LG M5404R Air Conditioner Instruction Manual

July 18, 2024
LG

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LG Room
Air Conditioner
SERVICE MANUAL
MODEL: ACQ058PL
KG5200ER
LW5200ER
WG5200ER
WG6000R
KG6000R
M5404R
WG5200R
M6004R
HBLG6000R
HBLG5200E
ACQ052PK
LW7000R
WM-5031
LW050CE
LWJ0515PAG
LW5200R

M5404R Air Conditioner

CAUTION

  • BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.
  • ONLY FOR AUTHORIZED SERVICE PERSONNEL.

PREFACE

This service manual provides various service information, including the mechanical and electrical parts, etc.
This room air conditioner was manufactured and assembled under a strict quality control system.
The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.
1.1 FEATURES

  • DESIGNED FOR COOLING ONLY
  • POWERFUL AND INCREDIBLE COOLING
  • TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE
  • WASHABLE ONE-TOUCH FILTER
  • COMPACT SIZE

1.2 SPECIFICATIONS

MODELS



ITEMS

| WG5200ER, LW5200ER, HBLG5200E, LWC051JGMK2 KG5200ER ACQ058PL|



LW050CE

| WG5200R ACQ052PK M5404R WM5031 LWJ0515PAG LW5200R| ****

WG6000R M6004R KG6000R HBLG6000R

| ****


LW7000R

---|---|---|---|---|---
COOLING CAPACITY (BTU/h)| 5,200| 5,050| 5,250| 6,000| 76,000
POWER SUPPLY (Phase, V, Hz)| 1ø, 115V, 60HZ
INPUT (W)| 470/480| 520| 540| 620| 720
OPERATING CURRENT (AMP.)| 4.3/4.4| 4.8| 5.0| 5.8| 6.7
REFRIGERANT CONTROL| CAPILLARY TUBE
REFRIGERANT CHARGE (R-22)| 330g (11.6 Oz)| 220g(7.8 Oz)| 235g (8.3 Oz)| 315g (11.1 Oz)
INSIDE FAN| TURBO
OUTSIDE FAN| PROPELLER FAN WITH SLINGER RING
AIR DISCHARGE| 2-WAY (RIGHT AND LEFT)
CHASSIS| TOP-DOWN


PROTECTOR

| •  OVERLOAD PROTECTOR FOR COMPRESSOR
•  INTERNAL PROTECTOR FOR FAN MOTOR
TEMPERATURE CONTROL| THERMISTOR
ROTARY SWITCH| 5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)
FAN MOTOR| 6 POLES, 21W| 6 POLES, 19W| 6 POLES, 21W| 6 POLES, 27W

  • NOTE: Specifications are subject 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.
  2. Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.
  3. After servicing, make an insulation resistance test to prevent the customer’s exposure to shock hazards.

1.4 INSULATION RESISTANCE TEST

  1. Unplug the power cord and connect a jumper between 2 pins (black and white).
  2. The grounding conductor (green or green and yellow) is to be open.
  3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all Mode [except POWER OFF].
  4. The value should be over 1 MΩ.

1.5 LOCATIONS OF CONTROLS
1.5.1 CONTROLS 

LG M5404R Air Conditioner - LOCATIONS

1.5.2 REMOTE CONTROLLER

LG M5404R Air Conditioner - LOCATIONS1

How to Insert Batteries

  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.

  3.  Re-attach the cover.

  • Do not use rechargeable batteries. Such batteries differ from standard dry cells in shape, dimensions, and performance.
  • Remove the batteries from the remote controller if the air conditioner is not going to be used for an  extended length oftime.

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS
2.1.1 FRONT GRILLE

  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.

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 9 screws that secure the cabinet to the base pan and condenser. (See Figure 3)
    LG M5404R Air Conditioner - PARTS2

  4. Lift the cabinet from the unit.

  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)

  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 9 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.)

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 brace to air guide upper and shroud. (See Figure 6)

  6.  Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6)

  7.  Lift air guide upper upward.

  8. Re-install by referring to the procedures above.

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)
    LG M5404R Air Conditioner - AIR GUIDE UPPER1

  7. Remove 2 screws that secures the shroud to channel of condenser.

  8.  Press the snap area of shroud with your thumbs.
    This allows you to remove it from the condenser.

  9.  Lift the compressor upward with the evaporator and condenser. (See Figure 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)
    LG M5404R Air Conditioner - AIR GUIDE UPPER3

  12.  Pull the fan and turbo fan outward.

  13. Remove the shroud.

  14.  Re-install by referring to the procedures above.

2.2.3 MOTOR

  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.

2.2.4 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.

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)

LG M5404R Air Conditioner - MOTOR2

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 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)

2.3.4 THERMISTOR

  1. Remove the cabinet. (Refer to Section 2.1.2)
  2. Remove the control board. (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)

LG M5404R Air Conditioner - MOTOR5

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)

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 air guide. (Refer to Section 2.1.3)
  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

  1. Remove the cabinet. (Refer to Section 2.1.2)
  2. Discharge the refrigerant by using a refrigerant recovery system.
  3. Remove 2 screws which fasten the condenser. (See Figure 19)
  4. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.
  5. Remove the condenser.
  6. Re-install by referring to the procedures above.

2.4.2 EVAPORATOR

  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 upper. (Refer to Section 2.2.1)
  4. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections.
  5. Remove the evaporator.
  6. Re-install by referring to the procedures above.

2.4.3 CAPILLARY TUBE

  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 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. When replacing the refrigerating cycle, be sure to discharge the refrigerant by using a refrigerant recovery system.

  2. After discharging the unit completely, remove the desired components, and unbraze the pinch-off tubes.

  3. Solder service valves into the pinch-off tube ports, leaving the valves open.

  4. Solder the pinch-off tubes with service valves.

  5. After completing the above procedures, the valve must be closed and left in place on the system for any subsequent procedures.

  6. Evacuate as follows:
    6-1. Connect the vacuum pump, as illustrated in figure 20A.
    6-2. Start the vacuum pump. Slowly open manifold valves A and B with two full turns counterclockwise and leave the valves closed. The vacuum pump is now pulling through valves A and B up to valve C by means of manifold and the entire system.
    CAUTION : 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-clockwise. This will keep oil from foaming and being drawn into the vacuum pump.
    6-3. Operate the vacuum pump for 20 to 30 minutes, until 600 micron vacuum is obtained. Close valves A and B and observe vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop the vacuum pump.
    6-4. Remove the hose from the vacuum pump and place it on the charging cylinder. See figure 20B. Open valve C. Discharge the line at the manifold connection.
    6-5. The system is now ready for final charging.

  7. Recharge as follows:
    7-1. Rotary compressor systems are charged from the high-side. If the total charge cannot be put in the high-side, the balance will be put in the suction line through the access valve which is installed as the system is opened.
    7-2. Connect the charging cylinder as shown in figure 20B. With valve C open, discharge the hose at the manifold connection.
    7-3. Open valve A and allow the proper charge to enter the system. Valve B is still closed.
    7-4. If more charge is required, the high-side will not take it. Close valve A.
    7-5. With the unit running, open valve B and add the balance of the charge. a. Do not add the liquid refrigerant to the lowside. 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.
    7-6. When the unit is operating correctly, use the pinch-off tool with the unit still running and the clamp on the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder the pinch-off tube closed. Turn off the unit, allow setting for a while and then test the leakage of the pinch-off connection.

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.

LG M5404R Air Conditioner - Vacuum

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. The outside of the cabinet must extend outward for at least 10″ and there should be no obstacles, such as a fence or wall, within 20″ from the back of the cabinet because it will prevent heat radiation of the condenser. Restriction of outside air will greatly reduce the cooling efficiency of the air conditioner.
    CAUTION
    All side louvers of the cabinet must remain exposed on the outdside of the structure.

  4.  Install the unit slanted slightly so the back is slightly lower than the front (about 1/4″). 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
NOTE: All supporting parts should be secured to firm wood, masonry, or metal.

  1. This unit is designed for installation in standard double 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 bottom of the sash to the window stool.
  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.
  3.  Install a second wood strip (approximately 6″ long by 11 /2″ wide and same thickness as first strip) in the center of the outer sill flush against the back off the inner sill. This will raise the L bracket as shown Figure. 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 necessary.

LG M5404R Air Conditioner - Vacuum2

Installation Kit (Some models)

LG M5404R Air Conditioner - Some models

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), asshown Figure. 24.

  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)

LG M5404R Air Conditioner - BEFORE INSTALLATION

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.

  2. ATTACH L BRACKET
    a. Install the L brackets behind the inner window sill, with the short side of bracket as shown.
    Use the 2 screws (TYPE A) provided.
    b. The bracket helps to hold unit securely in place. Be sure to place bracket edge flush against back of inner sill. See Figure. 27.
    CAUTION
    During the following step, hold unit firmly until window sash is lowered to top channel behind side panel frames. Personal injury or property damage may result if unit falls from window.

  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 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.

  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.

  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.
    b. Fasten the L bracket using a (TYPE A) screw, as shown in Figure. 30.
    LG M5404R Air Conditioner - BEFORE INSTALLATION1

  6. a. Remove the screws that secure the cabinet and base pan in the right side.
    b. Fasten the suport bracket (TYPE G) using a removed screw. Attach the suport bracket (TYPE G) in the inner window sill with a screw (TYPE B), as shown Figure. 31.

  7. Window installation of room air conditioner is now completed. See ELECTRICAL DATA for attaching power cord to electrical outlet.

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. 32)
Press the drain pipe into the hole by pushing down and away from the fins to avoid injury.
REMOVAL FROM WINDOW
Turn the air conditioner off, disconnect the power cord, remove the L bracket, the screws and support bracket 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. Lift the air conditioner from the window and remove the sash seal from between the windows.

3.3 ELECTRICAL DATA

LG M5404R Air Conditioner - data

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.

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS (unit: mm [in])

LG M5404R Air Conditioner - data1

4.2 PIPING SYSTEM

LG M5404R Air Conditioner - data2

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 33 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle.

LG M5404R Air Conditioner - ROOM AIR CONDITIONER

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.

LG M5404R Air Conditioner - Ineffective Cooling

LG M5404R Air Conditioner - Fails to Start

ELECTRIC PARTS TROUBLESHOOTING GUIDE:

LG M5404R Air Conditioner - ELECTRIC PARTS

LG M5404R Air Conditioner - ELECTRIC PARTS1

LG M5404R Air Conditioner - ELECTRIC PARTS2

ROOM AIR CONDITIONER VOLTAGE LIMITS

NAME PLATE RATING MINIMUM MAXIMUM
**** 115V ± 10% **** 103.5V **** 126.5V
COMPLAINT CAUSE REMEDY
--- --- ---
Fan motor will not run. No power Check voltage at outlet. Correct if none.
Power supply cord Check voltage to rotary switch. If none, check power supply

cord. Replace cord if circuit is open.
Rotary switch| Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective.
Wire disconnected or connection loose| Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal.
Capacitor (Discharge capacitor before testing.)| Test capacitor.
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.
COMPLAINT| CAUSE| REMEDY
---|---|---
Fan motor noise.| Fan| If cracked, out of balance, or partially missing, replace it.
Blower| If cracked, out of balance, or partially missing, replace it.
Loose set screw| Tighten it.
Worn bearings| If knocking sounds continue when running or loose, replace the motor. If the motor hums or noise appears to be internal while running, replace motor.
Compressor will not run, fan motor runs.| Voltage| Check voltage. See the limits on the preceding page. If not within limits, call an electrician.
Wiring| 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| Check the compressor for open circuit or ground. If open or grounded, replace the compressor.
Overload| 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.| Voltage| 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.)
COMPLAINT| CAUSE| REMEDY
---|---|---
Compressor cycles on overload| 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.
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.
Refrigeration system| Check the system for a restriction.
Insufficient cooling.| Air filter| If restricted, clean or replace.
Unit undersized| Determine if the unit is properly sized for the area to be cooled.
Excessive noise.| Blower or fan| Check the set screw, or clamp. If loose or miss- ing, correct. If the blower or fan is hitting scroll or barrier, rearrange the air handling parts.
Copper tubing| Remove the cabinet and carefully rearrange the tubing not to contact the cabinet, compressor, shroud, and barrier.

SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM

LG M5404R Air Conditioner -DIAGRAM

LOCATION NO. DESCRIPTION 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.B ASSEMBLY 1
6 THERMISTOR 1
7 CAPACITOR 1
8 OWERLOAD PROTECTOR 1

5.2 ELECTRONIC CONTROL DEVICE

LG M5404R Air Conditioner -DIAGRAM1

LG M5404R Air Conditioner -DIAGRAM2

EXPLODED VIEW

LG M5404R Air Conditioner - EXPLODED VIEW

SPECIFICATION AND PARTS LIST

**LOCATION NO** **DESCRIPTION** PART NO **REMARKS**
**WG5200R** **M5404R** **WG5200ER** **KG5200ER**
**LW050CE** **HBLG5200E**
130410 BASE ASSEMBLY,SINGLE 3041A10011E 3041A10011E
3041A10011E 3041A10011E 3041A10011E R
130910 CABINET ASSEMBLY,SINGLE 3091A10020D 3091A10020D
3091A10020D 3091A10020D 3091A10020D R
135312 GRILLE ASSEMBLY, FRONT(SINGLE) 3531AR1644H 3531AR1644H
3531AR1644H 3531AR1644T 3531A10130B R
135313 GRILLE ASSEMBLY, INLET 3530A10039A 3530A10039A
3530A10039A 3530A10039A 3530A10039A R
135500 COVER 3550U-L006A 3550U-L006A
3550A30048A R
148000 BRACE 4800A30003A 4800A30003A
4800A30003A 4800A30003A R
149980 SHROUD 4998A10008A 4998A10008A
4998A10008A 4998A10008A R
152302 FILTER(MECH),A/C 5231AR2148G 5231AR2148G
5231AR2148G 5231AR2148G R
159900-1 VANE,VERTICAL 5990AR3190A 5990AR3190A
5990AR3190C 5990AR3190A R
159900-2 VANE,VERTICAL 5990AR3190B 5990AR3190B
5990AR3190D 5990AR3190B R
237200 PANEL, CONTROL 3720A20017A 3720A20017A
3720A20017A 3720A20017A R
238310 ESCUTCHEON 3831A10001F 3831A10001F
3831A10001G 3831A10001F R
249950 CONTROL BOX ASSEMBLY 4995A20127H 4995A20127H
4995A20127H 4995A20127E 4995A20127H R
263230 THERMISTOR ASSEMBLY 6323A20003D 6323A20003D
6323A20003D 6323A20003D 6323A20003D R
264110 POWER CORD ASSEMBLY 2H00677P 2H00677P
2H00677P R
267110 REMOTE CONTROLLER ASSEMBLY 6711A20034A 6711A20034A
6711A20034A 6711A20034E 6711A90019B R
268712 PWB(PCB) ASSEMBLY, DISPLAY 6871A20193B 6871A20193B
6871A20193B 6871A20193B 6871A20193B R
268714 PWB(PCB) ASSEMBLY, MAIN 6871A20188L 6871A20188L
6871A20188L 6871A20188Q 6871A20188L R
346811 MOTOR ASSEMBLY,SINGLE 4681A10012B 4681A10012B
4681A10002N 4681A10012L 4681A10002P R
349480 ORIFICE 4948A10007A 4948A10007A
4948A10007A 4948A10007A R
352113 TUBE,DISCHARGE 5210A21100A 5210A21100A
5210A21100A 5210A21100A R
352115 TUBE ASSEMBLY, EVAPORATOR IN 5211A10063A 5211A10063A
5211A10063C 5211A10063A 5211A10063C R
35211A TUBE ASSEMBLY, SUCTION SINGLE 5211A10062A 5211A10062A
5211A10062B 5211A10062A 5211A10062B R
352390-1 AIR GUIDE ASSEMBLY 5239A30003A 5239A30003A
5239A30003A 5239A30003A 5239A30003A R
352390-2 AIR GUIDE ASSEMBLY 5239A10005A 5239A10005A
5239A10005B 5239A10005A 5239A10005B R
352410 EVAPORATOR ASSEMBLY, FIRST 5421A10008B 5421A10008B
5421A20016G 5421A10008B 5421A20016G R
359012 FAN, TURBO 5900A20005A 5900A20005A
5900A20005A 5900A20005A R
550140 ISOLATOR,COMPRESSOR 5040AR4195A 5040AR4195A
5040AR4195A 5040AR4195A 5040AR4195A R
552111 TUBE ASSEMBLY, CAPILLARY 5211AR3332V 5211AR3332V
5211AR3332R 5211AR3332V 5211AR3332R R
554030 CONDENSER ASSEMBLY, FIRST 5403AR6200C 5403AR6200C
5403A20009E 5403AR6200C 5403A20009E R
554160 COMPRESSOR 2520UABC2EA 2520UABC2EA
5416A20014D 5416A20014D R
559010 FAN, AXIAL 5900A20017A 5900A20017A
5900A20017A 5900A20017A R
567502 O.L.P 6750U-L050A 6750U-L050A
6750A30001U 6750A30001U R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V
6120AR2359V 6120AR2359V R
W48602 CLAMP, SPRING 3H02932B 3H02932B
3H02932B R
LOCATION NO DESCRIPTION PART NO REMARKS
--- --- --- ---
WG6000R M6004R KG6000R ACQ058PL ACQ052PK
HBLG6000R LW5200ER WM-5031 LW7000R
130410 BASE ASSEMBLY,SINGLE 3041A10011E 3041A10011F
3041A10011E 3041A10011E 3041A10011E 3041A10011E
130910 CABINET ASSEMBLY,SINGLE 3091A10020D 3091A10020D
3091A10020D 3091A10020D 3091A10020D 3091A10020A
135312 GRILLE ASSEMBLY, FRONT(SINGLE) 3531AR1644H 3531A10064G
3531A10130B 3531AR1644T 3531AR1644T 3531AR1644T
135313 GRILLE ASSEMBLY, INLET 3530A10039A 3530A10039A
3530A10039A 3530A10039A 3530A10039A 3530A10039A
135500 COVER 3550U-L006A 3550A30048A
L006A 3550U-L005A R
148000 BRACE 4800A30003A 4800A30003A
4800A30003A 4800A30003A 4800A30003A R
149980 SHROUD 4998A10006A 4998A10008A
4998A10008A 4998A10008A 4998A10008A R
152302 FILTER(MECH),A/C 5231AR2148G 5231AR2148G
5231AR2148G 5231AR2148G 5231AR2148G R
159900-1 VANE,VERTICAL 5990AR3190A 5990A30005A
5990AR3190C 5990AR3190C 5990AR3190C R
159900-2 VANE,VERTICAL 5990AR3190B 5990A30005B
5990AR3190D 5990AR3190D 5990AR3190D R
237200 PANEL,CONTROL 3720A20017A 3720A20017A
3720A20017A 3720A20017A 3720A20017A R
238310 ESCUTCHEON 3831A10001F 3831A10001L
3831A10001F 3831A10001G 3831A10001F R
249950 CONTROL BOX ASSEMBLY 4995A20127H 4995A20127B
4995A20127H 4995A20127H 4995A20127E 4995A20127X
263230 THERMISTOR ASSEMBLY 6323A20003D 6323A20003D
6323A20003D 6323A20003D 6323A20003D 6323A20003D
264110 POWER CORD ASSEMBLY 2H00677P 2H00677P
2H00677P 2H00677P R
267110 REMOTE CONTROLLER ASSEMBLY 6711A20034A 6711A20035K
6711A90019B 6711A20034E 6711A20034E 6711A20034E
268712 PWB(PCB) ASSEMBLY, DISPLAY 6871A20193B 6871A20193C
6871A20193B 6871A20193B 6871A20193B 6871A20193B
268714 PWB(PCB) ASSEMBLY, MAIN 6871A20188L 6871A20188Z
6871A20188L 6871A20188L 6871A20188Q 6871A20188L
346811 MOTOR ASSEMBLY,SINGLE 4681A10012G 4681A10002H
4681A10012G 4681A10002P 4681A10012B 4681A10002K
349480 ORIFICE 4948A10007A 4948A10007A
4948A10007A 4948A10007A 4948A10007A R
352113 TUBE,DISCHARGE 5210A20252A 5210A21100A
5210A21100B 5210A21100A 5211A10129A R
352115 TUBE ASSEMBLY, EVAPORATOR IN 5211A10063E 5211A10063C
5211A10063E 5211A10063C 5211A10063A 5211A10063C
35211A TUBE ASSEMBLY, SUCTION SINGLE 5211A10062D 5211A10062B
5211A10062D 5211A10062B 5211A10062A 5211A10062C
352390-1 AIR GUIDE ASSEMBLY 5239A30003A 5239A30003A
5239A30003A 5239A30003A 5239A10005A 5239A30003A
352390-2 AIR GUIDE ASSEMBLY 5239A10005B 5239A10005B
5239A10005B 5239A10005B 5239A30003A
352410 EVAPORATOR ASSEMBLY, FIRST 5421A20016G 5421A20016G
5421A20016G 5421A20016H 5421A10008B 5421A20016G
359012 FAN, TURBO 5900A10005A 5900A10005A
5900A10005A 5900A20005A 5900A10005A R
550140 ISOLATOR,COMPRESSOR 5040AR4195A 5040AR4195A
5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A
552111 TUBE ASSEMBLY, CAPILLARY 5211AR3332X 5211AR3332R
5211AR3332X 5211AR3332R 5211AR3332V 5211AR3332S
554030 CONDENSER ASSEMBLY, FIRST 5403A20038D 5403A20009E
5403A20038D 5403A20009E 5403AR6200C 5403A20009F
554160 COMPRESSOR 2520UAMC2AA 5416A20013M
5416A20014Q 2520UABC2JA 2520UAFC2BA R
559010 FAN, AXIAL 5900A20006A 5900A20017A
5900A20017A 5900A20017A 5900A20017A R
567502 O.L.P 6750U-L004A 6750A30001F
6750A30001U 6750U-L050A 6750U-L005A R
W0CZZ CAPACITOR, DRAWING 6120AR2359V 6120AR2359V
6120AR2359V 6120AR2359V 0CZZA20001W R
W48602 CLAMP, SPRING 3H02932B 3H02932B
3H02932B 3H02932B R
LOCATION No. DESCRIPTION PART No. REMARKS
--- --- --- ---
LWJ0515PAG LW5200R
130410 BASE ASSEMBLY,SINGLE 3041A10011E 3041A10011E
130910 CABINET ASSEMBLY,SINGLE 3091A10020D 3091A10020D
135312 GRILLE ASSEMBLY,FRONT(INDOOR) 3531A10130F 3531AR1644T
135313 GRILLE,INLET 3530A10039A 3530A10039A
135500 COVER 3550U-L006A
148000 BRACE 4800A30003A 4800A30003A
149980 SHROUD 4998A10008A 4998A10008A
152302 FILTER(MECH),A/C 5231AR2148G 5231AR2148G
159900-1 VANE,VERTICAL 5990AR3190A 5990AR3190C
159900-2 VANE,VERTICAL 5990AR3190B 5990AR3190D
237200 PANEL,CONTROL 3720A20017A 3831A10001F
238310 ESCUTCHEON 3831A10001F 3831A10001F
249950 CONTROL BOX ASSEMBLY,SINGLE 4995A20127H 4995A20127H
263230 THERMISTOR ASSEMBLY 6323A20003D 6323A20003D
264110 POWER CORD ASSEMBLY 2H00677P 2H00677P
267110 REMOTE CONTROLLER ASSEMBLY 6711A20034E 6711A20034E
268712 PWB(PCB) ASSEMBLY,DISPLAY 6871A20193B 6871A20193B
268714 PWB(PCB) ASSEMBLY,MAIN(AC) 6871A20188L 6871A20188L
346811 MOTOR ASSEMBLY,SINGLE 4681A10012B 4681A10012L
349480 ORIFICE 4948A10007A 4948A10007A
352113 TUBE,DISCHARGE 5210A21100A 5210A21100A
352115 TUBE ASSEMBLY,EVAPORATOR IN 5211A10063A 5211A10063A
35211A TUBE ASSEMBLY,SUCTION SINGLE 5211A10062A 5211A10062A
352390-1 AIR GUIDE ASSEMBLY 5239A30003A 5239A30003A
352390-2 AIR GUIDE ASSEMBLY 5239A10005A 5239A10005A
354210 EVAPORATOR ASSEMBLY,FIRST 5421A10008B 5421A10008B
359012 FAN,TURBO 5900A20005A 5900A20005A
550140 ISOLATOR,COMP 5040AR4195A 5040AR4195A
552111 TUBE ASSEMBLY, CAPILLARY 5211AR3332V 5211AR3332V
554030 CONDENSER ASSEMBLY,FIRST 5403AR6200H 5403AR6200C
554160 COMPRESSOR SET 2520UABC2EA 2520UABC2JA
559010 FAN,PROPELLER 5900A20017A 5900A20017A
567502 O.L.P 6750U-L050A 6750U-L050A
W0CZZ CAPACITOR,DRAWING 6120AR2359V 6120AR2359V
W48602 CLAMP,SPRING 3H02932B 3H02932B
LOCATION No. DESCRIPTION PART No. REMARKS
--- --- --- ---

LW050CE
130410| BASE ASSEMBLY,SINGLE| 3041A10011E| R
130910| CABINET ASSEMBLY,SINGLE| 3091A10020D| R
135312| GRILLE ASSEMBLY, FRONT(SINGLE)| 3531AR1644T| R
135313| GRILLE ASSEMBLY, INLET| 3530A10039A| R
148000| BRACE| 4800A30003A| R
149980| SHROUD| 4998A10008A| R
152302| FILTER(MECH),A/C| 5231AR2148G| R
159900-1| VANE,VERTICAL| 5990AR3190C| R
159900-2| VANE,VERTICAL| 5990AR3190D| R
237200| PANEL,CONTROL| 3720A20017A| R
238310| ESCUTCHEON| 3831A10001G| R
249950| CONTROL BOX ASSEMBLY| 4995A20127E| R
263230| THERMISTOR ASSEMBLY| 6323A20003D| R
264110| POWER CORD ASSEMBLY| 2H00677P| R
267110| REMOTE CONTROLLER ASSEMBLY| 6711A20034E| R
268712| PWB(PCB) ASSEMBLY, DISPLAY| 6871A20193B| R
268714| PWB(PCB) ASSEMBLY, MAIN| 6871A20188Q| R
346811| MOTOR ASSEMBLY,SINGLE| 4681A10002L| R
349480| ORIFICE| 4948A10007A| R
35211A| TUBE ASSEMBLY, SUCTION SINGLE| 5211A10062A| R
352113| TUBE,DISCHARGE| 5211A10129A| R
352115| TUBE ASSEMBLY, EVAPORATOR IN| 5211A10063A| R
352390-1| AIR GUIDE ASSEMBLY| 5239A30003A| R
352390-2| AIR GUIDE ASSEMBLY| 5239A10005A| R
352410| EVAPORATOR ASSEMBLY, FIRST| 5421A10008B| R
359012| FAN, TURBO| 5900A10005A| R
550140| ISOLATOR,COMPRESSOR| 5040AR4195A| R
552102| TUBE, CAPILLARY BEND| 5210A30018H| R
552111| TUBE ASSEMBLY, CAPILLARY| 5211AR3332V| R
554030| CONDENSER ASSEMBLY, FIRST| 5403AR6200C| R
554160| COMPRESSOR| 5416A20014D| R
559010| FAN, AXIAL| 5900A20017A| R
567502| O.L.P| 6750A30001U| R
W0CZZ| CAPACITOR, DRAWING| 6120AR2359V| R
W48602| CLAMP, SPRING| 3H02932B| R
731273| INSTALL PART ASSEMBLY, SINGLE| 3127A20016B| R

**NOTE)*** Please ensure GCSC since these parts may be changed depending upon the buyer’s request. (GCSC WEBSITE http://biz.lgservice.com)

P/No.: 3828A20038L
January, 2005
Printed in Korea

References

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