Page 1
Room Air Conditioner
SERVICE MANUAL
MODEL: R5003, R5204, R5205, WR-5210, R6003
WR-6010, R7003, LW5200E, R0500M
website http://www.lgservice.com
CAUTION
• BEFORE SERVICING THE UNIT, READ THE SAFETY
PRECAUTIONS IN THIS MANUAL.
• ONLY FOR AUTHORIZED SERVICE PERSONNEL.
Page 2
Air Conditioner Service Manual
TABLE OF CONTENTS
Safety Precautions..........................................................................................................................................3
Dimensions .....................................................................................................................................................5
Outside Dimensions ...................................................................................................................................5
Product Specifications ..................................................................................................................................6
Installation .......................................................................................................................................................7
Select the Best Location ...........................................................................................................................7
How to Install..............................................................................................................................................7
Kit Contents Installation ...........................................................................................................................8
Operation ......................................................................................................................................................10
Features ...................................................................................................................................................10
About the Controls on the Air Conditioner ...............................................................................................11
Disassembly ..................................................................................................................................................12
Mechanical Parts......................................................................................................................................12
Air Handling Parts ....................................................................................................................................14
Electrical Parts .........................................................................................................................................14
Refrigerating Cycle...................................................................................................................................16
Schematic Diagram.......................................................................................................................................19
Wiring Diagram.........................................................................................................................................19
Troubleshooting Guide.................................................................................................................................20
Piping System ..........................................................................................................................................20
Troubleshooting Guide .............................................................................................................................21
Room Air Conditioner Voltage Limits........................................................................................................23
Exploded View ..............................................................................................................................................26
Replacement Parts List..............................................................................................................................27A
2 Room Air Conditioner
Page 3
Safety Precautions
WARNING
CAUTION
WARNING
Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must
be followed.
■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is
classified by the following indications.
This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to property only.
■ Meanings of symbols used in this manual are as shown below.
Be sure not to do.
Be sure to follow the instruction.
■ Installation
Do not use damaged power cord plugs, or a
loose socket.
• There is risk of fire or electric shock.
Always use the power plug and socket with
the ground terminal.
• There is risk of electric shock.
Service Manual 3
Page 4
Safety Precautions
Sharp edges
Gasolin
Do not modify or extend the power cord.
• There is risk or fire or electric shock.
Be cautious when unpacking and installing
the product.
• Sharp edges could cause injury. Be especially careful
of the case edges and the fins on the condenser and
evaporator.
Do not install, remove, or re-install the unit by
yourself.
• There is risk of fire, electric shock, explosion, or injury.
Do not store or use flammable gas or combustibles near the air conditioner.
• There is risk of fire or failure of product.
Be sure the installation area does not deteriorate with age.
• If the base collapses, the air conditioner could fall with
it, causing property damage, product failure, and personal injury.
4 Room Air Conditioner
Page 5
Dimensions
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")
Operation
High
Fan
Low
Fan
High
Cool
Off
Low
Cool
Thermostat
1
2
3
4
5
6
7
8
9
Operation
High
Fan
Low
Fan
High
Cool
Off
Low
Cool
Thermostat
1
2
3
4
5
6
7
8
9
NOTICE
Symbols Used in this Manual
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that could cause harm to the
air conditioner.
This symbol indicates special notes.
Outside Dimensions
Dimensions
Service Manual 5
Page 6
Product Specifications
NOTICE
Product Specifications
Product Specifications
MODELS
ITEMS
COOLING CAPACITY (BTU/h) 5,000 5,200 6,000 7,000 5,200 5,050
POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ
INPUT (W) 515 520(530) 620 720 480 520
OPERATING CURRENT (AMP.) 4.8 4.8 5.6 6.7 4.4 4.8
REFRIGERANT CONTROL CAPILLARY TUBE
REFRIGERANT CHARGE (R-22)
INSIDE FAN TURBO
OUTSIDE FAN PROPELLER FAN WITH SLINGER RING
AIR DISCHARGE 2-WAY (RIGHT AND LEFT)
CHASSIS TOP-DOWN
PROTECTOR
TEMPERATURE CONTROL THERMOSTAT
ROTARY SWITCH
R5003
220g (7.8 Oz) 230g (8.1 Oz) 335g(11.8Oz)
5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)
R5204, R5205
WR-5210
• OVERLOAD PROTECTOR FOR COMPRESSOR
• INTERNAL PROTECTOR FOR FAN MOTOR
R6003,
WR-6010
R7003 LW5200E R0500M
315g (11.1 Oz)
330g(11.6 Oz) 220g (7.8 Oz)
FAN MOTOR
Specifications are subject to minor change without notice for further
improvement.
6 POLES, 16W
6 POLES, 24W 6 POLES, 27W 6 POLES, 21W
6 Room Air Conditioner
Page 7
Installation
NOTICE
ABOUT / "
Over 20"
HEAT
RADIATION
FENCE
AWNING
OUTSIDE
INSIDE
COOLED AIR
30"-60"
1
4
OUTDOORSINDOORS
INNERSILL
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
This air conditioner is designed with a button-down chassis so it can be easily installed in a window.
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.
CAUTION: All side louvers of the cabinet
must remain exposed on the outdside of
the structure.
Installation
4. Install the unit slanted slightly so the back is slightly lower
5. Install the unit with the bottom about 30"~60" above the
Window Requirements
1. This unit is designed for installation in standard double hung win-
2. If storm window presents interference, fasten a 2" wide wood strip
3. Install a second wood strip (approximately 6" long by 11/2" wide
4. If the distance between STORM WINDOW FRAME and WOOD
than the front (about 1/4"). This will force condensed
water to the outside.
floor level.
How to Install
All supporting parts should be secured
to firm wood, masonry, or metal.
dows 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.
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. 3. 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.
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. 3.
STRIP MOUNTED ON TOP OF INNER SILL is more than 1", two
of wood strip are not necessary.
Figure 1
Figure 2
Figure 3
Service Manual 7
Page 8
Installation
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
TYPE A
TYPE A
ROOM SIDE
CENTER LINE
INNER SILL
SEAL STRIP
(TYPE D)
Installation Kits Contents
Before Installation
1. Insert the guide panels into the guides of the air conditioner. Fasten the curtains to the unit with screws (TYPE A) as
shown Figure. 4.
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. 5)
Now Start Installation
1. Locating Unit in Window
2. Attach L Bracket
Open the window and mark center line on the center of the
inner sill, as shown in Figure. 6.
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. 6.
CAUTION: 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.
Figure 4
Figure 5
Figure 6
8 Room Air Conditioner
Page 9
How to Install(Models with Installaion Kit)
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
Operation
High
Fan
Low
Fan
High
Cool
Off
Low
Cool
Thermostat
1
2
3
4
5
6
7
8
9
OUTSIDE
INSIDE
L
BRACKET
OUTER SILL
SHORT SIDE
INNER SILL
TYPE A
8"
8"
CENTER LINE
3. WInstall the Air Conditioner in the Window
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. 7.
Installation
IMPORTANT :
When the air conditioner drops into the L bracket, the air
conditioner will be centered in window opening as shown
in Figure. 8.
b. While steadying the air conditioner, carefully bring
the window sash down behind the upper guide of
the air conditioner, as shown in Figure. 9.
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. 10.
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. 10.
b. Fasten the L bracket using a (TYPE A) screw, as
shown in Figure. 10.
6. Window installation of room air conditioner is now
completed. See ELECTRICAL DATA for attaching
power cord to electrical outlet.
Figure 7
Figure 8
Figure 9
TYPE B
Figure 10
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. 11)
Figure 11
Service Manual 9
Page 10
Operation
Operation
Feature
• DESIGNED FOR COOLING ONLY
• POWERFUL AND INCREDIBLE COOLING
• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE
• BUILT-IN ADJUSTABLE THERMOSTAT
• WASHABLE ONE-TOUCH FILTER
• COMPACT SIZE
Insulation Resistance Test
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 positions [except Off] of the ROTARY SWITCH.
4. The value should be over 1 MΩ.
10 Room Air Conditioner
Page 11
About the Controls on the Air Conditioner
Operation
High
Fan
Low
Fan
High
Cool
Off
Low
Cool
Thermostat
1
2
3
4
5
6
7
8
9
Off - Turns air conditioner off.
High Fan - High speed fan operation without cooling.
Low Fan - Low speed fan operation without cooling.
High Cool - Cooling with high speed fan operation.
Low Cool - Cooling with low speed fan operation.
This automatically controls the temperature of the indoor air.
Turn the knob so that arrow points to the larger marks for greater cooling.
Point the arrow to the smaller marks for more moderate cooling.
Operation
(i.e. the higher number, the greater cooling)
FOR NORMAL COOLING
1. Turn the operation switch to the high Cool or the Low Cool setting.
2. Set the thermostat control to the desired temperature mark(the mid-point is a good starting position).
If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or
warmer setting, as appropriate.
FOR MAXIMUM COOLING
1. Turn the operation switch to the High Cool setting.
2. Set the thermostat control to the largesttemperature mark.
FOR QUIETER OPERATION
1. Turn the operation switch to the Low Cool setting.
2. Set the thermostat control as needed.
CAUTION: When the air conditioner has been performed its cooling operation
and is turned off or set to the fan position, wait at least 3 minutes before resetting to the cooling operation again.
Service Manual 11
Page 12
Disassembly
NOTICE
Disassembly
Mechanical Parts
1. Front Grille
1. Disconnect the unit from source of power.
2. Remove the two knobs by pulling them off.
Using a screwdriver, remove the screw that secures
the front grille to control board. (See Figure 12)
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 13)
4. Replace the grille by placing the tabs in the slots and
push the grille until it snaps into place.
2. Cabinet
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to section 1)
3. Remove 9 screws that secure the cabinet to the base
pan and condenser. (See Figure 14)
4. Lift the cabinet from the unit.
5. Re-install by referring to the procedures above.
Figure 12
Figure 13
Figure 14
3. Control Board
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 1)
3. Remove the cabinet. (Refer to Section 2)
4. Remove 2 screws that secure the control board to
base pan and air guide. (See Figure 15)
5. Pull the control board toward yourself.
Controls, wires, and capacitor are
now accessible for servicing.
Discharge the capacitor before servicing. See step 2.3.3 on page 8 for
procedures.
6. Disconnect one housing terminal and 3 wires for the
fan motor and compressor. (See Figure 16)
7. Re-install components by referring to procedures
above. (Refer to wiring diagram on page 23 in this
manual or inside control board.)
12 Room Air Conditioner
Figure 15
Figure 16
Page 13
Air Handling Parts
Disassembly
4. Air Guide Upper
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 1)
3. Remove the cabinet. (Refer to Section 2)
4. Remove the control board. (Refer to Section 3)
5. Remove 2 screws that secure the air guide upper to air
guide lower. (See Figure 17)
6. Lift air guide upper upward.
7. Re-install by referring to the procedures above.
5. Orifice, Turbo Fan and Fan
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 1)
3. Remove the cabinet. (Refer to Section 2)
4. Remove the control board. (Refer to Section 3)
5. Remove the air guide upper. (Refer to Section 4)
6. Remove 2 screws that secure the base pan to condenser. (See Figure 18)
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 18)
10. Remove the orfice by pushing the snap area of the air
guide blower. (See Figure 19)
11. Remove the clamp springs which are clamped to the
boss of fan and turbo fan by hand plier. (See Figure
20)
12. Pull the fan and turbo fan outward.
13. Remove the shroud.
14. Re-install by referring to the procedures above.
Figure 17
Figure 18
Figure 19
Figure 20
Service Manual 13
Page 14
Disassembly
Air Handling Parts
6. Motor
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 1)
3. Remove the cabinet. (Refer to Section 2)
4. Remove the control board. (Refer to Section 3)
5. Remove the air guide upper. (Refer to Section 4)
6. Remove the compressor, turbo fan, fan and shroud.
(Refer to Section 5)
7. Remove 2 screws that secure the motor to the motor.
(See Figure 21)
8. Remove the motor.
9. Re-install by referring to the procedures above.
Figure 21
7. Air Guide
1. Disconnect the unit from the power source.
2. Remove the front grille. (Refer to Section 1)
3. Remove the cabinet. (Refer to Section 2)
4. Remove the control board. (Refer to Section 3)
5. Remove the air guide upper. (Refer to Section 4)
6. Remove the compressor, turbo fan, fan and shroud.
(Refer to Section 5)
7. Remove the motor. (Refer to Section 6)
8. Remove 2 screws that secure the air guide to the base
pan. (See Figure 22)
9. Push the air guide backward and lift it upward. (See
Figure 22)
10. Re-install by referring to the procedures above.
Electrical Parts
8. Overlode Protector
1. Remove the front grille and cabinet.
(Refer to Section 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.
5. Remove the overload protector.
6. Re-install the components by referring to the removal
procedure above. (See Figure 23 and 24)
Figure 22
Figure 23 Figure 24
14 Room Air Conditioner
Page 15
9 Compressor
1. Remove the front grille and cabinet.
(Refer to Section 1, 2)
2. Discharge the refrigerant by using a refrigerant recovery
system.
3. Remove the overload protector. (Refer to Section 8)
4. After discharging the unit completely, unbrace the suc-
tion 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 25)
10 Capacitor
1. Remove the cabinet. (Refer to Section 2)
2. Remove the control board. (Refer to Section 3)
3. Discharge the capacitor by placing a 20 KΩ resistor
across the capacitor terminals.
4. Remove the screw which fastens the capacitor clamp.
5. Remove all the leads of capacitor terminals.
6. Re-install the components by referring to the removal
procedure above. (See Figure 26)
Disassembly
Figure 25
Figure 26
11. Thermostat
1. Remove the cabinet. (Refer to Section 2)
2. Remove the control board. (Refer to Section 3)
3. Remove 2 screws which fasten the thermostat.
4. Remove all the leads of the thermostat terminals.
5. Remove the thermostat.
6. Re-install the components by referring to the removal
procedure above. (See Figure 27)
12. Rotary Switch
1. Remove the cabinet. (Refer to Section 2)
2. Remove the control board. (Refer to Section 3)
3. Remove 2 screws which fasten the rotary switch.
4. Remove all the leads of the rotary switch terminals.
5. Remove the rotary switch.
6. Re-install the components by referring to the removal
procedure above. (See Figure 28)
Figure 27
Figure 28
Service Manual 15
Page 16
Disassembly
13. Power Cord
1. Disconnect the unit from source of power.
2. Remove the front grille. (Refer to Section 1)
3. Remove the cabinet. (Refer to Section 2)
4. Remove a screw that secures control board to base pan.
(Refer to Section 3)
5. Pulls the control board toward you.
6. Disconnect the 2 receptacles and remove the grounding
screw.
7. Remove a screw securing the clip with cord to the control board.
8. Pull the power cord.
9. Re-install by referring to procedures above.
Refrigerating Cycle
Figure 29
15. Condenser
1. Remove the cabinet. (Refer to Section 2)
2. Discharge the refrigerant by using a refrigerant recovery
system.
3. Remove the air guide. (Refer to Section 4)
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.
Figure 30
16 Room Air Conditioner
Page 17
Disassembly
NOTICE
16. Evaporator
1. Remove the cabinet.
2. Discharge the refrigerant by using a refrigerant
recovery system.
3. Remove the air guide upper.
(Refer to Section 4)
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.
17. 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 4)
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.
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
31A.
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:
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 minutes,
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 31B.
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 figure
31B. 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(0.2mp).
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.
If high vacuum equipment is
Service Manual 17
Page 18
Disassembly
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
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.
Figure 31A-Pulling Vacuum Figure 31B-Charging
18 Room Air Conditioner
Page 19
MOTOR
C
F
H
7
8
6
4
2
1
5
3
H
L
M
POWER INPUT
ROTARY SWITCH
THERMOSTAT
BR
BK
RD
BK
RD
OR(BR)
YL
BK(BR)
(Plain)
WH(BL)
(Ribbed)
GN(GN/YL)
COMP.
YL
OR(BR)
R
S
C
CAPACITOR
BK
RD
BLBR
OLP
5
1
2
6
7
3
4
WIRING DIAGRAM
Schematic Diagram
Wiring Diagram
Schematic Diagram
REF. NO
1
2
3
4
5
6
7
POWER CORD ASSY
FAN MOTOR
COMPRESSOR
ROTARY SWITCH
THERMOSTAT
CAPACITOR
OVERLOAD PROTECTOR
DESCRIPTION & NAME
Q'TY
1
1
1
1
1
1
1
Service Manual 19
Page 20
Troubleshooting Guide
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
Troubleshooting Guide
Piping System
CONDENSER COILS
FAN
CAPILLARY
MOTOR
TUBE
TURBO FAN
EVAPORATOR
COILS
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.
20 Room Air Conditioner
Figure 32
Page 21
Troubleshooting Guide
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 Conditioning
caused by a defect in the refrigeration circuit and improper application.
Unit is running but cooling is ineffective.
Ineffective Cooling
Check cold air
circulation for smooth
flow.
Dirty indoor coil
(heat exchanger)
Malfunction of fan.
Clogging of air filter.
Obstruction at air outlet.
Check outdoor coil
(heat exchanger) and
fan operation.
Check gas leakage.
Repair gas leak.
Replacement of unit if
the unit is beyond repair.
Check heat load
increase.
Clean condenser.
Not on separate circuit
Check inside gas
pressure.
Adjust refrigerant
charge.
Remove obstruction.
Check clogging in refrigeration circuit.
Repair clogging in
refrigeration circuit.
Malfunction of
compressor.
Replacement of
compressor.
Satisfactory operation
with temperature
difference of inlet & outlet
air; 55~59°F (13~15°C)
Service Manual 21
Page 22
Troubleshooting Guide
Fails to Start
Check of power source.
Check of control switch
setting.
Compressor fails only to
start.
Drop of power voltage.
Defect of compressor
capacitor.
Improper thermostat
setting
Loose terminal
connection
Check of circuit breaker
and fuse.
Gas leakage of feeler
bulb of thermostat.
Check control switch.
Fan only fails to start.
Improper wiring.
Defect of fan motor
capacitor.
Capacitor check.
Replacement.
Irregular motor resistance (Ω)
Irregular motor insulation (Ω)
Replacement of compressor
(Motor damaged).
22 Room Air Conditioner
Improper wiring
Irregular motor
resistance (Ω)
Irregular motor
insulation (Ω)
Replacement of fan motor.
Regular but fails to start.
Replacement of compressor.
(Locking of piston, metal.)
Page 23
Troubleshooting Guide
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.
Service Manual 23
Page 24
Troubleshooting Guide
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 disconnected, refer to wiring diagram for identification,
and replace the wires. Check the wire connections;
If not according to the wiring diagram, correct
the connections.
Rotary Check for continuity, refer to the wiring diagram
for terminal identification. Replace the switch if
the circuit is open.
Thermostat Check the position of knob. If not at the coldest
setting, advance the knob to this setting and
restart the unit.
Check the continuity of the thermostat. Replace
the thermostat 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
Compressor cycles on Voltage Check the voltage. See the limits on the
overload. preceding page. If voltage is not within these limits,
Check the compressor overload if externally mounted.
Replace if open. (If the compressor temperature is
high, remove the overload, cool, and retest.)
call an electrician.
24 Room Air Conditioner
Overload Check overload, if externally mounted.
Replace if open. (If the compressor temperature
is high, remove the overload, cool, and retest.)
Page 25
Troubleshooting Guide
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.
Service Manual 25
Page 26
Exploded View
152302
135313
352390
149410
130410
359012
W48602
135312
354210
349480
352380
149980
559011
346811
554030
W48602
130910
266003
264110
269300
W0CZZ249950
135500
550140
554160
567502
352115
552111
352113
35211A
Exploded View
26 Room Air Conditioner
Page 27
Replacement Parts List
Replacement Parts List
LOCATION
NO
.
130410 BASE ASSY, SINGLE 3041A10011E 3041A10011E R
130910 CABINET ASSY, SINGLE 3091A10020A 3091A10020D R
135312 GRILLE ASSY, FRONT(SINGLE) 3531AR1644A 3531AR1644A R
135313 GRILLE ASSY, INLET 3530AR1616A 3530AR1616A R
135500 COVER 3550A20026A 3550A20026A R
148000 BRACE - 4800A30003A R
149410 KNOB ASSY 4941AR7315A 4941AR7315A R
149980 SHROUD 4998A10006A 4998A10008A R
152302 FILTER(MECH), A/C 5231AR2148A 5231AR2148G R
249950 CONTROL BOX ASSY, SINGLE 4995A20126A 4995A20126A R
264110 POWER CORD ASSY 2H00677P 2H00677P R
266003 SWITCH, ROTARY 2H00154H 2H00154H R
269310 THERMOSTAT ASSY 2H01109H 2H01109H R
346811 MOTOR ASSY, SINGLE 4681A10002A 4681A10012B R
349480 ORIFICE 4948A10007A 4948A10007A R
352113 TUBE, DISCHARGE 5210A20252A 5210A21100A R
352115 TUBE ASSY, EVPORATOR IN 5211A10063A 5211A10063A R
35211A TUBE ASSY, SUCTION SINGLE 5211A10062A 5211A10062A R
DESCRIPTION
R5003 R0500M
PART NO.
REMARK
352380 AIR GUIDE 5238A20004A 5239A10005A R
352390 AIR GUIDE ASSY 5239A30003A 5239A30003A R
354210 EVAPORATOR ASSY, FIRST 5421A10008A 5421A10008B R
359012 FAN TURBO 5900A20005A 5900A20005A R
550140 ISOLATOR, COMP 5040AR4195A 5040AR4195A R
552110 TUBE ASSY, CAPILLARY 5211A10065A 5211AR3332V R
554030 CONDENSER ASSY, FIRST 5403A20038C 5403AR6200C R
554160 COMPRESSOR 5416A20013M 5416A20014D R
559011 FAN, PROPELLER 5900A20006A 5900A20017A R
567502 O.L.P 6750A30001F 6750A30001U R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V R
W48602 CLAMP, SPRING 3H02932B 3H02932B R
Service Manual 27
Page 28
Replacement Parts List
LOCA-
TION NO
130410 BASE ASSY, SINGLE 3041A10011E 3041A10011E 3041A10011E 3041A10011E R
130910 CABINET ASSY, SINGLE 3091A10020A 3091A10020A 3091A10020A 3091A10020D R
135312 GRILLE ASSY, FRONT(SINGLE) 3531AR1644P 3531AR1644A 3531AR1644S 3531AR1644S R
135313 GRILLE ASSY, INLET 3530AR1616C 3530AR1616A 3530AR1616A 3530AR1616A R
135500 COVER 3550A20026A 3550A20026A 3550A20026A 3550A20026A R
149410 KNOB ASSY 4941AR7315B 4941AR7315A 4941AR7315A 4941AR7315A R
149980 SHROUD 4998A10006A 4998A10006A 4998A10006A 4998A10008A R
152302 FILTER(MECH), A/C 5231AR2148D 5231AR2148A 5231AR2148A 5231AR2148G R
249950 CONTROL BOX ASSY, SINGLE 4995A20126A 4995A20126A 4995A20126A 4995A20126A R
264110 POWER CORD ASSY 2H00677P 2H00677P 2H00677P 2H00677P R
266003 SWITCH, ROTARY 2H00154H 2H00154H 2H00154H 2H00154H R
269310 THERMOSTAT ASSY 2H01109H 2H01109H 2H01109H 2H01109H R
346811 MOTOR ASSY, SINGLE 4681A10002A 4681A10002A 4681A10002A 4681A10002P R
349480 ORIFICE 4948A10007A 4948A10007A 4948A10007A 4948A10007A R
352113 TUBE, DISCHARGE 5210A20252A 5210A20252A 5210A20252A 5210A21100A R
352115 TUBE ASSY, EVPORATOR IN 5211A10063A 5211A10063A 5211A10063A 5211A10063C R
35211A TUBE ASSY, SUCTION SINGLE 5211A10062A 5211A10062A 5211A10062A 5211A10062B R
352380 AIR GUIDE 5238A20004A 5238A20004A 5238A20004A 5238A20004B R
352390 AIR GUIDE ASSY 5239A30003A 5239A30003A 5239A30003A 5239A30003A R
354210 EVAPORATOR ASSY, FIRST 5421A10008B 5421A10008B 5421A10008B 5421A20016H R
359012 FAN, TURBO 5900A20005A 5900A20005A 5900A20005A 5900A10005A R
550140 ISOLATOR, COMP 5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A R
552111 TUBE ASSY, CAPILLARY 5211A10065B 5211A10065B 5211A10065B 5211AR3332R R
554030 CONDENSER ASSY, FIRST 5403A20038D 5403A20038D 5403A20038D 5403A20009E R
554160 COMPRESSOR 2520UABC2EA 2520UABC2EA 2520UABC2EA 5416A20014D R
559011 FAN, PROPELLER 5900A20006A 5900A20006A 5900A20006A 5900A20017A R
567502 O.L.P 6750U-L050A 6750U-L050A 6750U-L050A 6750A30001U R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V 6120AR2359V 6120AR2359V R
W48602 CLAMP, SPRING 3H02932B 3H02932B 3H02932B 3H02932B R
DESCRIPTION
R5204 R5205 WR-5210 LW5200E
PART NO
REMARKS
28 Room Air Conditioner
Page 29
Replacement Parts List
LOCATION NO
130410 BASE ASSY, SINGLE 3041A10011E 3041A10011E R
130910 CABINET ASSY, SINGLE 3091A10020A 3091A10020A R
135312 GRILLE ASSY, FRONT(SINGLE) 3531AR1644A 3531AR1644S R
135313 GRILLE ASSY, INLET 3530AR1616A 3530AR1616A R
135500 COVER 3550A20026A 3550A20026A R
149410 KNOB ASSY 4941AR7315A 4941AR7315A R
149980 SHROUD 4998A10008A 4998A10008A R
152302 FILTER(MECH), A/C 5231AR2148A 5231AR2148A R
249950 CONTROL BOX ASSY, SINGLE 4995A20126A 4995A20126A R
264110 POWER CORD ASSY 2H00677P 2H00677P R
266003 SWITCH, ROTARY 2H00154H 2H00154H R
269310 THERMOSTAT ASSY 2H01109H 2H01109H R
346811 MOTOR ASSY, SINGLE 4681A10002C 4681A10002C R
349480 ORIFICE 4948A10007A 4948A10007A R
352113 TUBE, DISCHARGE 5210A20511A 5210A20511A R
352115 TUBE ASSY, EVPORATOR IN 5211A10063C 5211A10063C R
35211A TUBE ASSY, SUCTION SINGLE 5211A10062B 5211A10062B R
352380 AIR GUIDE 5238A20004B 5238A20004B R
352390 AIR GUIDE ASSY 5239A30003B 5239A30003A R
354210 EVAPORATOR ASSY, FIRST 5421A20016G 5421A20016G R
359012 FAN, TURBO 5900A10005A 5900A10005A R
550140 ISOLATOR, COMP 5040AR4195A 5040AR4195A R
552111 TUBE ASSY, CAPILLARY 5211AR3332R 5211AR3332R R
554030 CONDENSER ASSY, FIRST 5403A20009E 5403A20009E R
554160 COMPRESSOR 2520UAMC2AA 2520UAMC2AA R
559011 FAN, PROPELLER 5900A20017A 5900A20017A R
567502 O.L.P 4750U-L004A 4750U-L004A R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V R
W48602 CLAMP, SPRING 3H02932B 3H02932B R
DESCRIPTION
R6003 WR-6010
PART NO
REMARKS
Service Manual 29
Page 30
Replacement Parts List
LOCATION
NO
.
130410 BASE ASSY, SINGLE 3041A10011E R
130910 CABINET ASSY, SINGLE 3091A10020A R
135312 GRILLE ASSY, FRONT(SINGLE) 3531AR1644A R
135313 GRILLE ASSY, INLET 3530AR1616A R
135500 COVER 3550A20026A R
149410 KNOB ASSY 4941AR7315A R
149980 SHROUD 4998A10008A R
152302 FILTER(MECH), A/C 5231AR2148A R
249950 CONTROL BOX ASSY, SINGLE 4995A20126G R
264110 POWER CORD ASSY 2H00677P R
266003 SWITCH, ROTARY 2H00154H R
269310 THERMOSTAT ASSY 2H01109H R
346811 MOTOR ASSY, SINGLE 4681A10002K R
349480 ORIFICE 4948A10007A R
352113 TUBE, DISCHARGE 5211A10129A R
352115 TUBE ASSY, EVPORATOR IN 5211A10063C R
35211A TUBE ASSY, SUCTION SINGLE 5211A10062C R
352380 AIR GUIDE 5238A20004B R
352390 AIR GUIDE ASSY 5239A30003A R
354210 EVAPORATOR ASSY, FIRST 5421A20016G R
359012 FAN, TURBO 5900A10005A R
550140 ISOLATOR, COMP 5040AR4195A R
552111 TUBE ASSY, CAPILLARY 5211AR3332S R
DESCRIPTION
PART NO.
R7003
REMARK
554030 CONDENSER ASSY, FIRST 5403A20009F R
554160 COMPRESSOR 2520UAFC2BA R
559011 FAN, PROPELLER 5900A20017A R
567502 O.L.P 4750U-L005A R
W0CZZ CAPACITOR, DRAWING 0CZZA20001W R
W48602 CLAMP, SPRING 3H02932B R
30 Room Air Conditioner
Page 31
P/No.: 3828A20038A
January, 2004
Printed in Korea
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