LG M5203R Service Manual

LG M5203R Manual

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  • LG M5203R | Service Manual - Page 1
    website: http://www.lgservice.com e-mail: http://www.lgeservice.com/techsup.html ROOM AIR CONDITIONER SERVICE MANUAL CAUTION BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. Dry Fan Cool MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011, LWJ0611PCG, LWC061JGMK1
  • LG M5203R | Service Manual - Page 2
    4.3 TROUBLESHOOTING GUIDE 18 5. SCHEMATIC DIAGRAM 26 5.1 CIRCUIT DIAGRAM 26 5.2 ELECTRONIC CONTROL DEVICE 27 5.3 COMPONENTS LOCATION(FOR MAIN P.W.B ASM)........ 28 5.4 COMPONENTS LOCATION(FOR DISPLAY P.W.B ASM)... 28 6. EXPLODED VIEW 29 7. SERVICE PARTS LIST 30 1. PREFACE This service manual
  • LG M5203R | Service Manual - Page 3
    .) REFRIGERANT CONTROL REFRIGERANT CHARGE (R-22) INSIDE FAN OUTSIDE FAN AIR DISCHARGE CHASSIS PROTECTOR M5403R M5203R M5203L to minor change without notice for further improvement. 1.3 SAFETY PRECAUTIONS 1. When servicing, set the POWER of CONTROL BOARD to Off and unplug the power cord.
  • LG M5203R | Service Manual - Page 4
    1.5 LOCATIONS OF CONTROLS 1.5.1 CONTROLS Dry Fan Cool 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
  • LG M5203R | Service Manual - Page 5
    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
  • LG M5203R | Service Manual - Page 6
    2. DISASSEMBLY INSTRUCTIONS 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE 1. Disconnect the unit from source of and air guide. (See 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
  • LG M5203R | Service Manual - Page 7
    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 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
  • LG M5203R | Service Manual - Page 8
    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 11
  • LG M5203R | Service Manual - Page 9
    2.3.2 COMPRESSOR 1. Remove the front grille and cabinet. (Refer to Section 2.1.2) 2. Discharge the refrigerant by using a refrigerant recovery system. 3. Remove the overload protector. (Refer to Section 2.3.1) 4. After discharging the unit completely, unbrace the suction and discharge pipes at the
  • LG M5203R | Service Manual - Page 10
    9. Re-install by referring to procedures above. Figure 18 2.4 REFRIGERANT CYCLE 2.4.1 CONDENSER 1. Remove the cabinet. (Refer to Section 2.1.2) 2. Discharge the refrigerant by using a refrigerant recovery system. 3. Remove the air guide. (Refer to Section 2.2.1) 4. Remove 2 screws which fasten the
  • LG M5203R | Service Manual - Page 11
    2.4.3 CAPILLARY TUBE 1. Remove the cabinet. 2. Discharge the refrigerant by using a refrigerant recovery system. 3. Remove the air guide upper. (Refer to Section 2.2.1) 4. After discharging the refrigerant completely, unbraze the interconnecting tube of the capillary tube. 5. Remove the capillary
  • LG M5203R | Service Manual - Page 12
    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) COMPRESSOR SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) CAPILLARY TUBE LO
  • LG M5203R | Service Manual - Page 13
    OUTSIDE AWNING FENCE HEAT RADIATION 30"-60" Figure 21 ABOUT / 1 4 " Over 20" 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
  • LG M5203R | Service Manual - Page 14
    PIPE 10mm 16mm TYPE D: 1EA (SEAL STRIP) (Adhesive backed) TYPE E: 1EA (SASH SEAL) (Not adhesive backed) 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
  • LG M5203R | Service Manual - Page 15
    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. IMPORTANT : When the air conditioner drops into the L bracket, the air
  • LG M5203R | Service Manual - Page 16
    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]) 370 (14 9/16") 42 (1 21/32") 120 (4 3/4") 27.5 (1 3/32") 472 (18 9/16") 42 (1 21/32") 29
  • LG M5203R | Service Manual - Page 17
    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 COOLED AIR COMPLETE LIQUID BOIL OFF POINT SUCTION LINE COOL LOW PRESSURE VAPOR ROOM AIR
  • LG M5203R | Service Manual - Page 18
    4.3 TROUBLESHOOTING GUIDE In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application. Unit is running but
  • LG M5203R | Service Manual - Page 19
    Check of power source. Check of control panel setting. Fails to Start Check of circuit breaker and fuse. Check control panel. Compressor fails only to start. Drop of power voltage. Defect of compressor capacitor. Capacitor check. Replacement. Improper thermistor setting Loose terminal connection
  • LG M5203R | Service Manual - Page 20
    ELECTRIC PARTS TROUBLESHOOTING GUIDE: Possible Trouble 1 • The unit does not operate. NO Is the Trans output power AC 115V? YES Is the Trans output power NO about AC 14V? YES Is
  • LG M5203R | Service Manual - Page 21
    Is the voltage N0.6 of NO IC01M DC 5V? YES • Exchange IC01M. Possible Trouble 3 • The compressor always operate. Is the Unit for 3 minutes NO delay? YES • Check the RY-COMP. • Connect LEAD Wire to RY-COMP again. Possible Trouble 4 • Fan does not operate. Is the voltage NO.2 or 4 NO of
  • LG M5203R | Service Manual - Page 22
    of NO CN-DISP2 all right? YES • Exchange Receiver Ass'y. • Exchange the battery. • Check the P.W.B pattern. • Connect connector to CN-DISP2 exactly. Possible Trouble 6 • It displays abnormally on Display P.W.B Ass'y. NO Is the IC01G all right? YES NO Is the connection of NO CN-DISP2 all
  • LG M5203R | Service Manual - Page 23
    ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM 115V ± 10% 103.5V MAXIMUM 126.5V COMPLAINT Fan motor will not run. Fan motor runs. CAUSE No power Power supply cord Rotary switch Wire disconnected or connection loose Capacitor (Discharge capacitor before testing.) Will not rotate
  • LG M5203R | Service Manual - Page 24
    Blower Loose set screw Worn bearings Compressor will not run, fan motor runs. Voltage Wiring Thermistor Capacitor (discharge capacitor before servicing.) Compressor Overload Compressor cycles on overload. Voltage Overload REMEDY If cracked, out of balance, or partially missing, replace it
  • LG M5203R | Service Manual - Page 25
    cycles on overload CAUSE Fan motor Condenser air flow restriction Insufficient cooling. Excessive noise. Condenser fins (damaged) Capacitor Wiring Refrigeration system Air filter Unit undersized Blower or fan Copper tubing REMEDY If not running, determine the cause. Replace if required
  • LG M5203R | Service Manual - Page 26
    5. SCHEMATIC DIAGRAM 5.1 CIRCUIT DIAGRAM • MODEL : M5403R, M5203R, M5203L, M6003R, WM-6011, LWJ0611PCG, LWC061JGMK1 POWER INPUT WH(BL) BK(BR) (Ribbed) (Plain) BK BK GN(GN/YL) THERMISTOR RD RD 2 MOTOR BL OR(
  • LG M5203R | Service Manual - Page 27
    5.2 ELECTRONIC CONTROL DEVICE -27-
  • LG M5203R | Service Manual - Page 28
    5.3 COMPONENTS LOCATION (FOR MAIN P.W.B ASM) 5.4 COMPONENTS LOCATION (FOR DISPLAY P.W.B ASM) -28-
  • LG M5203R | Service Manual - Page 29
    6. EXPLODED VIEW 130910 554030 559011 W48602 149980 349480 152302 267110 352380 135312 359012 W48602 354210 346811 352390 130410 135313 264110 W0CZZ 237200 249950 268714 263230 238310 268712 550140 -29- 567502 554160 352115 552111 352113 35211A
  • LG M5203R | Service Manual - Page 30
    7. SERVICE PARTS LIST LOCATION NO DESCRIPTION 130410 130910 135312 135313 137215 149980 152302 238310 GUIDE ASSY EVAPORATOR ASSY, FIRST FAN, TURBO ISOLATOR, COMP TUBE ASSY, CAPILLARY CONDENSER ASSY, FIRST COMPRESSOR FAN, PROPELLER O.L.P CAPACITOR, DRAWING CLAMP, SPRING M5403R PART NO M5203R
  • LG M5203R | Service Manual - Page 31
    R 35211A TUBE ASSY, SUCTION SINGLE 5211A10062B 5211A10062B 5211A10062D 5211A10062D R 352380 AIR GUIDE 5238A20004B 5238A20004B 5238A20005B 5238A20004B R 352390 AIR GUIDE ASSY 5239A30003B 5239A30003A 5239A30003A 5239A30003A R 354210 EVAPORATOR ASSY, FIRST 5421A20016G 5421A20016G 5421A20016G
  • LG M5203R | Service Manual - Page 32
    P/No.: 3828A20038B February, 2003 Printed in Korea
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ROOM AIR CONDITIONER
SERVICE MANUAL
CAUTION
BEFORE SERVICING THE UNIT,
READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
MODEL :
M5403R, M5203R, M5203L, M6003R, WM-6011,
LWJ0611PCG, LWC061JGMK1
Dry
Fan
Cool