Godrej GSC 18 FGA 5 WOG User manual

Godrej & Boyce Mfg. Co. Ltd –Appliance Division.
-----------------------------------------------------------------------------------------------------
CUSTOMER SERVICE, PLANT 11, PIROJSHA NAGAR, VIKHROLI, MUMBAI 400079.
Prepared by: Shreekant Jamble, Authorized & Issued by: S.A. Jamadar
(For private circulation only)
Rs. 250 /-
SERVICE MANUAL
For
Godrej Air-Conditioner
Model
GSC 18 FGA 5 WOG
SM 3274

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 2 of 23
Contents:
1. Preface ----------------------------------------------------------------------------------------------- 3
2. Tips for Service Personnel ---------------------------------------------------------------------- 4
3. Safety Precautions -------------------------------------------------------------------------------- 5
4. Good Servicing practices ------------------------------------------------------------------------ 6
5. Customer Relations ------------------------------------------------------------------------------- 7
6. Nomenclature --------------------------------------------------------------------------------------- 9
7. Specification for GSC 18 FGA 5 WOG-------------------------------------------------------- 10
8. Exploded View –Indoor GSC 18 FGA 5 WOG--------------------------------------------- 11
9. Exploded View –Outdoor GSC 18 FGA 5 WOG--------------------------------------------16
10.Wiring Diagram - GSC 18 FGA 5 WOG--------------------------------------------------------21
11.Features of Remote Controller -------------------------------------------------------------------22
12.Trouble Shooting ----------------------------------------------------------------------------------23

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 3 of 23
Preface:
Room air-conditioners are widely used not only in houses but also in small establishments/offices,
laboratories etc. which are innovated very fast. This also affects the competition in the industry. At Godrej,
we believe innovation, our Vision, Mission& in their accord, we have introduced new series of split type
room air-conditioners of various capacities to enhance the customer’s life style. The air-conditioners are
designed to suit Indian climatic conditions & are tested as per standards IS: 1391 part 2.
The air-conditioner is manufactured under strict quality control system. This service manual helps to know
more about air-conditioners along with its specifications, working etc. However the technician must refer
to installation manual before using this manual because in many cases the problem lies with installation
due to lack of knowledge & skills etc. This manual includes tips for service personnel, safety precautions
and recommended tools &equipment’s apart from technical details of air-conditioners. At the outset it is
better to note that the refrigeration system which is used in the air-conditioner is almost similar to Godrej
Refrigerator except the refrigerant that works like heat carrying media.
The manual is designed for the qualified/trained and well experienced service personnel engaged in
providing efficient service to valued customers. We certainly referred to many books, journals and other
documents to enable us to provide you updated information. An inexperienced and unauthorized person
should not attempt to make any adjustments or repair the air-conditioning unit as this may cause damage.
Also in case of new air-conditioners, it may lead to warranty becoming null & void.
All air-conditioners need careful handling & regular maintenance to extend its life. You as a service
provider have a responsibility to maintain the air-conditioner in good working condition, during its life
time. Therefore, it is essential that before you start any repair or diagnosis on the air-conditioner, please
read this service manual completely. Also the user manual supplied with the air-conditioner can tell you
how to remedy some of the problems that aren’t due to the unit failures and operation of various controls.
Assorted information including detailed exploded drawings, item code nos. of all spare parts, electric/
electronic circuit diagrams and the chart for trouble shooting are added for better understanding of the
product and effective after-sales-service to valued consumers.
The knowledge shared in the manual is wide and extensive but because of our regular emphasis towards
improvements, the procedures, specifications and accessories are subject to change without prior notice,
hence please check the same from time to time.
With Best Wishes for Efficient Customer Service, Always,
Godrej & Boyce Mfg. Co. Ltd,’
Service - Appliances Division.
Tips For Service Personnel

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Meeting the customer’s wants will go a long way towards improving satisfaction with quality of
after-sales-service. You the reader as a service personnel play a key role in meeting many of the
customer’s wants. Some of the important tips are given below for your perusal.
* Arriving on time (and apologizing if unavoidably late)
* Greet the customer in a polite and friendly manner, showing an awareness of the
appliance problem you have come to repair.
* Being professional...personal neatness, standard tool kit, courtesy.
* Listen, show concern.
* Making skillful diagnosis. Asking the customer for symptoms and zeroing in on the problem to
get facts.
* Making positive comments about the air-conditioner.
* Demonstrating that you are highly trained and competent.
* Repairing the air-conditioner right the first time.
* Showing respect to customer, the air-conditioner and the home.
* Using neat work habits and carefully cleaning up after the repair.
* Checking out the air-conditioner after repair to make it’s working properly and that there aren’t
other problems that may soon occur.
* Explaining what went wrong with the air-conditioner and what was done to repair it. Not
“talking down” to the customer.
* Explaining the bill and skillfully dealing with any concerns about the charge.
* Giving the customer hints or tips on the use of the air-conditioner or on how to avoid future
problems.
REMEMBER: Price is what the customer pays. Value is what the customer receives from the
whole repair experience. Satisfaction with the charge is a function of the price-value relationship.
By meeting the customer’s wants you can increase the value and increase their satisfaction with
quality of service
YOU NEVER GET A SECOND CHANCE TO MAKE A GOOD FIRST IMPRESSION
Safety Precautions

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To minimize the risk of personal injury or property damage it is important that the following safe servicing
practices be observed.
1) Read carefully the instruction booklet supplied with the air-conditioner from time to time. Be sure you
are operating air-conditioner properly.
2) Know the location of customer’s air-conditioner circuit breakers or fuses.
3) Before servicing the air-conditioner, UNPLUG the power cord before performing any repairs or
removing any panel. Note Except for electrical & partly mechanical performance testing, none of repairs
require electrical power.
4) Be careful when handling air-conditioner grille and access panel, parts or any components which may,
have sharp edges. Avoid placing your hand into any area of the air-conditioner which can’t first visually
inspect for sharp edges.
5) Always use the correct tools for a job and make sure tools are in good condition. Worn, faulty and
misused tools can cause accidents.
6) Never interfere with or bypass the operation of any switch, component or feature of the air-conditioner.
7) Use only replacement parts of the same size and capacity as per the list of parts. If you have any
questions contact our branch.
8) When replacing any component, be sure any green ground wires are connected securely in their original
position to avoid danger of shock or short circuit.
9) Before connecting the power supply, make sure no un insulating wires or terminals are touching the
cabinet. Electrical wiring and all grounds must be correctly reconnected and secured away from sharp
edges, components and moving parts. All panel and covers etc. should be reinstalled before the
air-conditioner is plugged in.
10) The line cord must be plugged into a grounded, three plug pin. Never cut or remove the third
(ground) or top pin from the power cord plug.
11) Do not substitute ordinary wire for any internal wiring of air-conditioner. The wire must carry heavy
current and can be subjected to heat. It is very important that all connections are tight and secure.
12) Make an insulation test, after the air-conditioner is repaired, to protect the customer from being
exposed to shock hazards. (Value to be not less than 1M)
13) Always work in an well ventilated space/area during sealed system repairs.
GOOD SERVICING PRACTICES:

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1. Proper training in servicing/repairing, before undertaking Installation, Service/Repairs to
appliance
2. Cleanliness in work, workplace well ventilated area.
3. Knowing which refrigerant is used in the system under installation.
4. Refrigerant recovery whenever possible
5. Do Not Purge refrigerant in the atmosphere at the time of installation.
6. When changing compressor, ensuring the replacement compressor to be of the
same capacity and is compatible with the refrigerant used apart from the other
components of the system
7. Using 2 stage rotary vacuum pump for evacuation of tubes and sealed system.
8. Minimize brazed joints and making proper joints(Flare joints)
9. Flushing with dry Nitrogen gas
10. Leak testing with leak detector
11. Use of digital weighing balance for measuring refrigerant charge.
12. If the connecting copper tubes are more than the standard length supplied with AC,Additional
8 grams refrigerant needs to be added/charged per extra meter.
13. Regular upkeep of tools &equipment’s, including periodic calibration.
14. Handling, storing and checking gas cylinders, regulators and hose pipes at regular interval
15. Keeping all relevant data of all services
16. Meeting safety requirements
17. Labeling each item with necessary details, including defective components.
CUSTOMER RELATIONS

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It is essential that technicians behave appropriately in customers’ premises. Technicians’ behavior reflects
strongly on the customer’s impression on Godrej.
The following is a list of do’s and don’ts for technicians to remember when dealing with customers.
Always note: smoking is not allowed inside any of the Godrej Appliance Division (GAD) and customer
premises.
2.1 Before leaving ASP location
Before leaving the Authorized Service Provider (ASP) location, the technician shall:
Check your toolkit for its completeness as per recommended list.
Ensure adequate spare-parts to be in the toolkit.
Prepare route chart as per allotted service calls and appointments etc.
Re-check customer’s availability by telephoning him/her.
Make sure you will be able to attend the service calls acceptably.
Update yourselves on company’s policies, prices etc.
Study if there is a need to carry specific tools/equipments.
Refer to history of each appliance to be attended.
Check your appearance in a mirror and ensure you look respectable.
2.2 Before entering customer’s premises
Before entering a customer’s premises, the technician shall:
Keeping appointments is compulsory. Customers are impressed with timekeeping.
If you expect to arrive late, genuinely, telephone immediately and explain reasons. It is extremely rude
to cancel an appointment.
Most customers take great pride in their homes that are kept neat and tidy at all times.
Wipe soil off shoes before entering customer house.
Gently push the bell switch and wait for some time for customer to reach the door.
Seek permission and never enter inside without it and then request customer to show the appliance
where it is installed.
If wet in monsoon, wipe your feet.
2.3 While attending service call
Whilst attending a service call at a customer’s premises, the technician shall:
First greet customer formally. Religion, education and social rank influence greetings.
Titles are important and denote respect. Use customer's title and his surname while talking. Professional
customers admire titles like professor, doctor, etc. If someone does not have a professional title, use the
honorific title "Sir" or "Madam". Status is also determined by age.
In different states of India different languages are preferred, hence use appropriate one to suit the
customer, though English/Hindi may be spoken in most cases.
Maintain eye contact while speaking with customer.
Customers do not like to hear 'no,' be it verbally or non-verbally.
Use body language to make you appear more confident, powerful, trusting, etc., as per situation.

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Avoid confrontational behavior or high-pressure tactics. It can be counterproductive.
Do not sit anywhere until told where to sit.
Regret the inconvenience caused due to failure of appliance.
Examine appliance and ask questions in sequence, to correctly ascertain the problem. Customer may not
be familiar with technical terminologies and hence talk in simple language that could be understood by
customer. Sometimes request customer to demonstrate use or what happened that led to problem.
Do not use abbreviations like RDC/BCO or model codes etc.
On examining the appliance, explain (a) what has been found out, (b) you will be able to do instantly or
(c) what can be done etc.
Look for customer’s approval to enable you to do as per your above proposal.
Show method to stay away from the problem in future.
Clean up the work area and appliance, throw the undesired material in dustbin.
Always keep in mind that relationships are built upon mutual trust and respect. In general, customers
prefer to have long-standing personal relationships prior to doing business.
2.4 Before leaving Customer’s premises
Before departing the customer’s premises, the technician shall:
Check the electrical power point where the appliance is connected.
Instruct customer to avoid use of extension power board/wire
Explain benefits of various features of the appliance
Advice the care customer can take to avoid repetition of problems
Diplomatically cover what is and is not covered by warranty/contracts etc.
Availability of accessories and service products, service contracts
Thank customer for calling Godrej Smartcare service and greet him for rest of the day
Smile and inform about your leaving the premises.
Leave behind impression that carries brand creditability and assurance of Godrej Smartcare service.
2.5 For all other ASP team members working indoor
The team members based at Authorized Service Provider (ASP) location for indoor jobs who would also
interact with customer occasionally, need to bear in mind that courtesy and empathy be shown towards
customers visited the service centre. There are visitors/guests who stay too long and those who don't stay
long enough. There are visitors/guests who are too demanding and visitors/guests who are too passive.
The common etiquettes:
Offering visitors a seat and water/tea/coffee in comfortable place
Paying attention to the visitors/guests
Give reading material if extra time is required to complete his/her task
Appreciate guests, GAD and ASP etc.
No whispering
No making insulting, impatient or indifferent comments about accompanying children
No asking unnecessary personal questions
Thanks can be expressed in many forms -- oral, written, or a small present upon arrival or while leaving.
Expressing gratitude is essential.

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Nomenclature
W –Window
S –Split
T –Tower
M –Multi
12 k Btu
18 k Btu
24 k Btu
G –Grille
F –Flat
S –Ultra Slim
M –Mirror
A –Atlas Series
P –Plain fascia
Z –Cu condenser
C –Cooling
H –Heating & Cooling
Color / Finish
Non IMD White
W- White
R –R410 model
Year of Launch:
Base A = 2001…
M = 2013
O = 2015
Version
G- Green Balance
P –Pearl
S –Silverline
M –Mirror Star
N –Navigator
C –Champagne
L –Lunar
H –Helix
G –Goldline
D –Diamond
E –Endure
O –Onxy
A –Atlas
For
Company
Use
1 –1 Star
2 –2 Star
3 –3 Star
4 –4 Star
5 –5 Star
Godrej
GS C 18 F GA 5 W O G

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 10 of 23
Specification GSC 18 FGA 5 WOG
NOTE: The above design and specifications are subject to change without prior notice for product improvement
Godrej Model Name
GSC 18 FGA 5 WOG
Function
Cooling
Rated Voltage
230 V
Operating voltage range
187V –264V
Rated Frequency ( Hz )
50
Total Capacity (W) (as per Is:1391 - Part 1 for WAC & Part 2 for SAC)
5000 W
Rated Input ( W )
1408 W
Rated Current ( A )
6.1 A
Air Flow Volume (m3 / h) (High/Medium/Low)
900 / 850 / 800
Dehumidifying Volume ( l / h )
-
C.O.P / EER ( W/W )
3.55
Product Code
5M3X07
Indoor unit
Blower Motor
Model
YYS25-4
Speed ( rpm ) ( High / Medium / Low )
1230/1080/1000
Rating ( Output W )
25 W
Capacitor Rating ( F / V)
450 / 2
Blower (Fan)
Type and size
Cross flow ( Ǿ108 X 741.5)
Evaporator
Pipe type
Internally grooved
No. of Rows
2
Swing Motor
Model
24BYJ48
Rating ( V ) (DC)
12
Other Details
Sound Level dB ( A )
48
Dimension ( W / D / H )( mm )
940 X 232 X 300
Net Weight ( kg )
14
Outdoor unit
Compressor
Compressor Model No.
GMCC (DSG 320S1UFT)
Compressor Type
ROTARY
Lock Rotor Current ( A )
33.7 A (220/240V)
Compressor Power Input ( W )
4870 (R290)
Capacitor Rating ( F / V )
40 / ≧400VAC
Overload Protector
Built-in
Refrigerant
Refrigerant Charge (gm ).
R290 ( 375 )
Condenser
Condenser Type
PFC (Al tubes & Al Fins)
Fin Type
Louvered Fins
No. of Rows
1
Fan Motor with
Axial Fan
Model
PICL/Haier
Output Power ( W )
54
Capacitor ( V / F )
- / 3.0 F
No. of Blades & Fan size (mm)
3 / Ǿ450
Other Details
Permissible Excessive Operating Pressure for
the Discharge Side ( MPa )
< 2.8
Permissible Excessive Operating Pressure for
the Suction Side( MPa )
< 0.7
Dimension ( W / D / H ) ( mm )
820 X 300 X 540
Net Weight ( kg )
41
Refrigeration Pipes
Liquid Pipe ( mm )
Ǿ6.35 ( 1/4" ) Cu
Gas Pipe ( mm )
Ǿ12.7 ( 1/2" ) Cu
Additional gas per meter (gm)
8

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Exploded View GSC 18 FGA 5 WOG Indoor Unit

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Item Codes –Indoor Unit GSC 18 FGA 5 WOG
Ref
#
Part Name
Item Code
Image For Reference only
1
MOUNTING PLATE
AMS97750845
3
REAR PANEL
APN97750846
4
INDOOR BLOWER
ABL97750847
5
RUBBER BEARING
AMS97750848
6
EVAPORATOR
AEV97750849
7
EVAPORATOR LH SUP
AMS97750850
8
SWING MOTOR
AMT97750851
9
VERTICAL LOUVER FIX PL
ALV97750852
10
VERTICAL LOUVER
AMS97750853

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 13 of 23
Ref
#
Part Name
Item Code
Image For Reference only
11
VERTICAL LOUVER LINK
AMS97750854
12
AIROUTLET ASSEMBLY
ALV97750855
14
HORIZONTAL LOUVER
ALV97750821
15
MIDDLE PANEL
AMS97750857
16
SCREW COVER
ACV97750858
17
AIR FILTER
AMS97750859
18
IDU FRONT PANEL
APN97750860
19
DISPLAY PCB
ACC97750861
21
WIRING COVER
ACV97750862
25
IDU TERMINAL BLOCK
AMS97750863

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 14 of 23
Ref
#
Part Name
Item Code
Image For Reference only
28
ELEC CNTRL BOX COVER
ACV97750864
29
MAIN PCB
ACC97750865
30
TRANSFORMER
ATR97750866
31
ELECTRIC CNTRL BX
AMS97750867
33
IDU BLOWER MOTOR
AMT97750868
WATER FLOW PIPE
AMS97750870
EVAP TUBING CLAMP
AMS97750871
SENSOR HOLDER
AMS97750872

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 15 of 23
Ref
#
Part Name
Item Code
Image For Reference only
ROOM TEMP SENSOR
ASN97750873
COIL SENSOR
ASN97750874
POWER CORD
AFN97750876
INTERCONN CABLE
AFN97750877
DRAIN PIPE
AMS97750878
REMOTE CONTROLLER
ACC97750879

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Exploded View GSC 18 FGA 5 WOG Outdoor Unit

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 17 of 23
Item Codes –Outdoor GSC 18 FGA 5 WOG
Ref#
Part Name
Item Code
Image For Reference only
1
ODU Front Grill
AMS97751181
2
ODU Front Panel
APN97751221
3
ODU Fan
AMS97751180
4
ODU FAN MOTOR
AMT97751184
5
MOTOR SUPPORT
STAND
AMT97751220

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Ref#
Part Name
Item Code
Image For Reference only
6
COMPRESSOR
ACM97750112
7
RIGHT SIDE BOARD
8
LEFT SUPPORTER
9
HANDLE
AMS97751185
10
TOP COVER
ACV97751222
11
CONDENSER
ACN97751204

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Ref#
Part Name
Item Code
Image For Reference only
12
REAR NET
AMS97751203
13
BASE PLATE
APN97751223
14
CAPILLARY ASSLY
15
SUCTION TUBE
ASLSGG718ST
16
DISCHARGE TUBE
ADLSGG718DT
17
PARTITION PLATE
AMS97751219
18
VALVE PLATE
19
DISCHARGE VALVE
AFN97751182
20
SUCTION VALVE
AFN97751183
21
COMPRESSOR
CAPACITOR CLAMP
22
COMPRESSOR
CAPACITOR
ACP97751211

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3274 - Page 20 of 23
Ref#
Part Name
Item Code
Image For Reference only
23
ELECTRIC PLATE
24
FAN CAPACITOR
ACP97751192
25
ODU TERMINAL BLOCK
AMS97751193