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CONSUMER SERVICES TECHNICAL

EDUCATION GROUP PRESENTS

R-96

JOB AID

Part No. 8178279

2003

5000 & 6000 BTU

AIR CONDITIONERS

Models: ACM052MM,

ACM062MM, ACD052MM

Models: ACQ058MM &

ACQ062MM

Summary of Contents for ACD052MM

Page 1: ...CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R 96 JOB AID Part No 8178279 2003 5000 6000 BTU AIR CONDITIONERS Models ACM052MM ACM062MM ACD052MM Models ACQ058MM ACQ062MM ...

Page 2: ...er The Wiring Diagrams and Strip Circuits used in this Job Aid are typical and should be used for training purposes only Always use the Wiring Diagram supplied with the product when servicing the unit GOALS AND OBJECTIVES The goal of this Job Aid is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair the 2003 5000 6000 BTU Air Condit...

Page 3: ...58MM ACQ062MM 3 5 Removing The Power Cord And Capacitor Models ACM052MM ACM062MM ACD052MM 3 6 Removing The Power Cord And Capacitor Models ACQ058MM ACQ062MM 3 8 Removing The Fan Motor 3 10 Removing The Evaporator 3 14 Removing The Condenser 3 17 Removing The Overload Protector Compressor 3 18 COMPONENT TESTING 4 1 Temperature Control 4 1 Thermistor 4 1 Fan Speed Control 4 2 Capacitor 4 2 Fan Motor...

Page 4: ... iv NOTES ...

Page 5: ...have provided many important safety messages in this Job Aid and on the appliance Always read and obey all safety messages This is the safety alert symbol This symbol alerts you to hazards that can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING These words mean All safety messages will tell you what the potential hazard is ...

Page 6: ...ailure may occur at a later date due to ESD stress Use an antistatic wrist strap Connect the wrist strap to the green ground connec tion point or to an unpainted metal sur face in the appliance OR Touch your finger repeatedly to a green ground connection point or to an un painted metal surface in the appliance Before removing the part from its pack age touch the antistatic bag to a green ground co...

Page 7: ... WALL NOMINAL CAPACITY 05 5 000 BTU HR 07 7 000 BTU HR 08 8 000 BTU HR 10 10 000 BTU HR 12 12 000 BTU HR 15 15 000 BTU HR 18 18 000 BTU HR 21 21 000 BTU HR 24 24 000 BTU HR ELECTRICAL CODE 2 115 VOLT STANDARD EER 4 230 VOLT STANDARD EER 8 115 VOLT ENERGY STAR EER 9 230 VOLT ENERGY STAR EER FEATURE CODE M M MODEL YEAR OF INTRODUCTION L 2002 M 2003 ENGINEERING CHANGE 0 1 2 ETC SERIAL NUMBER QM M 01 ...

Page 8: ...RIAL NUMBER LABEL LOCATIONS The Technician Model Serial Number label location is shown below Model Serial Number Location The Consumer Model Serial Number label location is shown below Model Serial Number Location ...

Page 9: ...requency Hz 60 60 60 60 Amps Cooling 4 8 4 7 5 7 5 7 Fuse Size Amps 15 15 15 15 Power Cord Length ft Cabinet to Wall 6 ft 6 ft 6 ft 6 ft Power Cord Length m Cabinet to Wall 1 8 m 1 8 m 1 8 m 1 8 m Exterior Fan Control Rotary Electronic Electronic Rotary Thermostat Control Rotary Electronic Electronic Rotary Miscellaneous Weight lbs kg 52 5 24 54 24 5 54 24 5 54 24 5 Filter Washable L R Access Wash...

Page 10: ...or costs for units operated outside the United States MANUFACTURER SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES Some states do not allow the exclusion or limitation of incidental or consequential damages so this exclusion or limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Outside the Unit...

Page 11: ...e and Care Guide D The removal and reinstallation of your air conditioner if it is installed in an overhead or other inaccessible location or is not installed in accordance with published instal lation instructions E Repairs to parts or systems resulting from unauthorized modifications made to the appliance WHIRLPOOL CORPORATION SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES Some stat...

Page 12: ...1 8 NOTES ...

Page 13: ...or the weight of the air conditioner The air conditioner weighs between 56 lbs 25 kg and 80 Ibs 36 kg Do not install the air conditioner in an area where the front panel will be exposed to heat sources that will raise the panel surface tem perature above 120 F 50 C Air Conditioner Size A B 5000 to 6000 BTUs 25 to 38 16 63 5 cm to 40 6 cm 96 5 cm Handle the air conditioner with care Watch out for t...

Page 14: ...n so that water will run to the outside The tilt should be about 1 2 bubble B on a spirit level If the cabinet is not properly positioned reposi tion or shim it to provide the proper tilt 5 Secure the left curtain with one of the round headscrews F tothewindowchan nel If desired use alternate hole G at the top of the curtain to secure it to the window channel see the illustration at the top of the...

Page 15: ...s are shown below COMPONENT ACCESS Evaporator Temperature Control Fan Speed Control Power Cord Compressor Capacitor Overload Protector Condenser Temperature Sensor Tube Models ACQ058MM ACQ062MM Use An Electronic Control Assembly Instead Of Manual Controls Models ACQ058MM ACQ062MM Use A Thermistor In Place Of A Temperature Sensor Tube Fan Motor ...

Page 16: ...ews from each of the side curtains b Slide the curtains out of the top and bottom guides and remove them Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock b Pull the grille forward and remove it Grille Screws 2 of 4 Front Grille 4 To remove the front grille a Remove the four screws two on...

Page 17: ...curtain guide and remove the cover and the guide 6 To remove the screen a Remove the two screws from each side of the screen b Pull the ends of the screen from the slots in the side holders c Lift the screen from the unit Top Cover Screw 1 of 9 Screen Screw 1 of 4 Screen Top Curtain Guide Screw 1 of 2 ...

Page 18: ... ser vicing removethetwoscrewsfromthefan speed control or the temperature control Fan Speed Control Screws Temp Control Screws 7 Disconnect the wire connectors from the control terminals and remove the control from the mounting plate 8 If you are removing the temperature con trol unclip the temperature sensor tube from the holder on the evaporator Black Red White Power Cord Lead White Yellow Fan S...

Page 19: ...age 3 2 for the procedures 4 Remove the thermistor by unclipping it from the holder and disconnecting it from the control board see step 7 5 Remove the screw from the electronic control box assembly 6 Lift the two locking arms and pull the assembly forward 7 Disconnect the wires from the electronic control board terminals as follows White from L2 Gray from L1 Yellow from COMP Black from TURBO Blue...

Page 20: ...thesmoothpowercordlead con nector from fan speed control terminal 1 7 Remove the three screws from the control housing and and remove the housing Screw 1 of 3 Control Housing Smooth Power Cord Lead At Terminal 1 Control Mounting Plate Screw 1 of 4 1 Unplugairconditionerordisconnectpower 2 Remove the air conditioner from the win dow 3 Remove the side curtains and the front grille see page 3 2 for t...

Page 21: ...ve the capacitor Capacitor Cover Screws Capacitor Perform the following steps to reinstall the capacitor and power cord 1 Reconnect the wires to the capacitor ter minals see below and reinstall the ca pacitor 2 Reinstall the capacitor cover with its two screws 3 Mount the control housing with its three screws 4 Connect the smooth power cord lead to fan speed control terminal 1 5 Mount the control ...

Page 22: ...wire screws from the evaporator frame 5 Remove the electronic control assembly fromthehousing seesteps5and6on page 3 5 for the procedure 7 Remove the three screws from the control housing and and remove the housing 8 Remove the two screws from the capaci tor cover pull the cover forward and re move it Control Housing Capacitor Cover Screws 6 Disconnectthesmoothpowercordlead con nector from electro...

Page 23: ...form the following steps to reinstall the capacitor and power cord 1 Reconnect the wires to the capacitor ter minals see below and reinstall the ca pacitor 2 Reinstall the capacitor cover with its two screws 3 Mount the control housing with its three screws 4 Connect the smooth power cord lead to terminalL1ontheelectroniccontrolboard 5 Mount the electronic control assembly to thecontrolhousingwith...

Page 24: ...Unclip the thermistor from its holder b Remove the lower screw from the two green ground wires that are mounted to the evaporator c Remove the electronic control box as sembly mounting screw and allow the assembly to hang off to the side d Remove the three screws from the con trol housing and remove the housing b Remove the lower screw from the two green ground wires that are mounted to the evapor...

Page 25: ...m air shields and rotate the guide to the left facing front Lay the guide on the work surface out of the way 9 Carefully lift the two upper styrofoam air shields off the unit Rotate Air Guide Fan Blade Clamp Screw Fan Shroud Upper Styrofoam Air Shields 12 Remove the two fan motor clamp screws and remove the clamp 13 Carefully lift the fan motor assembly the condenser fan shroud and the lower styro...

Page 26: ...ACD052MM ACM052MM ACM062MM Disconnect the black red and blue wires from the fan speed control terminals NOTE The model ACD052MM does not use the blue wire 16 Disconnect the white and brown wire con nectors from the capacitor terminals 17 Remove the screw from the wire clamp and remove the motor wires from the clamp Blue Red Black Fan Speed Control Wires Fan Access Slot 14 Models ACQ058MM ACQ062MM ...

Page 27: ...ower styrofoam shield over the evaporator fan 6 Carefully lift the fan motor assembly the condenserfanshroud andthelowerstyro foam air shield and install them in the unit 7 Rotate the fan motor so that the wires face down toward the bottom of the unit 8 Mount the fan motor clamp over the end of the motor with its two screws 9 Mount the condenser fan shroud with its two hex head screws 10 Install t...

Page 28: ...ng and remove the housing c Remove the screws from each of the two green ground wires that are mounted to the evaporator d Remove the four screws from the con trol mounting plate and allow the as sembly to hang off to the side e Remove the three screws from the con trol housing and remove the housing Control Housing Screw 1 of 3 Control Mtg Plate Screw 1 of 4 1 Unplugairconditionerordisconnectpowe...

Page 29: ...guideofftheupperstyrofoam air shields and rotate the guide to the left facing front Lay the guide on the work surface out of the way 10 Carefully lift the two upper styrofoam air shields off the unit Rotate Air Guide Upper Styrofoam Air Shields 11 Remove the two front and two side screws from the evaporator Continued on the next page Ground Wire Screws Electronic Control Box Assembly Screw Control...

Page 30: ...he evaporator 5 Mount the top air guide to the unit with its eight screws 6 Mount the brace with its four screws 7 Mount the control housing to the unit with its three screws 8 Mount the control assembly to the hous ing 9 Mount the two green ground wires to the evaporator with their hex head screws 4 Make sure that the rubber wire block is positioned in its cutout so that there are no air leaks ar...

Page 31: ...urtains and the front grille see page 3 2 for the procedures 4 Remove the four screws from the brace and remove the brace 5 Remove the two 3 8 mounting nuts from the studs of the condenser 6 Cut the plastic wire tie from around the tubing Screw 1 of 4 Brace 7 Braze on an access valve and discharge the refrigerant into an approved recovery system 8 Unbrazethetopandbottomjointsfromthe condenser and ...

Page 32: ...l parts and panels before operating Failure to do so can result in death or electrical shock Screw 1 of 4 Brace 6 To remove the overload protector a Disconnect the overload protector wire from compressor pin C b Disconnect the yellow wire from the overload protector terminal c Remove the overload protector and its spring from the compressor d Remove the spring from the overload protector 5 Remove ...

Page 33: ...e on an access valve and dis charge the refrigerant into an approved recovery system e Disconnect the high side line from the compressor and the suction line from the accumulator f Remove the cap nut from each of the feet and lift the compressor off the studs g Removethethreerubberisolatorsfrom the compressor Brown Wire S White Wire R Rubber Gasket Suction Line To Accumulator High Side Line To Com...

Page 34: ...3 20 NOTES ...

Page 35: ...hmmeter to the R x 10K scale 4 For the most accurate measurement im merse the thermistor in ice water for 5 minutes then use the 32 F 0 C reading in the chart 5 Touch the ohmmeter test leads to the wire terminals on the connector 6 The meter should indicate as shown in the following chart 10 Before testing any of the components perform the following checks Control failure can be the result of corr...

Page 36: ...ck Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock FAN SPEED CONTROL Refer to page 3 4 for the procedure for servic ing the fan speed control 1 Unplugairconditionerordisconnectpower 2 Disconnect the wires from the fan speed control terminals 3 Set the ohmmeter to the R x 1 scale 4 Touch the ohmmeter tes...

Page 37: ...ts and panels before operating Failure to do so can result in death or electrical shock 4 Models ACM052 ACM062 ACQ058 ACQ062 Touch the ohmmeter test leads to the indicated fan motor wire connec tors The meter should indicate as follows Black to Brown Start 45 to 55 Ω Black to White Turbo 45 to 55 Ω Blue to White High 60 to 70 Ω Red to White Low 80 to 90 Ω OVERLOAD PROTECTOR Refer to page 3 18 for ...

Page 38: ...t the ohmmeter to the R x 1 scale 4 Touch the ohmmeter test leads to the followingcompressorterminals Themeter shouldindicate approximately asshown Terminal R to C 1 1 Ω Terminal S to C 2 8 Ω R WH S BN C BK Compressor Terminals Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock ...

Page 39: ...he HIGH LED will light and the fan will operate at high speed 6 Press the ADJUST keypad The LOW LED will light and the fan will operate at low speed 7 Press the ADJUST keypad and exit the Diagnostics Mode Step Number Component Tested Description 1 LEDs All LEDs will be lit 2 Thermistor All LEDs will turn off and the display will indicate the thermistor temperature reading Warming the thermistor wi...

Page 40: ...ed mo tor windings open selector switch or control 4 No cooling compres sor and fan motor running 4a Airflow restriction 4a Check for airflow through con denser and evaporator 4b Check sealed system for loss of refrigerant or restrictions 4b Sealed system problem 5 Insufficient cooling compressor and fan motor running 5a Improper airflow 5a Clean or replace air filter Check for air passage restric...

Page 41: ...d 7 House circuit tripping 7a Incorrect fuse or breaker 7a Check for proper fuse or breaker Check amp draw 7b Check wiring and connections Check operation of all compo nents 7b Failed component or incorrect wiring 8 Noisy operation 8a Loose parts 8a Check fan blades cabinet washers tubing contact or vibration or loose screws 8b Normal operation 8b Pinging sound noticed as drops of water condensate...

Page 42: ...oes replace batteries in remote 10b Replace remote control 10b Remote failed 11 Moisture dripping into room 11a Extreme humidity 11a Advise customer of possible sweating formations under abnormal conditions Check and improve all possible seals 11b Check and improve all sealed areas 11c Check for proper side to side level of unit Check for 1 2 rear slope or 1 full bubble on spirit level 11d Replace...

Page 43: ... WIRING DIAGRAM 1 Model ACD052MM Compressor Capacitor Ground BR BR BR BR BK BK BK RD RD YL GN GN YL WH WH WH WH WH WH 2 Speed Motor Overload Selector Switch Thermostat Power Supply Ground R S C G S H L F H C 5 2 3 1 L1 L2 Low Comp High ...

Page 44: ...52MM ACM062MM Compressor Capacitor Ground BR BR BR BR BK BK BU BK RD RD YL GN GN YL WH WH WH WH WH WH 2 Speed Motor Overload Selector Switch Thermostat Power Supply Ground R S C G S T M L F H C 2 3 4 5 L1 L1 L2 L2 Low Comp Turbo High ...

Page 45: ...MM ACQ062MM Compressor Capacitor Ground BR BR BR BR BK BK BU BU RD RD YL YL GN GN YL WH WH WH WH WH BK 3 Speed Motor Overload Electronic Control Thermistor Power Supply Ground R S C G S T L H F H C 5 2 3 L1 L1 Comp L2 L2 Low Turbo High ...

Page 46: ...y L1 L2 WH L2 L1 Electronic Control Board Compressor Comp L1 YL BK BR WH L2 Overload R S C L1 Electronic Control Board Electronic Control Low L1 L1 L2 High Turbo 3 Speed Motor G Capacitor S T BK BU RD BR GN H L POWER ON COMPRESSOR ON FAN MOTOR ON ...

Page 47: ...art 8171429 isavail able The adapter easily mounts to the rear of the base plate using predrilled holes Connect a length of tubing purchased locally to the adapter and route it away from the air condi tioner to a convenient drainage area Drain Adapter Gasket 2 Hex Head Screws Continued on the next page IMPORTANT Never install the adapter on air conditioners that are not designed for its use otherw...

Page 48: ...up 2 Mount the adapter and gasket to the two predrilled mounting holes in the rear of the base plate with the two hex head screws provided 3 Slide the end of a length of tubing over the end of the adapter and route it to the drainage location Gasket Drain Adapter Mounting Holes Base Plate Hex Head Screws Drain Adapter Gasket Flat Side ...

Page 49: ...7 3 NOTES ...

Page 50: ...7 4 NOTES ...

Page 51: ...R READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR LITERATURE ORDERS PHONE 1 800 851 4605 IN CANADA FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL 1 800 461 5681 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL THE TECHNICAL ASSISTANCE LINE 1 800 488 4791 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR WHIRLPOOL PRODUCTS 1 800 253 1301 FOR KITCHENA...

Page 52: ...CORPORATION ...

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