMP 5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A R
552111 TUBE ASSY, CAPILLARY 5211AR3332R 5211AR3332R - - R
552102 TUBE CAPILLARY BEND - - 5210A30018K 5210A30018K R
554030 CONDENSER ASSY, FIRST 5403A20009E 5403A20009E 5403A20038D 5403A20038D R
554160 COMPRESSOR 2520UAMC2AA 2520UAMC2AA 2520UAMC2AA2520UAMC2AA R
559011 FAN, PROPELLER 5900A20017A 5900A20017A 5900A20006A 5900A20006A R
567502 O.L.P 6750U-L004A 6750U-L004A 6750U-L060A 6750U-L060A R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V 6120AR2359V 6120AR2359V R
W48602 CLAMP, SPRING 3H02932B 3H02932B 3H02932B 3H02932B R
LOCATION
NO
DESCRIPTION
REMARK
PART NO
Page 32
P/No.: 3828A20038B
February, 2003
Printed in Korea
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