Goldstar M6003R User Manual

ROOM AIR CONDITIONER  
SERVICE MANUAL  
CAUTION  
BEFORE SERVICING THE UNIT,  
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.  
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MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011,  
LWJ0611PCG, LWC061JGMK1  
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 M.  
—3—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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—  
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 ()  
Irregular motor  
insulation ()  
Capacitor check.  
Replacement.  
Improper wiring  
Replacement of fan motor.  
Regular but fails to start.  
Irregular motor resistance ()  
Irregular motor insulation ()  
Replacement of compressor.  
(Locking of piston, metal.)  
Replacement of compressor  
(Motor damaged).  
19—  
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—  
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—  
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—  
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—  
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 manufacturers  
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—  
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—  
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—  
5.2 ELECTRONIC CONTROL DEVICE  
27—  
5.3 COMPONENTS LOCATION  
(FOR MAIN P.W.B ASM)  
5.4 COMPONENTS LOCATION  
(FOR DISPLAY P.W.B ASM)  
28—  
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—  
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—  
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—  
February, 2003  
Printed in Korea  
P/No.: 3828A20038B  

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