ROOM AIR CONDITIONER
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
D
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F
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MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011,
LWJ0611PCG, LWC061JGMK1
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1.2 SPECIFICATIONS
M6003R
WM-6011
LWJ0611PCG
LWC061JGMK1
MODELS
ITEMS
M5403R
M5203R
M5203L
COOLING CAPACITY (BTU/h)
POWER SUPPLY (Phase, V, Hz)
INPUT (W)
5,300
5,200
5,200
1ø, 115V, 60HZ
470
6,000
6,000
530
4.8
610
5.6
620
5.8
OPERATING CURRENT (AMP.)
REFRIGERANT CONTROL
REFRIGERANT CHARGE (R-22)
INSIDE FAN
4.3
CAPILLARY TUBE
230g (8.1 Oz )
330g(11.6 Oz) 335g (11.8 Oz) 235g (8.3 Oz)
TURBO
OUTSIDE FAN
PROPELLER FAN WITH SLINGER RING
2-WAY (RIGHT AND LEFT)
TOP-DOWN
AIR DISCHARGE
CHASSIS
• OVERLOAD PROTECTOR FOR COMPRESSOR
• INTERNAL PROTECTOR FOR FAN MOTOR
PROTECTOR
TEMPERATURE CONTROL
ROTARY SWITCH
FAN MOTOR
THERMISTOR
5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)
6 POLES, 16W
6 POLES, 21.3W 6 POLES, 24W
6 POLES, 21.4W
• NOTE: Specifications are subject to minor change without notice for further improvement.
1.3 SAFETY PRECAUTIONS
1.4 INSULATION RESISTANCE TEST
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 cir-
cuit.
3. After servicing, make an insulation resistance test
to prevent the customer's exposure to shock
hazards.
1. Unplug the power cord and connect a jumper
between 2 pins (black and white).
2. The grounding conductor (green or green and yel-
low) 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.
—3—
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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.
FAN/COOL/DRY
• Everytime you push this button, it will toggle between
COOL, FAN and DRY.
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.
Dry Fan
Cool
- 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)
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).
FAN SPEED
• Everytime you push this button it is set as follows.
{High(F2) Low(F1) High(F2)...}.
—4—
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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).
Power
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)...)
Temp
ON/OFF TIMER
- STOPPING OPERATION
Fan Speed
• Everytime you push this button, when the set is operating,
timer is set as follows.
Timer
Mode
(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.
Energy
Saver
- 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)
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.
COOL/FAN/DRY
How to Insert Batteries
• Do not use rechargeable batteries. Such bat-
teries
differ from standard dry cells in shape, dimen-
sions, and performance.
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.
• Remove the batteries from the remote con-
troller if the air conditioner is not going to be
used for an extended length of time.
3. Re-attach the cover.
—5—
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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 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.
Figure 3
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)
Figure 4
5. Pull the control board toward yourself.
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.
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 5
—6—
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Figure 6
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.
Figure 7
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.
Figure 8
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 9
—7—
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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.
Figure 11
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.
Figure 13
Figure 12
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)
—8—
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2.3.2 COMPRESSOR
1. Remove the front grille and cabinet.
Figure 14
(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.
Figure 15
(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.
Figure 16
(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)
Figure 17
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)
—9—
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Figure 18
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
Figure19
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.
—10—
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6-4. Remove the hose from the vacuum pump and
place it on the charging cylinder. See figure
23B. Open valve C.
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)
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.
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.
7-2. Connect the charging cylinder as shown in fig-
ure 21B. With valve C open, discharge the
hose at the manifold connection.
NOTES
Replacement of the refrigeration cycle.
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.
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.
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.
6. Evacuate as follows:
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 cut-
ter, 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 leak-
age of the pinch-off connection.
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 counter-
clockwise 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-clock-
wise. 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.
—11—
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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.
COMPOUND GAUGE
MANIFOLD
GAUGE
B
A
CONDENSER
(HIGH PRESSURE SIDE)
SEE INSETS
BELOW
COMPRESSOR
EVAPORATOR
(LOW PRESSURE SIDE)
CAPILLARY TUBE
LO
HI CHARGING CYLINDER
A
A
B
B
EXTERNAL VACUUM PUMP
C
Figure 20A-Pulling Vacuum
Figure 20B-Charging
—12—
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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.
INSIDE
OUTSIDE
AWNING
FENCE
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.
COOLED AIR
HEAT
RADIATION
CAUTION
ABOUT 1/4
"
All side louvers of the cabinet must remain
exposed on the outdside of the structure.
Over 20"
Figure 21
4. Install the unit slanted slightly so the back is slight-
1
ly lower than the front (about /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
INNER
SILL
NOTE: All supporting parts should be secured to firm
wood, masonry, or metal.
1. This unit is designed for installation in standard dou-
ble 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 bot-
tom of the sash to the window stool.
OUTER
SILL
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.
INDOORS
OUTDOORS
Figure 22
1" MAX.
WOOD STRIP MOUNTED
ON TOP OF INNER SILL
3/4"
CLEARANCE
STORM
WINDOW
FRAME
INNER
SILL
3. Install a second wood strip (approximately 6" long by
11/2" wide and same thickness as first strip) in the cen-
ter 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 neces-
sary.
WOOD STRIP
FOR BRACKET
L
OUTER
SILL
INDOORS
OUTDOORS
Figure 23
—13—
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Installation
HARDWARE
TYPE A: 11EA
(SHORT SCREW)
TYPE B: 4EA
(WOOD SCREW)
TYPE C: 3EA
BACKET)
DRAIN PIPE
(L
TYPE D: 1EA
(SEAL STRIP)
TYPE E: 1EA
(SASH SEAL)
TYPE F: 2EA
(GUIDE PANEL)
(Adhesive backed)
(Not adhesive backed)
3.2.2 BEFORE INSTALLATION
1. Insert 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.
TYPE A
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)
Figure 24
TYPE C
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.
SEAL STRIP
(TYPE D)
2. ATTACH L BRACKET
a. Install the L brackets behind the inner window sill, with
the short side of bracket as shown.
Figure 25
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.
CAUTION
CENTER LINE
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.
INNER SILL
ROOM SIDE
Figure 26
—14—
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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
INNER SILL
TYPE A
OUTER SILL
INSIDE
CENTER LINE
L bracket. See Figure. 27.
8"
SHORT SIDE
OUTSIDE
8"
Figure 27
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. While steadying the air conditioner, carefully bring the
window sash down behind the upper guide of the air
conditioner, as shown in Figure. 29.
CENTER LINE
Figure 28
WINDOW FRAME
UPPER GUIDE
SEAL
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.
ABOUT 1/4"
BOTTOM
GUIDE
Figure 29
L
BRACKET
L BRACKET
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.
TYPE A
SASH SEAL
(TYPE E)
TYPE B
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.
Figure 30
hang
push
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)
Figure 31
DRAIN CAP
DRAIN PIPE
—15—
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REMOVAL FROM WINDOW
Turn the air conditioner off, disconnect the power cord, remove the L bracket and the screws installed through the top and bot-
tom 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.
3.3 ELECTRICAL DATA
Line Cord Plug
Use Wall Receptacle
Power Supply
Do not under any
circumstances cut
or remove the
grounding prong
from the plug.
Use 15 AMP, time
delay fuse, or circuit
breaker.
Power supply cord with
3-prong grounding plug
Standard 125V, 3-wire grounding
receptacle rated 15A, 125V AC
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.
4. TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS (unit: mm [in])
21
9
21
42 (1 /32")
370 (14 /16")
472 (18 9/16")
42 (1 /32")
3
120 (4 /4")
3
27.5 (1 /32")
22.5(0.8 3/32")
155(6 3/32")
9
370 (14 /16")
9
472 (18 /16")
—16—
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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.
ROOM AIR CONDITIONER
CYCLE OF REFRIGERATION
EVAPORATOR COILS
CONDENSER COILS
VAPOR INLET
SUCTION LINE
COOL LOW PRESSURE VAPOR
HOT
DISCHARGED
AIR
COMPLETE LIQUID
BOIL OFF POINT
COOLED
AIR
ROOM AIR HEAT LOAD
OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH
MOTOR
DISCHARGE
LINE
NOT HIGH PRESSURE
VAPOR
COMPRESSOR
OIL
LIQUID
PRESSURE
DROP
LIQUID OUTLET
(LIQUID REFRIGERANT)
HIGH PRESSURE VAPOR
LIQUID REFRIGERANT
LOW PRESSURE VAPOR
CAPILLARY TUBE
Figure 32
—17—
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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
Check cold air
circulation for smooth
flow.
Check outdoor coil
(heat exchanger) and
fan operation.
Check heat load
increase.
Clean condenser.
Dirty indoor coil
(heat exchanger)
Check gas leakage.
Repair gas leak.
Not on separate circuit
Malfunction of fan.
Check inside gas
pressure.
Replacement of unit if
the unit is beyond repair.
Clogging of air filter.
Obstruction at air outlet.
Remove obstruction.
Adjust refrigerant
charge.
Malfunction of
compressor.
Check clogging in refrigera-
tion circuit.
Replacement of
compressor.
Satisfactory operation
with temperature
Repair clogging in
refrigeration circuit.
difference of inlet & outlet
air; 55~59°F (13~15°C)
—18—
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Fails to Start
Check of circuit breaker
and fuse.
Check of power source.
Check of control panel
setting.
Check control panel.
Compressor fails only to
start.
Fan only fails to start.
Improper wiring.
Improper thermistor
setting
Drop of power voltage.
Defect of fan motor
capacitor.
Defect of compressor
capacitor.
Loose terminal
connection
Irregular motor
resistance (Ω)
Irregular motor
insulation (Ω)
Capacitor check.
Replacement.
Improper wiring
Replacement of fan motor.
Regular but fails to start.
Irregular motor resistance (Ω)
Irregular motor insulation (Ω)
Replacement of compressor.
(Locking of piston, metal.)
Replacement of compressor
(Motor damaged).
—19—
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ELECTRIC PARTS TROUBLESHOOTING GUIDE:
• The unit does not operate.
Possible Trouble 1
NO
•
•
Check the Fuse.
Check the wiring diagram.
Is the Trans output power
AC 115V?
YES
NO
NO
•
Check the Main
P.W.B pattern.
Is the Trans output power
about AC 14V?
Is shorted the Trans. output?
YES
YES
• Exchange the Trans.
Exchange D02D~D05D.
•
NO
NO
Is output Voltage of IC01D
DC 12V?
• Exchange IC01D.
YES
• Exchange IC02D.
Is output Voltage of IC02D
DC 5V?
YES
NO
NO
Is the reset circuit all right?
(The No.16 of Micom
is 5V.)
• Exchange IC01A.
YES
Is the
• Connect connector
exactly.
connection between
Main and Display
all right?
YES
• Check the P.W.B
pattern.
NO
Is the voltage No.20 of Micom
DC 5V?
YES
Exchange Main P.W.B Ass'y.
—20—
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• The compressor does not operate.
• Set the Temp. setting to higher Temp.
Possible Trouble 2
Is Temp.
setting set lower than Room
Temp.-0.5°C?
NO
NO
YES
NO
NO
Is the voltage No.11
of IC01M 0V?
Is the voltage N0.6 of
Is the Unit for 3 minutes
delay?
IC01M DC 5V?
YES
YES
YES
• Check the RY-COMP.
• Check the wiring
Diagram.
• Exchange IC01M.
• Wait 3 Minutes
• Exchange MAIN
P.W.B Ass'y.
• The compressor always operate.
Possible Trouble 3
• Connect LEAD Wire to
RY-COMP again.
NO
Is the wire connection of
RY-COMP all right?
YES
• Check the RY-COMP.
• Fan does not operate.
Possible Trouble 4
NO
Is the voltage NO.2 or 4
of IC01M DC 5V?
• Exchange IC01M.
• Exchange IC01M.
YES
NO
Is the voltage NO.13 or 15
of IC01M 0V?
YES
• Check the RY-Hi or
RY-Lo.
•
Check the wiring diagram.
—21—
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• Romote controller does not operate.
(only for M-5400, M-6000, M-7000)
Possible Trouble 5
NO
NO
Is the voltage of Battery
about over 2.3V?
• Exchange the battery.
YES
Is the voltage No.10
of CN-DISP2 on Main P.W.B
Ass'y DC 5V?
•
Check the P.W.B pattern.
YES
• Connect connector to
CN-DISP2 exactly.
NO
Is the connection of
CN-DISP2 all right?
YES
•
Exchange Receiver Ass'y.
• It displays abnormally on Display P.W.B Ass'y.
Possible Trouble 6
NO
• Exchange IC01G.
Is the IC01G all right?
YES
NO
• Connect connector
to CN-DISP2 exactly.
NO
NO
Is the connection of
CN-DISP2 all right?
YES
Does the Q12G,
Q13G, Q14G operate normally
on main P.W.B Ass'y?
• Exchange Q12G,
Q13G, Q14G
YES
• Exchange the display
P.W.B Ass'y.
—22—
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ROOM AIR CONDITIONER VOLTAGE LIMITS
NAME PLATE RATING
115V ± 10%
MINIMUM
103.5V
MAXIMUM
126.5V
COMPLAINT
CAUSE
REMEDY
Fan motor will not run.
No power
Check voltage at outlet. Correct if none.
Power supply cord
Rotary switch
Check voltage to rotary switch. If none, check
power supply cord. Replace cord if circuit is
open.
Check switch continuity. Refer to wiring diagram
for terminal identification. Replace switch if
defective.
Wire disconnected or
connection loose
Connect wire. Refer to wiring diagram for
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.
—23—
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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
Worn bearings
Tighten it.
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,
fan motor runs.
Voltage
Wiring
Check voltage. See the limits on the preceding
page. If not within limits, call an electrician.
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
capacitor before
servicing.)
Check the capacitor.
Replace if not within ±10% of manufacturer’s
rating, replace if shorted, open, or damaged.
Compressor
Overload
Voltage
Check the compressor for open circuit or
ground. If open or grounded, replace the
compressor.
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
overload.
Check the voltage. See the limits on the
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.)
—24—
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COMPLAINT
CAUSE
Fan motor
REMEDY
Compressor cycles on
overload
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.
Condenser fins
(damaged)
If the condenser fins are closed over a large
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.
Check the system for a restriction.
If restricted, clean or replace.
Refrigeration system
Air filter
Insufficient cooling.
Excessive noise.
Unit undersized
Blower or fan
Determine if the unit is properly sized for the
area to be cooled.
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.
—25—
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5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM
• MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011, LWJ0611PCG, LWC061JGMK1
POWER INPUT
1
POWER INPUT
1
WH(BL)
(Ribbed)
BK(BR)
(Plain)
WH(BL)
(Ribbed)
BK(BR)
(Plain)
GN(GN/YL)
GN/YL(GN)
THERMISTOR
CN-TH1
THERMISTOR
CN-TH1
BK
RD
BL
BK
RD
BK
BL
RD
BK
BL
RD
OR(BR)
YL
6
4
6
4
2
7
2
7
MOTOR
MOTOR
OR(BR)
YL
OR(BR)
YL
OR(BR)
YL
GN/YL
(GN)
RY-L RY-H
CAPACITOR
CAPACITOR
F
F
C
OR
BK
RD
C
OR
BK
RD
SYNC
MOTOR
SYNC
MOTOR
WH
BK
WH
BK
H
H
RY-SYNC
RY-SYNC
5
ZNR01J
RY-COMP
ZNR
BK
RD
BL
BK
RD
BL
R
S
C
R
S
C
RY-COMP
5
COMP.
COMP.
3
8
3
8
4
3
TRANS
TRANS
FORMER
BR
BL
BL
FORMER
FUSE 250V/T2A
OLP
OLP
FUSE 125V 2A
(115V/T2A)
3854AR2330K
3854A20022K
WIRING DIAGRAM
WIRING DIAGRAM
LOCATION
Q'TY
DESCRIPTION
NO.
PER SET
1
2
3
4
5
6
7
8
POWER CORD ASSEMBLY
FAN MOTOR
1
1
1
1
1
1
1
1
COMPRESSOR
DISPLAY P.W.B ASSEMBLY
MAIN P.W.B ASSEMBLY
THERMISTOR
CAPACITOR
OWERLOAD PROTECTOR
—26—
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5.2 ELECTRONIC CONTROL DEVICE
—27—
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5.3 COMPONENTS LOCATION
(FOR MAIN P.W.B ASM)
5.4 COMPONENTS LOCATION
(FOR DISPLAY P.W.B ASM)
—28—
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6. EXPLODED VIEW
W48602
559011
130910
554030
149980
349480
267110
352380
135312
359012
346811
352390
W48602
152302
354210
130410
135313
W0CZZ
264110
552111
567502
554160
352115
352113
237200
249950
268714
263230
35211A
550140
238310 268712
—29—
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7. SERVICE PARTS LIST
PART NO
M5203R
LOCATION NO
DESCRIPTION
REMARKS
M5403R
M5203L
130410
130910
135312
135313
137215
149980
152302
238310
249950
263230
264110
267110
268712
268714
346811
349480
352113
352115
35211A
352380
352390
354210
359012
550140
552111
554030
554160
559011
567502
W0CZZ
W48602
BASE ASSY, SINGLE
CABINET ASSY ,SINGLE
GRILLE ASSY, FRONT(SINGLE)
GRILLE ASSY, INLET
PANEL, CONTROL
3041A10011E
3091A10020A
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
3531AR1644H
3530A10039A
3720A20017A
4998A10006A
5231AR2148A
3831A10001F
3531AR1644U
3720A20111A
4998A10008A
SHROUD
FILTER(MECH), A/C
ESCUTCHEON
3831A10013A
CONTROL BOX ASSY, SINGLE
THERMISTOR ASSY
POWER CORD ASSY
REMOTE CONTROLLER ASSY
PWB(PCB) ASSY, DISPLAY
PWB(PCB) ASSY, MAIN
MOTOR ASSY, SINGLE
ORIFICE
4995A20127D 4995A20127A 4995A20127G
6323A20003D
2H00677P
6711A20034A
6871A20115B
6711A20034U
6871A20142A
6871A10013M 6871A10013C 6871A10031B
4681A10002A 4681A10002F 4681A10002H
4948A10007A
TUBE, DISCHARGE
TUBE ASSY, EVPORATOR IN
TUBE ASSY, SUCTION SINGLE
AIR GUIDE
5210A20252A
5211A10063A
5211A10062A
5238A20004A
5210A20511A
5211A10063C
5211A10062B
5238A20004B
AIR GUIDE ASSY
5239A30003A
EVAPORATOR ASSY, FIRST
FAN, TURBO
5421A10008B
5900A20005A
5421A20016H
5900A10005A
ISOLATOR, COMP
5040AR4195A
TUBE ASSY, CAPILLARY
CONDENSER ASSY, FIRST
COMPRESSOR
5211A10065B
5403A20038D
2520UABC2EA
5900A20006A
6750U-L050A
5211AR3332R
5403A20009E
5416A20013M
5900A20017A
6750A30001F
FAN, PROPELLER
O.L.P
CAPACITOR, DRAWING
CLAMP, SPRING
6120AR2359V
3H02932B
—30—
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PART NO
LOCATION
NO
DESCRIPTION
REMARK
M6003R
WM-6011
LWJ0611PCG LWC061JGMK1
130410
130910
135312
135313
137215
149980
152302
238310
249950
263230
264110
267110
268712
268714
346811
349480
352113
352115
35211A
352380
352390
354210
359012
550140
552111
552102
554030
554160
559011
567502
W0CZZ
BASE ASSY, SINGLE
3041A10011E 3041A10011E 3041A10011E 3041A10011E
3091A10020A 3091A10020A 3091A10020D 3091A10020D
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
CABINET ASSY, SINGLE
GRILLE ASSY, FRONT(SINGLE) 3531AR1644H 3531AR1644T 3531AR1644T 3531AR1644T
GRILLE ASSY, INLET
PANEL, CONTROL
3530A10039A 3530A10039A 3530A10039A 3530A10039A
3720A20017A 3720A20017A 3720A20017A 3720A20017A
4998A10008A 4998A10008A 4998A10006A 4998A10006A
5231AR2148A 5231AR2148A 5231AR2148G 5231AR2148G
3831A10001F 3831A10001G 3831A10001G 3831A10001G
4995A20127D 4995A20127E 4995A20127E 4995A20127E
6323A20003D 6323A20003D 6323A20003D 6323A20003D
SHROUD
FILTER(MECH), A/C
ESCUTCHEON
CONTROL BOX ASSY, SINGLE
THERMISTOR ASSY
POWER CORD ASSY
REMOTE CONTROLLER ASSY
PWB(PCB) ASSY, DISPLAY
PWB(PCB) ASSY, MAIN
MOTOR ASSY, SINGLE
ORIFICE
2H00677P
2H00677P
2H00677P
2H00677P
6711A20034A 6711A20034E 6711A20034E 6711A20034E
6871A20115B 6871A20115B 6871A20193B 6871A20193B
6871A10013M 6871A10013D 6871A20188Q 6871A20188Q
4681A10002C 4681A10002C 4681A10012G 4681A10012G
4948A10007A 4948A10007A 4948A10007A 4948A10007A
5210A20511A 5210A20511A 5210A20252A 5210A20252A
5211A10063C 5211A10063C 5211A10063E 5211A10063E
5211A10062B 5211A10062B 5211A10062D 5211A10062D
5238A20004B 5238A20004B 5238A20005B 5238A20004B
5239A30003B 5239A30003A 5239A30003A 5239A30003A
5421A20016G 5421A20016G 5421A20016G 5421A20016G
5900A10005A 5900A10005A 5900A10005A 5900A10005A
5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A
TUBE, DISCHARGE
TUBE ASSY, EVPORATOR IN
TUBE ASSY, SUCTION SINGLE
AIR GUIDE
AIR GUIDE ASSY
EVAPORATOR ASSY, FIRST
FAN, TURBO
ISOLATOR, COMP
TUBE ASSY, CAPILLARY
TUBE CAPILLARY BEND
CONDENSER ASSY, FIRST
COMPRESSOR
5211AR3332R 5211AR3332R
-
-
-
-
5210A30018K 5210A30018K
5403A20009E 5403A20009E 5403A20038D 5403A20038D
2520UAMC2AA 2520UAMC2AA 2520UAMC2AA 2520UAMC2AA
5900A20017A 5900A20017A 5900A20006A 5900A20006A
FAN, PROPELLER
O.L.P
6750U-L004A 6750U-L004A
6120AR2359V 6120AR2359V 6120AR2359V 6120AR2359V
3H02932B 3H02932B 3H02932B 3H02932B
6750U-L060A 6750U-L060A
CAPACITOR, DRAWING
W48602 CLAMP, SPRING
—31—
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February, 2003
Printed in Korea
P/No.: 3828A20038B
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