www.LGEservice.com
DISCOVERY WASHER TRAINING MANUAL
CAUTION!
READ THIS MANUAL CAREFULLY
BEFORE
DIAGNOSING
OR
SERVICING THIS PRODUCT.
Page 1: ...www LGEservice com DISCOVERY WASHER TRAINING MANUAL CAUTION READ THIS MANUAL CAREFULLY BEFORE DIAGNOSING OR SERVICING THIS PRODUCT ...
Page 2: ...0 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 ...
Page 3: ...st 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 repac...
Page 4: ...ation 17 Connections 18 Control Panel 19 Option Buttons 20 Program Chart 21 Before Performing Service 21 Detergent Dispenser 22 Direct Drive DC Motor 24 Hall Effect Sensor 25 Test Mode and Chart 26 Checking the Water Level Frequency 26 Error Display 27 Diagnosis and Check List Abnormal Operation 29 Fault Diagnosis and Troubleshooting 32 No Power 32 Vibration and Spin Noise 33 No Water Supply 34 De...
Page 5: ...ng Diagram 41 Control Panel 41 Main Board 42 Dispenser 43 Noise Filter 43 Front Cabinet Cover 44 Door 46 Door Switch 46 Pump 47 Heater 48 Thermistor 48 Foreign Object Between Drum and Tub 49 Interior Light 49 Motor 50 Tub and Drum 51 Damper 52 Turbo Steam Generator TSG 53 Tips and Tricks 55 Exploded Views 56 Exploded View Cabinet and Control Panel 56 Exploded View Drum and Tub 57 Exploded View Dis...
Page 6: ...NTRODUCTION 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 SPECIFICATIONS WM2688H M Page 6 of 64 TRAINING MANUAL ...
Page 7: ... opening allow easier loading and unloading 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 perfo...
Page 8: ... allows the user to lock the controls Children then cannot play with the buttons and disturb the 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 LCD Display The bright display replaces numerous LEDs and shows instructions when the controls are set WM2688H M Page 8...
Page 9: ...mber 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 This chart will help you decode the serial number WM2688H M Page 9 of 64 TRAINING MANUAL ...
Page 10: ...k 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 DOOR LOCKED LAMP The DOOR LOCK ...
Page 11: ...circulation 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 a safe temperature The pumps and filter are located at the bottom left front corner The filter can be unscrewed...
Page 12: ...WM2688H M Steam Washer PARTS IDENTIFICATION Front of Washer WM2688H M Page 12 of 64 TRAINING MANUAL ...
Page 13: ... Additional space may be needed for servicing 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 f...
Page 14: ...e event you need to remove the modem for some reason The socket should be covered at all times 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 and monitor in that order Turn on the washer a...
Page 15: ...WM2688H M Steam Washer INSTALLATION REMOVE THE SHIPPING BOLTS INSTALL THE WASHER ON A FIRM FLAT SURFACE ADJUST THE FEET TO BE LEVEL WM2688H M Page 15 of 64 TRAINING MANUAL ...
Page 16: ...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 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 ELECTRICAL...
Page 17: ...WM2688H M Steam Washer CONTROL PANEL The control panel is locates on the front of the Steam Washer All options are available from the control panel WM2688H M Page 17 of 64 TRAINING MANUAL ...
Page 18: ...rum light on while the washer is operating EXTRA RINSE Press to add an extra rinse cycle Tub Clean Press and hold to run a tub cleaning cycle The washer must be empty STAIN CYCLE Press to add additional washing time WATER PLUS Press to add extra water to the Language wash and rinse cycles Press this button with the washer OFF and then press POWER to access the language menu To select the optional ...
Page 19: ...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 WM2688H...
Page 20: ...e 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 designation Do not use regular detergents in the washer or oversudsing will occur The top of the dispenser box is shown here WM2688H M Page 20 of 64 TRAINING MANUAL ...
Page 21: ...iquid detergent is added to the pre wash 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 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 The...
Page 22: ...or 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 rather than being attached to it A Hall Effect sensor determines the speed and direction of the motor It also can read that the loa...
Page 23: ...place when you push the rotor onto the shaft Otherwise the drum may move forward enough to make replacing the bolt difficult The helper can also hold the drum from turning while you tighten the bolt Before going to this trouble check the connector on the main board It is the red connector closest to the heat sink Pull the connector off and verify the board is receiving a signal from the sensor WM2...
Page 24: ... washer must be empty and off to enter the test mode 1 Press and hold SPIN SPEED and SOIL LEVEL 2 Press POWER 3 Press START PAUSE to cycle through the test modes See chart CHECK THE WATER LEVEL FREQUENCY WM2688H M Page 24 of 64 TRAINING MANUAL ...
Page 25: ...WM2688H M Steam Washer ERROR DISPLAY continued on next page WM2688H M Page 25 of 64 TRAINING MANUAL ...
Page 26: ...WM2688H M Steam Washer WM2688H M Page 26 of 64 TRAINING MANUAL ...
Page 27: ...WM2688H M Steam Washer DIAGNOSIS and CHECK LIST Abnormal Operation WM2688H M Page 27 of 64 TRAINING MANUAL ...
Page 28: ...WM2688H M Steam Washer DIAGNOSIS and CHECK LIST Abnormal Operation continued WM2688H M Page 28 of 64 TRAINING MANUAL ...
Page 29: ...WM2688H M Steam Washer DIAGNOSIS and CHECK LIST Abnormal Operation continued WM2688H M Page 29 of 64 TRAINING MANUAL ...
Page 30: ...WM2688H M Steam Washer FAULT DIAGNOSIS and TROUBLESHOOTING WM2688H M Page 30 of 64 TRAINING MANUAL ...
Page 31: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 31 of 64 TRAINING MANUAL ...
Page 32: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 32 of 64 TRAINING MANUAL ...
Page 33: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 33 of 64 TRAINING MANUAL ...
Page 34: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 34 of 64 TRAINING MANUAL ...
Page 35: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 35 of 64 TRAINING MANUAL ...
Page 36: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 36 of 64 TRAINING MANUAL ...
Page 37: ...WM2688H M Steam Washer DIAGNOSIS TROUBLESHOOOTING continued WM2688H M Page 37 of 64 TRAINING MANUAL ...
Page 38: ... 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 below Proper diagnosis will eliminate unnecessary labor and expedite repairs BLOCK WIRING DIAGRAM WM2688H M Page 38 of 64 TRAINING MANUAL ...
Page 39: ...4 Remove two screws behind the detergent drawer 5 Disconnect the connector for the Display PWB 6 Remove one screw from the corner of the control panel 7 Lift the top away from the support rail and pull the control panel up and away to remove 8 Remove eight screws to separate the control panel and PWB 9 Reassembly is the reverse of these steps WM2688H M Page 39 of 64 TRAINING MANUAL ...
Page 40: ...he way to remove the cover The main board is potted so no repairs to it are possible 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 6 Remove the main board by sliding it to the right and lifting it up Replacement ...
Page 41: ...e dispenser to soak up any spillage 5 Disconnect the connector from the solenoid Make a note of the color codes and connections 1 Blue yellow and black wires 2 Red violet and black wires 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 DISASSEMBLY REPAIR Noise Filter 1 Remove the connectors from the noise filt...
Page 42: ...e filter cover 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 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 WM2688H M Page 42 o...
Page 43: ...n the cabinet front forward being careful to avoid breaking the glass The door is HEAVY 11 Disconnect the door switch connector 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 MODEL PRODUCT Page 43 of 64 TRAINING MANUAL ...
Page 44: ...ew at the bottom of the hinge 5 Lift the door off the hinge CAUTION The door is HEAVY DISASSEMBLY 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 change it 6 Make sure the wires don t fall back in before you can replace the switch WM2688...
Page 45: ...clamps and hoses 4 Remove two screws and push the pump backward and up 5 Press down the plastic tab on the base to slide the pump assembly backward 6 You can tilt the pump in either direction to remove replace the individual pumps without having to remove the tub Have a towel handy to catch the spillage WM2688H M Page 45 of 64 TRAINING MANUAL ...
Page 46: ...t that holds 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 DISASSEMBLY REPAIR Thermistor 1 Remove the front cabinet See page 39 2 Drain the water from the sump See page 42 3 Unplug the white connector 4 Hold the bracket and pull the thermistor out WM2688H M Page 46 of 64 TRAINING MANUAL ...
Page 47: ...page 39 3 Remove the heater See page 46 4 Fish out the foreign object s using a wire or bar DISASSEMBLY REPAIR Interior light 1 Remove the top cover See page 39 2 Separate the connector near the lamp 3 Remove the lamp assembly and lead wire from the gasket 4 Replacement is the reverse of this procedure WM2688H M Page 47 of 64 TRAINING MANUAL ...
Page 48: ...elper can hold the inside of the drum 3 Pull the rotor off the shaft 1 Remove two screws from the tub bracket 2 Remove six bolts on the stator 3 Unplug two connectors on the stator 4 Pull the stator off the shaft 5 When re installing the clamps and the ground screw must be installed and the connectors pressed into place before the rotor is bolted onto the shaft WM2688H M Page 48 of 64 TRAINING MAN...
Page 49: ...e page 39 4 Remove the front cabinet See page 39 5 Disconnect all hoses and electrical connections 6 Separate the three dampers See page 50 You can remove just one end now and the other one after the drum is out 7 Pry apart the spring retainer clip 8 Carefully lift the tub up off the springs and remove it from the machine 9 Unbolt the bolts around the circumference of the seam Separate the halves ...
Page 50: ...s through while the pin is pushed out The color and or appearance of the damper may vary by model 3 Use special tool 383EER4003A 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 the tub back into ...
Page 51: ...e draining it be sure to avoid tipping it and spilling the water 1 The steam generator can be removed as an assembly for diagnosis and replacement 2 Unplug the washer 3 Disconnect all electrical connections including ground 4 Drain the water You can drain the water later and it is easier 5 Remove all the cable straps by squeezing the tabs and pulling them out They can be reused 6 Remove the four s...
Page 52: ...o the steam generator There is a check valve that fits into the input port The valve sometimes comes off and is stuck in the hose This could cause the water not to flow which would cause the steam generator to malfunction 3 Pull the check valve out of the hose gently and replace it into the water input port Then slide the hose onto the port and install the clamp WM2688H M Page 52 of 64 TRAINING MA...
Page 53: ...fle and rollers without having to remove the drum Unscrew the retaining screw at the back of the baffle Slide it toward the front of the washer to remove it You can unscrew the retainer inside the baffle to replace the roller balls MUSHROOM VALVE Be sure the mushroom is in place before attaching the hose If the stem is too long it will contact the drum and make significant noise when the drum turn...
Page 54: ...1 NA to display board 10 BL fill valves 2 NA to display board 11 BL fill valves 3 RD modem display to control 12 YL steam level sensor 4 RD lamp 13 BL steam heater 5 NA wash and steam thermistors 14 BK wash heater 6 RD motor control 15 YL noise filter 7 NA Hall effect sensor 16 WH noise filter ground 8 BL pressure sensor 17 NA modem control to socket 9 NA door lock 18 BL LEDs not on all models WM2...
Page 55: ...WM2688H M Steam Washer WIRING DIAGRAM WM2688H M Page 55 of 64 TRAINING MANUAL ...
Page 56: ...WM2688H M Steam Washer EXPLODED VIEW Cabinet and Control Panel WM2688H M Page 56 of 64 TRAINING MANUAL ...
Page 57: ...WM2688H M Steam Washer EXPLODED VIEW Drum and Tub Assembly WM2688H M Page 57 of 64 TRAINING MANUAL ...
Page 58: ...WM2688H M Steam Washer EXPLODED VIEW Dispenser Assembly WM2688H M Page 58 of 64 TRAINING MANUAL ...
Page 59: ...3 2W20017E Gasket Clamp A140 4775ER2002A Hinge Assembly A141 4930ER4018A Guide A150 3581ER1012A Door Assembly A151 3212ER1037C Door Frame Inner A152 3212ER1036A Door Frame Outer A153 3650ER2006A Door Handle A154 4026ER4004A Door Latch Hook A155 3650FA3488M Hand Hold Cover A200 3041ER0001C Base Assembly A201 4810ER3006A Base Leg Bracket A220 4779ER3002A Leg Assembly A275 5215FD3715G Inlet Hose Hot ...
Page 60: ...15B Dispenser Assembly F310 4738ER1004B Bellows F315 4738ER2002A Bellows F321 5214ER4001R Inlet Hose F322 5214ER4001J Inlet Hose F323 5214ER4002F Inlet Hose F326 5214ER4002F Inlet Hose F327 5214FR4006F Inlet Hose F328 5214FR4006R Connecting Hose F430 5215ER2002G Drain Hose Assembly F431 4932FR3156A Drain Hose Connector Vacuum Break F432 3W50712A Drain Hose Hanger F435 5214FD3663E Drain Hose Vacuum...
Page 61: ...bly Front Half K141 4036ER4001B Gasket K143 4011FA4353B Bolt Standard K310 6322FR2046F Thermistor NTC K311 4036FR4050A Gasket K320 5301FR1158J Heater Assembly K340 4681EA2001D Drain Pump Motor K342 5214FR4006L Recirculating Hose K344 3108ER1001A Pump Casing K345 4681EA2001C Recirculating Pump Motor K346 383EER2001A Filter Cover Assembly K350 4417FA1994G Stator Assembly K351 6501KW2002A Hall Effect...
Page 62: ...J Damper Assembly K611 4433ER0001A Damper Pin M400 Turbo Steam Generator M410 3210ER1318A Support Rail 383EER4001A GASKET PLIER SPECIAL TOOL 383EER4003A DAMPER PLIER SPECIAL TOOL 383EER4004A GASKET PLIER SPECIAL TOOL 5214FR3018D DRAIN HOSE EXTENSION 5 FEET WM2688H M Page 62 of 64 TRAINING MANUAL ...
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Page 64: ... 2006 LG Electronics Inc Printed in the USA ...
