LG LFX21960ST Training Manual Download

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REFRIGERATOR TROUBLESHOOTING

SEALED SYSTEM DIAGNOSIS

Complaint:

No cooling, all components operating, no airflow issues, not frosted up.

The EQUALIZATION test is trying to restart a compressor using a start kit after

the refrigerator has been running.

LFX21960ST/LFX25960xx

Page 4

of 75

TRAINING MANUAL

Summary of Contents for LFX21960ST

Page 1: ...LG TRAINING MANUAL French Door Refrigerator Fall 2007 LG TRAINING MANUAL Models LFX21960ST LFX25960xx ...

Page 2: ...Website biz lgservice com LG CS Academy lgcsacademy com This manual was current at the time of publication however all information contained herein is subject to change When ordering parts always order by model number and serial number If the part has been changed the newer part will be provided Published by LG Technical Support Service LFX21960ST LFX25960xx Page 2 of 75 TRAINING MANUAL ...

Page 3: ...t must be recovered using an approved recovery device 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 yo...

Page 4: ...RATION 16 Controls 16 Ice Plus 16 Dispenser Lock 16 Filter Reset 16 DISASSEMBLY 17 Refrigerator Door Removal 17 Freezer Door Removal 18 Freezer Door Replacement 19 Door Frame Removal 20 Door Gasket Clip Release 20 Door Gasket Replacement 22 Door Gasket Clip Replacement 22 Door Frame Replacement 23 Dispenser 24 Filter 24 Freezer Fan and Motor 25 Ice Room Fan 25 Defrost Control Assembly 26 Refrigera...

Page 5: ...mpressor and Electrical Components 37 PTC and OLP 38 Other Electrical Components 39 Service Diagnosis Chart 40 Refrigeration Cycle 41 Sealed System 42 LED Test 43 Test Mode 43 ERROR CODES Defect Diagnosis 44 MICOM CIRCUITS AND FUNCTIONS 45 Display Defaults O F or O C Lock Filter 45 Ice Plus 46 Lamp Auto Off 46 Door Open Alarm 47 Buzzer 47 Defrost Mode 47 Initialization Sequence 48 Demo Mode 48 LFX...

Page 6: ...rcuit 53 Temperature Compensation Table 54 Freezer Sensor Resistance Specification 54 Display Light and Button Circuit 55 SCHEMATICS 56 Circuit Diagram 56 Main Board Layout 57 58 Main Board Parts List Display Board Schematic 59 Display Board Parts Layout 60 Display Board Parts List 60 EXPLODED VIEWS 61 Case Parts 61 Freezer Parts 62 Refrigerator Parts 63 Door Parts 64 Ice and Water Parts 65 Icemak...

Page 7: ...hey can be removed if necessary for moving the refrigerator through doorways Some models include a water dispenser in the left door and or a tilt out freezer door The freezer door is easily removed This training manual covers installation operation testing diagnosis and repair There is a special section for Tips Tricks to make the job easier Full schematics and parts lists are included Drawings an...

Page 8: ...REFRIGERATOR SPECIFICATIONS SPECIFICATIONS LFX21960ST LFX25960xx Page 8 of 75 TRAINING MANUAL ...

Page 9: ...REFRIGERATOR SPECIFICATIONS FEATURES LFX21960ST LFX25960xx Page 9 of 75 TRAINING MANUAL ...

Page 10: ...REFRIGERATOR WARRANTY WARRANTY May vary by model LFX21960ST LFX25960xx Page 10 of 75 TRAINING MANUAL ...

Page 11: ...igerator to the installation area If you have to remove the doors there is a section in the manual covering that See pages 20 21 Be cautious to avoid damaging the refrigerator or the flooring Connect the water line if applicable Turn on the water and check for leaks There is a section in this manual covering that See page 15 Roll the refrigerator into place Level the refrigerator by lowering the l...

Page 12: ...STALLATION While most kitchens have a place already designed for a refrigerator we remind you not to install the refrigerator near a heat source a damp spot or in bright sunlight The refrigerator is designed to be installed in an area where the ambient temperature is between 55 F and 110 F 13 C and 43 C If the ambient temperature is outside this specification the refrigerator s performance may be ...

Page 13: ...r is lower the doors will hang crookedly Turn the leg under the lower door clockwise to raise that side If there is not sufficient adjustment it may be necessary to use up to three snap rings as shims on the lower hinge pin Three snap rings are provided with the refrigerator LFX21960ST LFX25960xx Page 13 of 75 TRAINING MANUAL ...

Page 14: ...ndle UP to remove it DOWN to replace it The freezer door handle works in a similar manner Slide it RIGHT to remove it LEFT to replace it If it is necessary to remove the doors to get the refrigerator into the house see the DOOR REMOVAL section on pages 20 21 DOOR REMOVAL Child entrapment and suffocation are not things of the past Junked or abandoned refrigerators are dangerous If you must scrap a ...

Page 15: ...refrigerator is unplugged Connect the water line to the water valve on the back of the refrigerator The connection is a standard 1 4 inch fitting that will accept either a compression fitting or one of the many braided reinforced hoses available for this purpose at most hardware stores LFX21960ST LFX25960xx Page 15 of 75 TRAINING MANUAL ...

Page 16: ... 13 C ICE PLUS Pressing the ICE PLUS button activates that feature and turns on the LED for 24 hours During that time the cooling speed of the freezer and ice production will be intensified DISPENSER LOCK PRESS and HOLD the LOCK button for 3 seconds to lock or unlock the dispenser When locked the dispenser will not operate and the display will be off The dispenser will not operate if any door is o...

Page 17: ...REFRIGERATOR DISASSEMBLY DISASSEMBLY REFRIGERATOR DOOR REMOVAL Figure 1 LFX21960ST LFX25960xx Page 17 of 78 TRAINING MANUAL ...

Page 18: ...ift the top of the door to unhook the door supports from the rail Then lift the door to remove it DO NOT HOLD the door by the handle Be careful when setting the drawer down to avoid injury to floor or feet Alternate method The freezer door can be removed by tilting it out and then raising the clips as shown one clip on each side LFX21960ST LFX25960xx Page 18 of 75 TRAINING MANUAL ...

Page 19: ...d the door CAUTION Be careful removing the doors They are heavier than you might expect and dropping them could damage the doors or cause personal injury To prevent accidental child or pet entrapment or suffocation DO NOT allow them to play inside the freezer drawer DO NOT sit or stand on the freezer door It may tip over and cause severe injury or damage LFX21960ST LFX25960xx Page 19 of 75 TRAININ...

Page 20: ...REFRIGERATOR DISASSEMBLY DOOR FRAME COVER REMOVAL LFX21960ST LFX25960xx Page 20 of 75 TRAINING MANUAL ...

Page 21: ...n the photo to release the clips They can be re installed in the same manner Removing the gasket is easy after the clips are released Start at the top corner on the side where the door edges meet Pull the gasket out of the channel from top to bottom holding the top to keep it from falling Continue across the bottom up the side and back across the top of the door until the gasket is free LFX21960ST...

Page 22: ... Push the clip in until you feel it snap firmly into place 4 Replace the remaining clips the same way Make certain no part of the bracket protrudes at the frame edge DOOR GASKET BRACKET AND CLIP PLACEMENT 5 Insert the gasket into the channel and slide it all the way down the bracket This is easier when you start it from the top and work toward the bottom LFX21960ST LFX25960xx Page 22 of 75 TRAININ...

Page 23: ...ng three sides of the gasket into the groove DOOR FRAME COVER REPLACEMENT Press the door frame cover into place starting at the top and working down Be careful to avoid breaking the plastic tabs LFX21960ST LFX25960xx Page 23 of 75 TRAINING MANUAL ...

Page 24: ...t a small piece of tape below the dispenser to avoid scratching the finish 3 Separate the connector before pulling the dispenser away 4 Replacement is the reverse of these steps FILTER Twist the filter counterclockwise to remove it Insert the new filter and twist it clockwise until it clicks into place Put a cup under the hole at the rear of the filter holder to catch the drip when the filter is r...

Page 25: ... guide on the left side of the freezer 4 Remove the screw in the access panel of the grille 5 Remove two screws to take off the fan bracket and motor as an assembly 6 Pull the fan blade off the shaft and remove the motor from the bracket ICE ROOM FAN 1 Remove the grille steps 1 4 above 2 Disconnect the wire harness from the grille 3 Remove the fan assembly by removing two screws LFX21960ST LFX2596...

Page 26: ... before working on it 2 Remove the freezer grille as described above to expose the evaporator coil 3 Cut the cable tie and remove the defrost control assembly 4 Separate the connector to remove and replace the defrost control 5 Replace the cable tie to hold the control assembly in place REFRIGERATOR LAMP 1 Unplug the refrigerator before working on it 2 Remove the refrigerator shelves for easier ac...

Page 27: ...eld and the tabs will click into place MULTI DUCT 1 Remove the upper and lower caps using a small screwdriver 2 Remove the two screws holding the duct in place 3 Pull the duct away from the back of the refrigerator from the top 4 Disconnect the lead wire at the bottom of the duct before pulling the duct out any farther 5 Replacement is the reverse of disassembly LFX21960ST LFX25960xx Page 27 of 75...

Page 28: ...REFRIGERATOR ICEMAKER ICEMAKER THEORY OF OPERATION Turn the icemaker switch OFF and then ON again to reset it LFX21960ST LFX25960xx Page 28 of 75 TRAINING MANUAL ...

Page 29: ...REFRIGERATOR ICEMAKER LFX21960ST LFX25960xx Page 29 of 75 TRAINING MANUAL ...

Page 30: ...REFRIGERATOR ICEMAKER LFX21960ST LFX25960xx Page 30 of 75 TRAINING MANUAL ...

Page 31: ...her than that for which they were manufactured 2 Do not use an inverter to power this refrigerator Inverters usually output a square wave instead of a sine wave and this destroys the compressor quickly The damage is not repairable 3 If compressor is dropped or handled carelessly poor operation and noise may result 4 Use proper electric components appropriate to the particular compressor in your pr...

Page 32: ... restart The PTC device generates heat during operation Therefore it must be allowed to cool before the compressor can restart If the compressor attempts to restart before the PTC device is cooled the PTC device will allow current to flow only to the main winding The OLP will open because of the over current condition This same process will continue 3 to 5 times when the compressor attempts to res...

Page 33: ...art could result in damage to the product fire injury or death OVERLOAD PROTECTOR OLP The OLP OVERLOAD PROTECTOR is attached to the compressor and protects the motor by opening the circuit to the motor if the temperature rises and activates the bimetal spring in the OLP When high current flows to the compressor motor the heater inside the OLP caused the bimetal spring to trip protecting the motor ...

Page 34: ...ts Order these parts by part number model number and serial number Several OLPs may look physically identical but have electrically different capacities and ratings Using the wrong one could result in product damage or destruction fire electrical shock injury or death LFX21960ST LFX25960xx Page 34 of 75 TRAINING MANUAL ...

Page 35: ...REFRIGERATOR TROUBLESHOOTING TROUBLESHOOTING LFX21960ST LFX25960xx Page 35 of 75 TRAINING MANUAL ...

Page 36: ...REFRIGERATOR TROUBLESHOOTING TROUBLESHOOTING continued LFX21960ST LFX25960xx Page 36 of 75 TRAINING MANUAL ...

Page 37: ...REFRIGERATOR TROUBLESHOOTING COMPRESSOR AND ELECTRICAL TROUBLESHOOTING LFX21960ST LFX25960xx Page 37 of 75 TRAINING MANUAL ...

Page 38: ...REFRIGERATOR TROUBLESHOOTING PTC AND OLP PTC Terminals 5 6 PTC Continuity Check Figure 20 Figure 21 LFX21960ST LFX25960xx Page 38 of 75 TRAINING MANUAL ...

Page 39: ...REFRIGERATOR TROUBLESHOOTING OTHER ELECTRICAL COMPONENTS LFX21960ST LFX25960xx Page 39 of 75 TRAINING MANUAL ...

Page 40: ...REFRIGERATOR TROUBLESHOOTING SERVICE DIAGNOSIS CHART LFX21960ST LFX25960xx Page 40 of 75 TRAINING MANUAL ...

Page 41: ...REFRIGERATOR TROUBLESHOOTING REFRIGERATION CYCLE TROUBLESHOOTING MOISTURE RESTRICTION LFX21960ST LFX25960xx Page 41 of 75 TRAINING MANUAL ...

Page 42: ...OSIS Complaint No cooling all components operating no airflow issues not frosted up The EQUALIZATION test is trying to restart a compressor using a start kit after the refrigerator has been running LFX21960ST LFX25960xx Page 42 of 75 TRAINING MANUAL ...

Page 43: ...defective part Enter the TEST MODE by pressing FRZ and LOCK on the control panel or by pressing the TEST SWITCH on the main board In TEST MODE the control buttons are deactivated but the buzzer still sounds a ding To exit the TEST MODE unplug the refrigerator for one minute If a malfunction such as a sensor failure is detected in the TEST MODE the TEST MODE is cleared and the error code is display...

Page 44: ...frigerator has a built in diagnostic mode When a malfunction is discovered the control buttons are deactivated but the buzzer still sounds when they are pressed ERROR CODES are shown on the display ERROR CODE CHART LFX21960ST LFX25960xx Page 44 of 75 TRAINING MANUAL ...

Page 45: ...REFRIGERATOR MICOM MICOM CIRCUIT AND FUNCTION DEFAULTS LFX21960ST LFX25960xx Page 45 of 75 TRAINING MANUAL ...

Page 46: ...us will complete its cycle after the defrost is completed If defrost begins more than 90 minutes into the Ice Plus cycle Ice Plus will run for two hours after the defrost has ended The freezer fan normally runs at 2 400 rpm The high speed 2 700 rpm is used when ICE PLUS is operated at initial power up and when the freezer is overloaded When the ICE PLUS option is functioning the LED is on In the e...

Page 47: ...enever a button on the control panel is pushed See schematic of this circuit page 68 DEFROST MODE A defrost cycle is initiated every time the compressor has logged 7 hours run time At initial power up or when power is restored after an outage the first defrost cycle will begin after 4 hours run time Defrosting stops automatically when the sensor detects a temperature over 46 4 F 8 C If the tempera...

Page 48: ...E The DEMO MODE is available so the lights and controls will operate normally in a sales setting Even the LAMP AUTO OFF feature can be demonstrated In DEMO MODE the heavy loads compressor fans damper and heater are inactivated To enter DEMO MODE press and hold ICE PLUS and FREEZER for more than three seconds The same procedure will turn DEMO MODE off LFX21960ST LFX25960xx Page 48 of 75 TRAINING MA...

Page 49: ...inside elements are short circuited and broken resulting in blowing the fuse to protect the elements of the secondary part of the TRANSFORMER OSCILLATOR CIRCUIT This circuit generates the base clock for calculating time and the synchro clock for transmitting data from and to the inside logic elements of the IC1 MICOM Be sure to use specified replacement parts since calculating time by the IC1 may ...

Page 50: ...the power is initially supplied or the power supply to the MICOM is restored after a momentary power failure For the initial 10ms of power supply LOW voltage is applied to the MICOM RESET terminal During a normal reset 5V is applied to the RESET terminal If a malfunction occurs in the RESET IC the MICOM will not operate LOAD DRIVE CIRCUIT LFX21960ST LFX25960xx Page 50 of 75 TRAINING MANUAL ...

Page 51: ... ISs inside of the fan motor in the fan motor OFF It allows a temporary change of speed for the fan motor and applies voltage up to 7 5VDC 16VDC to motor and prevents over driving the fan motor by cutting off power applied to the fan motor if it is locked by sensing the operation RPM of the fan motor LFX21960ST LFX25960xx Page 51 of 75 TRAINING MANUAL ...

Page 52: ...s REFRIGERATOR temperature FREEZER Temperature and DEFROST SENSOR temperature for defrosting It reads the indoor temperature for compensating for the surrounding temperature into MICOM The OPEN or SHORT state of each TEMPERATURE SENSOR is as follows LFX21960ST LFX25960xx Page 52 of 75 TRAINING MANUAL ...

Page 53: ...m its set position to fully open to fully closed and back to the original position on an hourly basis to keep it from becoming ice bound DISPENSER INPUT CIRCUIT TEMPERATURE COMPENSATION CIRCUIT This circuit allows adjustment of the temperature in the refrigerator if there is a discrepancy between the set temperature and the actual temperature LFX21960ST LFX25960xx Page 53 of 75 TRAINING MANUAL ...

Page 54: ... you can change the value of the RCR Refrigerator Compensation Resistor to compensate for the difference from the current temperature For example if the RCR is changed from 10K the current resistance to 18K the adjusted resistance the temperature of the refrigerator rises from 32 F 0 C to 33 8 F 1 C LFX21960ST LFX25960xx Page 54 of 75 TRAINING MANUAL ...

Page 55: ... measure the resistance after the sensor has stabilized for 3 minutes Delay necessary due to sensor response speed DISPLAY LIGHT BUTTON CIRCUIT This circuit determines which button on the control panel is pushed and drives the corresponding LED on the display LFX21960ST LFX25960xx Page 55 of 75 TRAINING MANUAL ...

Page 56: ...REFRIGERATOR PCBs LFX21960ST 25960xx Page 56 of 75 TRAINING MANUAL ...

Page 57: ...REFRIGERATOR PCBs Main Board Layout LFX21960ST LFX25960xx Page 57 of 75 TRAINING MANUAL ...

Page 58: ...REFRIGERATOR PCBs Main Board Parts List LFX21960ST LFX25960xx Page 58 of 75 TRAINING MANUAL ...

Page 59: ...REFRIGERATOR PCBs Display Board Schematic LFX21960ST LFX25960xx Page 59 of 75 TRAINING MANUAL ...

Page 60: ...REFRIGERATOR PCBs Display Board Layout LFX21960ST LFX25960xx Page 60 of 75 TRAINING MANUAL ...

Page 61: ...REFRIGERATOR EXPLODED VIEWS EXPLODED VIEWS CASE PARTS LFX21960ST LFX25960xx Page 61 of 75 TRAINING MANUAL ...

Page 62: ...REFRIGERATOR EXPLODED VIEWS FREEZER PARTS LFX21960ST LFX25960xx Page 62 of 75 TRAINING MANUAL ...

Page 63: ...REFRIGERATOR EXPLODED VIEWS RERIGERATOR PARTS LFX21960ST LFX25960xx Page 63 of 75 TRAINING MANUAL ...

Page 64: ...REFRIGERATOR EXPLODED VIEWS DOOR PARTS LFX21960ST LFX25960xx Page 64 of 75 TRAINING MANUAL ...

Page 65: ...REFRIGERATOR EXPLODED VIEWS ICE WATER PARTS LFX21960ST LFX25960xx Page 65 of 75 TRAINING MANUAL ...

Page 66: ...REFRIGERATOR EXPLODED VIEWS ICEMAKER PARTS LFX21960ST LFX25960xx Page 66 of 75 TRAINING MANUAL ...

Page 67: ...REFRIGERATOR EXPLODED VIEWS DISPENSER PARTS LFX21960ST LFX25960xx Page 67 of 75 TRAINING MANUAL ...

Page 68: ...ssembly Multi ABCD 131A 5074JA2004A Bucket Ice ABCD 135D 3551JJ2028A Cover Assembly Grille Fan BCD 136A 3390JJ1072A Tray Drawer A 136A 3390JJ1073A Tray Drawer ABCD 136B 3391JA2054C Tray Assembly Drawer A 140A 5027JJ2014E Shelf Assembly Refrigerator BCD 140A 5027JJ2014F Shelf Assembly Refrigerator BCD 140B 5027JJ2012D Shelf Assembly Net BCD 140C 4975JA2028A Guide Assembly Rail A 140C 4975JA2028B Gu...

Page 69: ...J1070B Cover Lamp ABCD 158B 3550JA1386B Cover Lamp ABCD 160B 3551JJ2019D Cover Assembly Tray A 161C 5218JA2010B Rail Slide A 161D 5218JA2010A Rail Slide A 161E 4975JJ2019E Guide Assembly Rail A 161F 4975JJ2019F Guide Assembly Rail BCD 167B 3550JJ1069A Cover Magic Room A 167B 3550JJ1073A Cover Magic Room A 200A 3581JA8817B Door Assembly Freezer C 200A 3581JA8820A Door Assembly Freezer D 200A 3581JA...

Page 70: ...68A Holder Rail BCD 249D 4930JA1066B Holder Rail A 249D 4930JA1068B Holder Rail ABCD 249E 5218JA1009E Rail Slide A 249F 5218JA1009F Rail Slide BCD 249F 5218JA1010F Rail Slide A 249G 5098JA2001E Connector Assembly BCD 249G 5098JA2001H Connector Assembly A 249H 5098JA2001F Connector Assembly BCD 249H 5098JA2001G Connector Assembly ABCD 250A 4270JA3009H Bar ABCD 250B 4403JA3005A Connector Assembly AB...

Page 71: ...ass Door ABCD 280B 4930JA2074B Holder Button ABD 280C 5020JA2040E Button Lever C 280C 5020JA2040F Button Lever C 281A 3806JA2118A Decor Drain D 281A 3806JA2118B Decor Drain AB 281A 3806JA2150A Decor Drain ABCD 281C 4811JJ2015A Bracket Assembly Door ABCD 281D 3550JA2267B Cover Hinge ABCD 281E 3550JA2267A Cover Hinge ABCD 281F 3550JA2264A Cover Hinge ABCD 282F 3806JL1037C Decor Duct BCD 282G 5006JA3...

Page 72: ...e Fan ABCD 400A 6615JB2005H Controller Assembly CD 402A 6600JB3007A Switch Push Button AB 402A 6600JB3007E Switch Push Button ABCD 402C 6600JB3001E Switch Micro ABCD 404A 4681JB1029E Motor DC ABCD 405A 6421JB2002D Solenoid Assembly ABCD 405B 4810JJ2005A Bracket Motor ABCD 405C 5040JA2009B Damper Motor Support ABCD 405F 5040JA2004B Damper Motor Support ABCD 406B 6600JB1004A Switch Push Button BCD 4...

Page 73: ...ssembly ABCD 607A 4931JA3005B Holder Assembly Bracket ABCD 610A 3550JA2247A Cover Sensor ABCD 610B 6500JB1003G Sensor ABCD 610C 6500JB2002N Sensor ABCD 611A 5075JA1044A Bucket Assembly Ice ABCD 615A 4838JA2003A Tank Water ABCD 616D 5210JA3005L Tube Plastic ABCD 616F 5210JA3004U Tube Plastic ABCD 616G 5210JA3005W Tube Plastic ABCD 616H 4932JA3009A Connector Tube ABCD 617A 4970JA3004J Spring ABCD 61...

Page 74: ...BCD B04 1BZZJA2002A Bolt Common BCD B06 1SBZJA3004L Screw Customzied AB B06 1SBZJA3004W Screw Customzied BCD S01 4J00415D Screw Customzied ABCD S03 4J01424B Screw Customzied ABCD S08 1SZZJJ3005E Screw Customzied A S10 1SBZJA3004L Screw Customzied ABCD S11 3J05696W Screw Customzied ABCD S12 1SZZJJ3005E Screw Customzied CD S14 1SZZJJ3010B Screw Customzied AB S14 1SZZJJ3010D Screw Customzied ABCD S15...

Page 75: ...REFRIGERATOR PARTS NOTES LFX21960ST LFX25960xx Page 75 of 75 TRAINING MANUAL ...

Page 76: ... 14 57 2 15 9 4 15 59 16 8 9 16 60 8 17 8 3 17 62 6 18 7 8 18 64 4 19 7 2 19 66 2 20 6 7 20 68 21 6 1 21 69 8 22 5 6 22 71 6 23 5 0 23 73 4 24 4 4 24 75 2 25 3 9 25 77 26 3 3 26 78 8 27 2 8 27 80 6 28 2 2 28 82 4 29 1 7 29 84 2 30 1 1 30 86 31 0 6 31 87 8 32 0 0 32 89 6 33 0 6 33 91 4 34 1 1 34 93 2 35 1 7 35 95 36 2 2 36 96 8 37 2 8 37 98 6 38 3 3 38 100 4 39 3 9 39 102 2 40 4 4 40 104 For temper...

Page 77: ...inting Copies of files attached to the service bulletins are also included Servicers of LG products should regularly check for updated service bulletins to be certain that they have the latest information on parts and servicing procedures for the product they are repairing Service bulletins can be checked online using GCSC aic lgservice com or using CS Academy www lgcsacademy com LFX21960ST LFX259...

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