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.
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 2.4 REFRIGERANT CYCLE ...........................................
1.2 SPECIFICATIONS MODELS ITEMS M5403R M5203R M5203L M6003R WM-6011 LWJ0611PCG LWC061JGMK1 5,300 5,200 5,200 6,000 6,000 COOLING CAPACITY (BTU/h) 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 REFRIGERANT CHARGE (R-22) CAPILLARY TUBE 230g (8.
1.5 LOCATIONS OF CONTROLS 1.5.1 CONTROLS 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. 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.
1.5.2 REMOTE CONTROLLER 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). 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.
2. DISASSEMBLY INSTRUCTIONS 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE Figure 1 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. Figure 2 2.1.
2.2 AIR HANDLING PARTS Figure 6 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. Figure 7 2.2.2 ORIFICE, TURBO FAN AND FAN 1.
2.2.3 MOTOR Figure 10 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.
2.3.2 COMPRESSOR Figure 14 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.
2.3.6 POWER CORD Figure 18 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 Figure19 1.
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.
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.
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.
Installation HARDWARE 16mm TYPE B: 4EA (WOOD SCREW) 10mm TYPE A: 11EA (SHORT SCREW) TYPE D: 1EA (SEAL STRIP) TYPE E: 1EA (SASH SEAL) (Adhesive backed) (Not adhesive backed) TYPE C: 3EA (L BACKET) DRAIN PIPE TYPE F: 2EA (GUIDE PANEL) 3.2.2 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. 24. 2. Cut the adhesive-backed seal strip (TYPE D) to the window width.
3. INSTALL 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. 27. INNER SILL TYPE A OUTER SILL INSIDE CENTER LINE 8" SHORT SIDE Figure 27 8" OUTSIDE L BRACKET 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.
REMOVAL FROM WINDOW Turn 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 grip 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.
4.2 PIPING SYSTEM CONDENSER COILS FAN MOTOR CAPILLARY 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.
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 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. Check outdoor coil (heat exchanger) and fan operation. Dirty indoor coil (heat exchanger) Check gas leakage.
Fails to Start Check of power source. Check of circuit breaker and fuse. Check of control panel setting. Check control panel. Compressor fails only to start. Fan only fails to start. Drop of power voltage. Improper thermistor setting Defect of compressor capacitor. Loose terminal connection Capacitor check. Improper wiring Improper wiring. Defect of fan motor capacitor. Irregular motor resistance (Ω) Irregular motor insulation (Ω) Replacement. Replacement of fan motor.
ELECTRIC PARTS TROUBLESHOOTING GUIDE: Possible Trouble 1 Is the Trans output power AC 115V? • The unit does not operate. NO • Check the Fuse. • Check the wiring diagram. YES Is the Trans output power about AC 14V? NO Is shorted the Trans. output? YES Is output Voltage of IC01D DC 12V? YES NO • Check the Main P.W.B pattern. • Exchange the Trans. • Exchange D02D~D05D. • Exchange IC01D. NO YES Is output Voltage of IC02D DC 5V? NO • Exchange IC02D.
Possible Trouble 2 • The compressor does not operate. Is Temp. NO setting set lower than Room Temp.-0.5°C? • Set the Temp. setting to higher Temp. YES Is the voltage No.11 of IC01M 0V? NO Is the voltage N0.6 of IC01M DC 5V? NO YES YES • Check the RY-COMP. • Check the wiring Diagram. • Exchange IC01M. Is the Unit for 3 minutes delay? NO YES • Wait 3 Minutes • Exchange MAIN P.W.B Ass'y. Possible Trouble 3 Is the wire connection of RY-COMP all right? • The compressor always operate.
• Romote controller does not operate. (only for M-5400, M-6000, M-7000) Possible Trouble 5 Is the voltage of Battery about over 2.3V? NO • Exchange the battery. YES Is the voltage No.10 of CN-DISP2 on Main P.W.B Ass'y DC 5V? NO • Check the P.W.B pattern. YES Is the connection of CN-DISP2 all right? • Connect connector to CN-DISP2 exactly. NO YES • Exchange Receiver Ass'y. Possible Trouble 6 Is the IC01G all right? • It displays abnormally on Display P.W.B Ass'y. NO • Exchange IC01G.
ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 115V ± 10% 103.5V 126.5V COMPLAINT Fan motor will not run. CAUSE REMEDY 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 connection loose Connect wire.
COMPLAINT Fan motor noise. Compressor will not run, fan motor runs. CAUSE REMEDY 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. Voltage Check voltage. See the limits on the preceding page.
COMPLAINT Compressor cycles on overload Insufficient cooling. Excessive noise. CAUSE REMEDY Fan motor If not running, determine the cause. Replace if required. Condenser air flow restriction Remove the cabinet, inspect the interior surface of the condenser. If restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before re-assembling.
5. SCHEMATIC DIAGRAM 5.1 CIRCUIT DIAGRAM • MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011, LWJ0611PCG, LWC061JGMK1 1 (Ribbed) (Plain) GN/YL(GN) 7 H COMP. R S C BR BK RD BL MAIN P.W.B ASM OR BK RD OR BK RD 7 H BK 5 ZNR01J RY-COMP BL 3 TRANS FORMER FUSE 125V 2A COMP. BK RD BL R S C BL 8 DESCRIPTION NO. Q'TY PER SET 1 POWER CORD ASSEMBLY 1 2 FAN MOTOR 1 3 COMPRESSOR 1 4 DISPLAY P.W.B ASSEMBLY 1 5 MAIN P.W.
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5.3 COMPONENTS LOCATION (FOR MAIN P.W.B ASM) 5.4 COMPONENTS LOCATION (FOR DISPLAY P.W.
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LOCATION NO PART NO DESCRIPTION M6003R WM-6011 REMARK 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 499
P/No.