SHARP p060331 Service Manual

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PRODUCT TRAINING
WM2688H*M Discovery Steam Washer
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Contact Information

Customer Service (and Part Sales) (800) 243-0000 Technical Support (and Part Sales) (800) 847-7597
USA Website us.lgservice.com Customer Service Website us.lgservice.com B2B Service Website biz.lgservice.com
LG CS Academy lgcsacademy.com
Published March 2006 by LG Technical Support and Training
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Preliminary Matters (The Fine Print)
IMPORTANT SAFETY NOTICE
The information in this training manual is intended for use by persons possessing an adequate background in electrical equipment, electronic devices, and mechanical systems. In any attempt to repair a major appliance, personal injury and property damage can result. The manufacturer or seller maintains no liability for the interpretation of this information, nor can it assume any liability in conjunction with its use. When servicing this product, under no circumstances should the original design be modified or altered without permission from LG Electronics. Unauthorized modifications will not only void the warranty, but may lead to property damage or user injury. If wires, screws, clips, straps, nuts, or washers used to complete a ground path are removed for service, they must be returned to their original positions and properly fastened.
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Preliminary Matters (The Fine Print)

CAUTION
To avoid personal injury, disconnect the power before servicing this product. If electrical power is required for diagnosis or test purposes, disconnect the power immediately after performing the necessary checks. Also be aware that many household appliances present a weight hazard. At least two people should be involved in the installation or servicing of such devices. Failure to consider the weight of an appliance could result in physical injury.
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Preliminary Matters (The Fine Print)

ESD NOTICE
Some of the electronic in appliances are electrostatic discharge (ESD) sensitive. ESD can weaken or damage the electronics in these appliances in a manner that renders them inoperative or reduces the time until their next failure. Connect an ESD wrist strap to a ground connection point or unpainted metal in the appliance. Alternatively, you can touch your finger repeatedly to a ground connection point or unpainted metal in the appliance. Before removing a replacement part from its package, touch the anti-static bag to a ground connection point or unpainted metal in the appliance. Handle the electronic control assembly by its edges only. When repackaging a failed electronic control assembly in an anti-static bag, observe these same precautions.
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Preliminary Matters (The Fine Print)

REGULATORY INFORMATION
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential installation. This equipment generates, uses, and can radiate radio frequency energy, and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna; Increase the separation between the equipment and the receiver; Connect the equipment to an outlet on a different circuit than that to which the receiver is connected; or consult the dealer or an experienced radio/TV technician for help.
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Preliminary Matters (The Fine Print)

COMPLIANCE
The responsible party for this device’s compliance is:
LG Electronics Alabama, Inc. 201 James Record Road, Huntsville, AL, 35824.
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Introduction

The DISCOVERY series of washers and dryers is the top of the line and includes every option and feature.
Most notable are the steam generator and the LCD display.
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Specifications

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Features

LARGE CAPACITY
The larger drum (4.0 cu. ft.) allows washing of larger (heavier) loads and oversized items (comforters, curtains, blankets, etc.) There is less wrinkling and tangling of the laundry.
DIRECT DRIVE
The brushless DC motor drives the drum directly
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without belts, pulleys, or transmissions. The maximum spin speed of 1,320 RPM extracts more water from the laundry, reducing drying times.
TILTED DRUM/LARGE DOOR
The tilted drum (10°) and large door opening allow easier loading and unloading.
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Features (continued)

STEAM WASHING/SteamFresh®
The steam feature works with the recirculating pump to increase washing performance while maintaining low energy and water usage. SteamFresh® removes wrinkles from dry clothes.
ROLLER JETS and BALLS
The baffles pick up water as the drum turns and allow it to pour through the clothing as it tumbles. The balls enhance the washing performance while maintaining fabric care.
AUTOMATIC LOAD DETECTION
The microprocessor reads the current required to turn the drum and determines the weight of the load. This input is used to make numerous decisions during the wash cycle.
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Features (continued)

BUILT-IN HEATER
The internal heater helps maintain the water at its optimal temperature for selected cycles. The SANITARY cycle kills most common germs and bacteria.
CHILD LOCK
This allows the user to lock the controls. Children then cannot play with the buttons and disturb the
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wash cycle.
REMOTE LAUNDRY MONITOR
Available separately, the remote monitor displays the cycle and remaining time of the washer and dryer. It can be plugged in to any outlet in the house.
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Features (continued)

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LCD Display
The bright display replaces numerous LEDs and shows instructions when the controls are set.
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Serial Number Identification

The serial number is unique to each product. It gives information concerning the time and place of manufacture. The serial number is required to be paid for warranty service and to get the correct part in the event a running production change was made. Some models may have four (4) letters instead of two (2) for the product code number. The third and fourth letters are significant only to the manufacturing facility.
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Fuzzy Logic

To get the best washing performance, the user selects one of the standard cycles. Sensors in the COMBO make an infinitely variable number of adjustments as the cycle progresses. Adjustments are automatically made for load size, incoming water temperature, soil level, rinses required, and other variables.
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Door Lock

The door has an automatic, electrically operated lock system. When the machine is off or paused, the door can be opened by pulling it. When the machine is operating, the electric latch keeps the door closed. The door cannot be opened:
•When the COMBO is operating
•When the power failed or the washer is unplugged (until the capacitor discharges and releases the lock)
•When the DOOR LOCK light is on
•When the drum is still turning
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Door Locked Lamp

DOOR LOCKED LAMP
The DOOR LOCK lamp lights:
• When the COMBO is operating
• When the water level sensor frequency is lower than 22.9 kHz
• When the temperature inside the tub is over 45° C (113°F)
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Water Circulation

The recirculation pump circulates the water during most of the cycle. During the WASH cycle, it runs continuously for the first 3 minutes and then intermittently throughout the cycle. During the RINSE cycle, it runs continuously as soon as the appropriate amount of rinse water has been added. This recirculated water enters the drum at the top of the door at a small shower head. This spray not only keeps the window and gasket clean, it allows the clothes to be soaked with detergent or rinse water more quickly and can be used to control an oversudsing event.
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Water Recirculation

The recirculation pump is separate from the drain pump, but they are attached to opposite sides of the filter housing.
The steam is not pumped; it comes into the washer drum under its own pressure. When steam or the sanitary cycle is used, the door will remain locked until the laundry has cooled to
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a safe temperature. The pumps and filter are located at
the bottom left front corner. The filter can be unscrewed, cleaned, and replaced.
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Water Circulation

Use the small drain hose to evacuate the water remaining in the bottom of the tub before removing the filter.
The drain pump is on the left and exhausts the water via the gray corrugated hose.
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The recirculating pump is on the right and recirculates water from the tub to the shower spray at the top of the door gasket via the smaller black hose.
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Parts Identification

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Air Vent

The air vent on the back of the machine must be left open and clear at all times.
If the washer is installed in a closet or closed laundry alcove, there must be sufficient clearance and ventilation. The closet should have a full louvered door with at least 800 square inches (0.5 m2) of open area for ventilation.
The washer requires a space of at least 1 inch (2.5 cm) between the wall and the machine on each side and at least 4 inches (10 cm) between the back of the washer and the wall.
Additional space may be needed for servicing.
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Accessories

The washer comes with the two input hoses. The blue stripe is for cold water and the red stripe is for hot water. While the hoses are mechanically identical, it is critical to the performance of the washer to have the hot and cold hoses connected correctly.
The wrench is used to remove (and replace) the shipping bolts and to adjust the leveling feet. Be sure to leave it and encourage the customer to retain the wrench, the four shipping bolts, and the manual in a safe place in the event the washer requires service or the customer moves.
The shipping bolts MUST BE REMOVED before operating the washer.
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Remote Laundry Monitor and Modem

The remote laundry monitor (RLM) allows the user to monitor the progress of both washer and dryer, provided they are quipped with a modem.
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Install The Washer Modem

Remove the cover and install the modem on the back of the washer.
Save the small socket cover and screws in the event you need to remove the modem for some reason. The socket should be covered at all times.
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Install the Dryer Modem

If you’re installing both the washer and the dryer at this time, you might as well install the dryer modem now.
Remove the cover and install the modem on the back of the dryer.
Save the small socket cover and screws in the event you need to remove the modem for some reason. The socket should be covered at all times.
After installation is complete, plug in the washer, dryer,
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and monitor, in that order. Turn on the washer and dryer. Press and hold the SET button on the monitor.
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Remove The Shipping Bolts

Remove the shipping bolts.
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Install On A Firm, Flat Surface

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Level The Washer

Rock the corners to determine which leg is off. Adjust the front legs to get the washer level both front-to-back
and side-to-side. Push it into position and fine-tune the leveling.
Lock the adjusters when you are finished.
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Water Connections

Be sure the rubber washer is inside the hose end. Attach the hoses to the washer (red is HOT, blue is COLD).
Tighten them firmly but don’t strip the plastic threads on the washer connections.
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Drain Connections

The drain pipe should be firmly attached to the standpipe or the laundry tub or sink where it drains. The pump has sufficient power to cause the pipe to move around when the water is expelled. The pump can lift the drain water a maximum of 96 inches (2.4 m), but there is no minimum height
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requirement. The vacuum breaker in the drain line will prevent drainage by gravity or siphoning. The hose can lay flat into a floor drain as long as the end of it is not submerged.
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Electrical Connections

The steam washer requires a 120 VAC, 60 Hz., dedicated, 20-amp circuit.
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Control Panel

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Option Buttons

Press to add a pre-wash cycle. (Press and hold to select or deselect the Child Lock function)
Press after power-up without selecting a cycle to rinse and spin ONLY, without washing! (Press and hold to turn the drum light on while the washer is operating.)
Press to add an extra rinse cycle. (Press and hold to run a tub cleaning cycle. The washer must be empty!)
Press to add additional washing time. Press to add extra water to the wash and rinse cycles.
(Press and hold this button with the washer OFF and then press POWER to access the language menu.)
To select the optional feature, follow the instructions in parentheses.
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Program Chart

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Safety Revisited

BEFORE PERFORMING SERVICE
•Be careful to avoid electric shock when disconnecting parts for troubleshooting.
•Most terminals in the steam washer have 120 VAC or DC on them, sometimes even when the washer is off.
•The steam generator operates at a high temperature. Be careful when servicing it. It can be drained in place by removing the drain cap, but have a hose or a big towel ready to soak up the spillage.
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Dispenser

Main Wash (Siphon box for liquids in place)
Liquid Bleach
The dispenser drawer is a multi­chambered reservoir that allows the user to add all the appropriate laundry additives before starting the cycle. It has a place for pre-wash detergent, main wash detergent, fabric softener, and bleach. Powdered or liquid detergents may be used, but softener and bleach must be liquids.
Detergents should carry the HE
Liquid Softener
Pre Wash (Liquid or Powder)
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designation.
Do not use regular detergents in the washer or oversudsing will occur.
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Dispenser

The dispenser works by using various solenoids to apply water to different compartments. The liquid products are dispensed from a siphon box. As the appropriate chamber is flooded,
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the box fills and the water flushes the laundry product into the tub. It is mixed with water before contacting the laundry to prevent spotting or damaging the fabric.
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Dispenser

Notice that the pre-wash and main wash fill tubes enter the dispenser at an angle. If one or the other fill valve is opened, the water goes into the appropriate detergent compartment. However, if they are opened simultaneously, the streams deflect and dispense the
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softener. Some water may run through the main and pre­wash compartments, but since the detergent has already been dispensed in an earlier part of the cycle, this is of no consequence.
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Dispenser

If liquid detergent is added to the pre­wash box, it will run immediately into the tub. This does not affect the operation of the cycle.
To use liquid detergent in the main wash, place the detergent siphon box in the main wash compartment.
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Otherwise, the main wash liquid detergent will run into the tub along with the pre-wash detergent, causing oversudsing in the pre-wash and no cleaning in the main wash.
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Dispenser

The siphon boxes are designed to hold a liquid laundry product until the appropriate time for dispensing into the load.
When the box fills with water, it begins to discharge its contents into the washer fill stream. Once the siphon action has started, it will continue until the siphon box has
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emptied itself. Use only regular viscosity bleaches
and softeners; the ultra versions are usually much thicker and do not dispense well, if at all.
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Direct Drive Motor

The motor is a direct-drive, brushless, DC motor. It is attached to the drum via a splined shaft, eliminating belts, pulleys, transmissions, and the inherent problems associated with them. The rotor is attached to the shaft by one large bolt.
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Direct Drive Motor

The DC motor can be driven from stopped to maximum speed in infinite steps in either direction. There are 36 poles on the stator; 12 permanent magnets spaced around the rotor. There are no brushes to wear out. Unlike a more traditional brushless motor, the rotor surrounds the stator
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rather than being attached to it. A Hall Effect sensor determines the speed and direction of the motor. It also can read that the load is off balance when the drum speed fluctuates.
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Motor

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Motor/Hall Effect Sensor

The Hall Effect sensor is easily removed and replaced. You’ll have to remove the rotor and stator to access the sensor. When replacing the rotor, you’ll probably need a helper to hold the drum in place when you push the rotor onto the shaft. Otherwise, the drum
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may move forward enough to make replacing the bolt difficult. The helper can also hold the drum from turning while you tighten the bolt.
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Motor/Hall Effect Sensor

Before going to this trouble, check the connector on the main board. It is the red connector closest to the
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heat sink.
Pull the connector off and verify the board is receiving a signal from the sensor.
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Test Mode

The steam washer must be empty and off to enter the test mode.
Press and hold SPIN SPEED and SOIL LEVEL.
Press POWER. Press
START/PAUSE to cycle through the test modes.
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Check Water Level Frequency

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Error Display

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Error Display

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Error Display

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Diagnosis

No Power
Water Inlet Issue
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Diagnosis

Door Error
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Diagnosis

Drain Issue
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Diagnosis

Oversudsing
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Diagnosis

Dispenser Issue
Error Code – Service
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Troubleshooting

No Power
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Troubleshooting

Vibration/Spin Noise
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Troubleshooting

No Water Supply
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Troubleshooting

Dispenser
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Troubleshooting

Unusual Noise
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Troubleshooting

Heater Error
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Troubleshooting

Drain Issue
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Troubleshooting

Wash Heater Issue
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Troubleshooting

Over-Temp Issue
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Troubleshooting

No Circulation
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Troubleshooting

Spin Issue
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Troubleshooting

dE Error
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Disassembly and Repair

The following pages will show the instructions for disassembly, repair, replacement of parts, and re-assembly. Many times, electrical components may be tested by connecting the appropriate meter to the leads or connectors on the main PC Board.
(Refer to the block wiring diagram, next slide.) Proper diagnosis will eliminate unnecessary labor and expedite repairs.
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Block Wiring Diagram

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Disassembly and Repair

Control Panel
1. Remove two screws on the back of the top plate.
2. Pull the top plate backward and lift, as shown.
3. Remove the detergent drawer.
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4. Remove two screws behind the detergent drawer.
5. Disconnect the connector for the Display PWB.
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Disassembly and Repair

Control Panel, continued
6. Remove one screw from the
7. Lift the top away from the
corner of the control panel.
support rail and pull the control panel up and away to remove.
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8. Remove eight screws to separate the control panel and PWB.
9. Reassembly is the reverse of these steps.
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Disassembly and Repair

Main Board Often, you can diagnose a failed part by removing its connector on the
main board and connecting the tester to the leads in the connector.
1. Disconnect the POWER connector and the Water Level Sensor Switch.
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2. Remove the protective cover. Press the plastic tabs out of the way to remove the cover. The main board is potted, so no repairs to it are possible.
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Disassembly and Repair

Main Board, continued
3. Disconnect the connectors on the main board. They are all different, keyed, and color-coded to prevent incorrect connection.
4. Pull the wires out of the way.
5. Remove one screw on the back of the washer to release the main board housing.
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6. Remove the main board by sliding it to the right and lifting it up.
Replacement is accomplished by pressing it toward the back of the washer and sliding it toward the left.
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Disassembly and Repair

Dispenser
1. Remove the top plate.
2. Remove the dispenser drawer.
3. Remove two screws to release
4. Loosen the clamp on the large
the dispenser.
hose that runs from the
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dispenser to the drum.
Have an old towel handy to stuff under the dispenser to soak up any spillage.
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Disassembly and Repair

Dispenser, continued
5. Disconnect the connector from
#1 Blue; yellow and black wires #2 Red; violet and black wires
the solenoid. Make a note of the color codes and connections.
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#3 White; white and black wires #4 Blue; gray and black wires #5 Red; blue and black wires (hot)
6. Remove two screws from the back of the cabinet
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Disassembly and Repair

Noise Filter
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1. Remove the connectors from the noise filter.
2. Remove the screw from the top bracket.
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Disassembly and Repair

Front Cover
1. Remove the top plate.
2. Remove the control panel.
3. Remove four screws that secure the front panel.
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4. Remove the screw that secures the filter cover.
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Disassembly and Repair

Front Cover, continued
5. Use a flat screwdriver or a putty knife to loosen the filter cover and pull it out.
6. Stick the screwdriver into the cover slot and pry it out sideways to free it.
7. Drain the sump by pulling out
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the little hose by the filter cover. Let the water (maybe as much as a quart) drain into a shallow pan. Don’t pull the hose out so far you kink it or the water will not flow.
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Disassembly and Repair

Front Cover, continued
8. Open the door.
9. Remove the clamp using special tool 383EER4001A.
10. Lean the cabinet front forward, being careful to avoid breaking the glass. The door is HEAVY.
11. Disconnect the door switch connector.
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(Remember to replace it upon
reassembly.)
12. Lift the door and front cover off the cabinet base as an assembly. Lay it face down on a blanket or some other protective surface.
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Disassembly and Repair

Door Remove the door with the front cover still
on the machine.
1. Open the door.
2. Remove seven screws from the hinge cover.
3. Pry off the hinge cover with a flat screwdriver.
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4. Remove the screw at the bottom of the hinge.
5. Lift the door off the hinge.
CAUTION! The door is HEAVY!
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Disassembly and Repair

Door Switch Removal
1. Open the door.
2. Remove the gasket clamp using special tool 383EER4001A.
3. Remove the two screws holding the switch.
4. Push the gasket aside to remove the switch.
5. Unplug the switch to
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change it.
6. Make sure the wires don’t fall back in before you can replace the switch.
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Disassembly and Repair

Pump
1. Remove the front cabinet.
2. Drain the water from the
3. Remove the clamps and
4. Remove two screws and push
sump.
hoses.
the pump backward and up.
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5. Press down the plastic tab on the base to slide the pump assembly backward.
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Disassembly and Repair

Pump
6. You can tilt the pump in either direction to remove/replace the
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individual pumps without having to remove the tub.
Have a towel handy to catch the spillage.
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Disassembly and Repair

Heater
1. Remove the front cabinet.
2. Drain the water from the
3. Remove the push-on
4. Remove the nut that holds
sump.
connectors from the heater.
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the ground wire. Then loosen but do not remove the nut that secures the heater clamp and pull the heater out. You may have to wiggle it to release the gasket.
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Disassembly and Repair

Thermistor
1. Remove the front cabinet.
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2. Drain the water from the sump.
3. Unplug the white connector.
4. Hold the bracket and pull the thermistor out.
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Disassembly and Repair

Removal of Foreign Objects
1. Remove the top cover.
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2. Remove the front cabinet cover.
3. Remove the heater.
4. Fish out the foreign object(s) using a wire or bar.
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Disassembly and Repair

Interior Light
1. Remove the top cover.
2. Separate the connector near
3. Remove the lamp assembly
4. Replacement is the reverse of
the lamp.
and lead wire from the gasket.
this procedure.
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Disassembly and Repair

Motor
For technical information concerning the direct drive DC motor, refer to page 22.)
1. Remove the back cover.
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2. Remove the large bolt in the center shaft. (Your helper can hold the inside of the drum.)
3. Pull the rotor off the shaft.
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Disassembly and Repair

Motor
1. Remove two screws from the
2. Remove six bolts on the stator.
tub bracket.
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3. Unplug two connectors on the stator.
4. Pull the stator off the shaft.
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Disassembly and Repair

Motor
5. When re-installing, the clamps and the ground screw must be installed and the connectors pressed into place
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before the rotor is bolted onto the shaft.
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Disassembly and Repair

Tub and Drum
Removing the tub/drum assembly is major surgery. It is much lighter if you remove the weights and the motor. Generally speaking, you’ll have to remove all that anyway.
1. Remove the motor.
2. Drain the water from the sump.
3. Remove the control panel.
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4. Remove the front cabinet.
5. Disconnect all hoses and electrical connections.
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Disassembly and Repair

6. Separate the three dampers.
Tub and Drum
You can remove just one end now and the other one after
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the drum is out.
7. Pry apart the retainer clip.
8. Carefully lift the tub up off the springs and remove it from the machine.
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Disassembly and Repair

Tub and Drum
[photo goes here]
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9. Unbolt the bolts around the circumference of the seam. Separate the halves. Be careful to avoid damaging the gasket. Do not pry on the surfaces between the halves.
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Disassembly and Repair

Dampers
1. Disconnect the dampers from the tub and the base. (See photos, left.)
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Be sure to press in the safety tab before pushing the pin out of the damper. You can use a socket to hold the tab in while you squeeze the pin with the special tool 383EER4003A.
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Disassembly and Repair

Dampers
2. The flat end goes on the pointed end and the split
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end allows the head end to pass through while the pin is pushed out.
The color and/or appearance of the damper may vary by model.
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Disassembly and Repair

3. Use special tool 383EER4003A
Dampers
to remove the damper pins. If you are replacing the dampers, you’ll have to remove both ends. If you are removing the tub for major repair work, disconnect the damper ends at the base and leave the other ends connected until you remove the tub. When putting
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the tub back into the machine, connect the dampers to the tub first. It is much easier that way.
4. Be careful not to pull the dampers apart while they are disconnected.
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Disassembly and Repair

Turbo Steam Generator (TSG)
The TSG (Turbo Steam Generator) is supplied as an assembly only; parts like the sensor, thermistor, or heater cannot be replaced individually.
Diagnosis is limited to determining malfunction and replacing as an assembly.
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Have a hose available to slip onto the connector or a large towel to catch the water so it doesn’t run down into the machine cabinet. If you remove the steam generator before draining it, be sure to avoid tipping it and spilling the water.
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Disassembly and Repair

Turbo Steam Generator (TSG)
1. The steam generator can be
2. Unplug the washer.
removed as an assembly for diagnosis and replacement.
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3. Disconnect all electrical connections, including ground.
4. Drain the water. (You can drain the water later and it is easier.)
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Disassembly and Repair

Turbo Steam Generator (TSG)
5. Remove all the cable straps by squeezing the tabs and pulling them out. They can be reused.
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6. Remove the four screws holding the support rail in place and two screws attaching the steam generator.
7. Disconnect the hoses (water input and steam output.)
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