Godrej GSC 18 FV 5 HRML User manual

Godrej & Boyce Mfg. Co. Ltd –Appliance Division.
---------------------------------------------------------------------------------------------------
CUSTOMER SERVICE, PLANT 11, PIROJSHA NAGAR,VIKHROLI, MUMBAI 400079.
Prepared by: Larkins D’souza, Authorized & Issued by: S.A.Jamadar
(For private circulation only)
Rs.250 /-
SERVICE MANUAL
For
Godrej Air-Conditioner
Models
GSC 18 FV 5 HRML
SM 3202

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 1 of 23
Contents:
1. Preface ----------------------------------------------------------------------------------------------- 2
2. Tips for Service Personnel ---------------------------------------------------------------------- 3
3. Safety Precautions -------------------------------------------------------------------------------- 4
4. Good Servicing practices ------------------------------------------------------------------------ 5
5. Nomenclature --------------------------------------------------------------------------------------- 6
6. Specification for GSC 18 FV 5 HRML --------------------------------------------------------- 7
7. Exploded View –Indoor GSC 18 FV 5 HRML ----------------------------------------------- 8
8. Exploded View –Outdoor GSC 18 FV 5 HRML --------------------------------------------- 13
9. Wiring Diagram - GSC 18 FV 5 HRML --------------------------------------------------------- 17
10.Features of Remote Controller ------------------------------------------------------------------ 18
11. Trouble Shooting ---------------------------------------------------------------------------------- 20

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 2 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 & equipments 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.
7th March 2013

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 3 of 23
Tips For Service Personnel
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)
* Getting 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

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 4 of 23
Safety Precautions
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)

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 5 of 23
GOOD SERVICING PRACTICES:
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 R-22 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 20 grams refrigerant needs to be added/charged per extra meter.
13. Regular upkeep of tools & equipments, 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.

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 6 of 23
Nomenclature
W –Window
S –Split
9 k Btu
10 k Btu
12 k Btu
13 k Btu
14 k Btu
18 k Btu
19 k Btu
21 k Btu
24 k Btu
G –Grille
F –Flat
C –Cooling
H –Heating & Cooling
G S C 18 F V 5 H R M L
Color / Finish
White / Red /Aurica
/ Silver / Gold / Black
/ Mirror etc..
Year of Launch:
Base A = 2001…
M = 2013
Version
V –Vogue
* ( Numeric for existing modes / Alpha for new models)
1 –1 Star
2 –2 Star
3 –3 Star
4 –4 Star
5 –5 Star
Z -Zephyr
K - Krystal
H - Harmony
Godrej
For
Company
Use

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 7 of 23
SPECIFICATION FOR GSC 18 FV 5 HRML
NOTE: The above design and specifications are subject to change without prior notice for product improvement
Godrej Model Name
GSC 18 FV 5 HRML
Function
Cooling
Rated Voltage
230 V
Operating voltage range
220 V-240 V
Rated Frequency ( Hz )
50
Total Capacity ( Btu / h ) ( W )
17623( 5165 W)
Rated Input ( W )
1556
Rated Current ( A )
6.74
Air Flow Volume (m3 / h) (H / M /L)
850 / 710 / 675
Dehumidifying Volume ( l / h )
2
EER ( W/W )
3.32
Product Code
5K3H17
Indoor unit
Blower Motor
Model
FN20V-PG
Rating ( Output W )
20W
Capacitor Rating ( F/V )
1.5/ 450
Blower (Fan)
Type
Cross flow
Evaporator
Pipe type
Internally grooved
No. of Rows
2
Swing Motor
Model
MP24AA
Rating ( V ) DC
12
Other Details
Sound Level dB ( A ) ( H / M / L )
46 / 42 / 38
Dimension ( W / D / H )( mm )
940 X 200 X 298
Net Weight ( kg )
13
Outdoor unit
Compressor
Compressor Model No.
Highly / SH295RY-C7PUA
Compressor Type
ROTORY
Lock Rotor Current ( A )
34
Compressor Power Input ( W )
1519
Capacitor Rating ( F )
35
Overload Protector
Internal
Refrigerant
Refrigerant Charge (gm ).
R22 ( 750 )
Condenser
Condenser Type
Tube(Al) and Fin(Al) Type
Pipe Type
PFC
No. of Rows
1
Fan Motor with
Axial Fan
Model
95HH050 (MARATHON)
Output Power ( W )
54
Capacitor ( V / F )
450 / 3
No. of Blades & Fan size
3 / Ǿ 432 X 130
Other Details
Permissible Excessive Operating Pressure for
the Discharge Side ( psig )
380
Permissible Excessive Operating Pressure for
the Suction Side( psig )
85
Dimension ( W / D / H ) ( mm )
840 X 300 X 540
Net Weight ( kg )
35
Refrigeration Pipes
Liquid Pipe ( mm ) 4 Meters
Ǿ6.35 ( 1/4" ) Cu
Gas Pipe ( mm ) 4 Meters
Ǿ12.7 ( 1/2" ) Cu
Additional gas per meter (gm)
20

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 8 of 23
Exploded View –GSC 18 FV 5 HRML Indoor Unit

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 9 of 23
Item Codes - Indoor Unit GSC 18 FV 5 HRML
REF #
Part Description
Baan Codes
Image For Reference Only
1
Front Panel
AGRSHV518F2
2
Filter Sub-assy
AFLSHV518FA
3
Rear Panel
AGRSHV518RP
4
Screw Cover
AMSSHV512SC
5
Display PCB
ACCSHV518DP
6
Evaporator Assy
AEVSHV518EA
7
LH Evaporator Support
ABKSHV518ES
8
Cross Flow Blower
ABL97740444
9
O-Gasket sub-assy of Bearing
AMS97740344
10
Rubber Bear Support
AMS97740345
11
Middle Panel (Silver Finish)
APLSHV518MP

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 10 of 23
REF #
Part Description
Baan Codes
Image For Reference Only
12
Wall Mounting Frame
AMS97740446
13
Helicoid tongue
AMSSHV518HT
14
Swing Louver ( RH )
ALVSHV518VR
15
Left Axile Bush
AMS97740349
16
Axile Bush
AMS97740399
17
Swing Louver ( Horizontal)
(Silver)
ALVSHV518HL
18
Louver link
AMS97740400
19
Swing Motor
AMT97740450
20
Swing Louver ( LH )
ALVSHV518VL
21
Drain Pipe
AMS97740452
22
Pipe Clamp
AMS97740368
23
Blower Motor
AFMS18D3MTR
24
Motor Cover
AMS97740454
25
Electric Box Assy
ACCSHV518EA

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 11 of 23
REF #
Part Description
Baan Codes
Image For Reference Only
26
Electric Box
AMSS24D2ELB
27
Main PCB
ACCSHV518MP
28
Transformer
AFN97740458
29
IDU Terminal Block
AMS97740460
30
Electric Box Cover1
AMSS24D2BC1
31
Shield cover of Electric Box
AMSS24D2EBS
32
Baffle Plate
ABKSHV518SH
33
Electric Box Cover2
ACVSHV518EC
34
Tube Sensor
AMS97740465

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 12 of 23
REF #
Part Description
Baan Codes
Image For Reference Only
35
Ambient Temperature Sensor
AMS97740466
36
Remote Controller
ACC97740356
37
Connecting Cable
AMSS18D3CNC
38
Power Cord
AICSHV518PC
39
Drain Stopper
AMSS10D3DRS
Shield cover of Electric Box
ACVSHV518CE
Oil Bearing
AMSS10D3OGK
IDU Cartoon Box
APB97742724

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 13 of 23
Exploded View –GSC 18 FV 5 HRML Outdoor Unit

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 14 of 23
Item Codes - Outdoor Unit GSC 18 FV 5 HRML
Ref#
Part Name
Item Code
Image For Reference only
1
Air Outlet Grill
AGRSLJ218DG
2
Front Panel
AMSSLZ518FP
3
Condenser Fan
AFBSLZ518FB
4
Fan Motor
AMTSLZ518FM
5
Support Motor
ABKSLJ218MS
6
Compressor
ACMSLZ518CM
7
Side Panel LH
AMSSLJ218LH
8
Side Panel RH
AMSSLJ218RH
9
Plastic Handle RH
ACVSLJ218EC

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 15 of 23
Ref#
Part Name
Item Code
Image For Reference only
10
Partition Panel
AMSSLJ218PP
11
Interconnecting Cable
AMSSLJ218CC
12
Suction Valve
AVLSLJ218SV
13
Liquid Valve
AVLSLJ218LV
16
Top Cover
AMSSLJ218TC
17
Base Pan
ABSSLZ518BS
18
Condenser Coil
ACNSLZ518CN
19
Rear Net
AMSSLJ218RN
EPS Top
APASLJ218ET
EPS Bottom
APASLJ218EB

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 16 of 23
Ref#
Part Name
Item Code
Image For Reference only
Poly Bag
APASLJ218PB
Corrugated Base Tray
APASLJ218CB
Angle Board
AMSSLJ218AB
21
Metal Control Box
ACCSLJ218CB
22
Compressor Capacitor
ACPSLZ518CC
23
Fan Motor Capacitor
ACPSLZ518FC
24
Capacitor Clamp
AMSSLJ218CP
Wiring Harness
AMSSLJ218WH

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 17 of 23
Model GSC 18 FV 5 HRML
Schematic Wiring Diagram - IDU
Schematic Wiring Diagram –ODU

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 18 of 23
Features of Remote Controller
● ON/OFF button
Press this button, the unit will be turned on, press it once more, the unit will be
turned off. When turning on or turning off the unit, the Timer, Sleep function will
be canceled, but the preset time will remain.
● MODE button
Press this button, Auto, Cool, Dry, Fan, Heat mode can be selected circularly.
Auto mode is default when switched on.
Under Auto mode, the temperature will not be displayed; Under Heat mode, the
initial value is 28°C ;Under other modes, the initial value is 25°C .
●SLEEP button
By pressing this button, Sleep On and Sleep Off can be selected. After
switching on, the Sleep duration is selected by default. After the unit is turned
off, the Sleep function is canceled. After sleep function is set up, the icon of
'Sleep' will be displayed. In this mode, the time of timer can be adjusted. Under
Fan and Auto modes, this function is not available.
● FAN button
By pressing this button, Auto, Low, Middle, High speed can be circularly
selected. After powered on, Auto fan speed is by default. Under Dehumidify
mode, Low fan speed only can be set up.
Note: Under the Dry mode, the fan speed isn't adjustable, low fan speed is
imperative.
● CLOCK button
By pressing this button, the clock can be set up. Icon blinks and displays. Within 5 seconds, the value can
be adjusted by pressing + or - button. If continuously pressed for 2 seconds or more the set time will change by
1 min. To register the timing repress the 'Clock' key. 12:00 is the default setting.
● LIGHT button
Press this button to select LIGHT on or off on the displayer. When the LIGHT on is set, the icon will be
displayed and the indicator light in the displayer will be on. When the LIGHT is set as off, the icon will be
displayed and the indicator light in the displayer will be off.
●BLOW button
Press this button, to turn on or turn off the drying. In Cool and Dehumidifying Mode, pressing this button and will
display "BLOW" on the hand set and Blow function is turned on. If repressed, "BLOW" will disappear on the
hand set and the Blow function is turned off. When the unit is switched on, Blow OFF is the default setting.
When operating the ON/OFF button or switching mode to Cool or Dehumidifying Mode, the Blow function will
retain its set status. If Blow ON is set and the unit is turned off, Blow continues functioning for some time before
shutting off. In Auto and Fan Mode, Blow Function can not be set up and BLOW is not displayed.
●TURBO button
In Cool or Heat Mode, pressing this button can turn on or turn off the Turbo function. When the Turbo function is
turned on, its icon will be displayed. When switching the mode off or changing fan speed, this function will be
canceled automatically.
●+button
For presetting temperature increase: Press this button, to increase the temperature, when unit is on.
Continuously press and hold this button for more than 2 seconds, and the corresponding contents will change
rapidly, until the button is released. The set temperature will be displayed on the unit. In Auto mode, the
temperature can not be set up. Centigrade scale setting range is16-30.Fahrenheit scale setting range is
61-86
COOL
DRY
FAN
AUTO

Godrej & Boyce Mfg. Co. Ltd, HO Service, Mumbai SM 3202 - Page 19 of 23
●-button
For presetting temperature decrease: Press this button, to decrease the temperature, when unit is on.
Continuously press and hold this button for more than two seconds, and the corresponding contents will change
rapidly, until the button is released. The set temperature will be displayed on the unit. The temperature
adjustment is unavailable in the Auto Mode.
● TEMP button
After switching on the unit, the temperature displayed on the indoor unit will be as per the display settings
previously selected. In absence of previous display selection the default temperature is displayed, and there is
no icon displayed on wireless remote control. On pressing the TEMP button if is displayed on the handset,
the indoor unit will display the set temperature; indicates that the indoor unit will display the indoor ambient
temperature; indicates that the current display status on the indoor unit will remain unchanged. If current
display is indoor ambient temperature and another signal is received from the hand set, the display will change
to the preset temperature; 5 s later, it will return to displaying the ambient temperature.
●SWING UP AND DOWN Button
Press this button, to set up swing angle, which circularly changes as below:
●TIMER ON Button
When TIMER ON button is pressed, 'ON' will display and blink for 5 sec on the handset. During these 5 sec, by
pressing + or -, the Timer on time can be set in increments or decrements of 1 minute. If either of the +/- keys is
continuously pressed, a rapid change of set time occurs. After setting the desired ON time, press the TIMER
ON button within 5 sec (while ON is blinking) to set and register the timer ON.
If the TIMER ON button is pressed again, the TIMER ON settings will be cancelled.
Before setting the Timer, please adjust the Clock to the current actual time.
●TIMER OFF BUTTON
Press this key once to enter into TIMER OFF setup, in which case the TIMER OFF icon will blink.
The method of setting is the same as for TIMER ON.