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LG WD-803(4)0(W)(F)(H) Service Manual

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WASHING MACHINE

SERVICE MANUAL

CAUTION
READ THIS MANUAL CAREFULLY TO DIAGNOSE TROUBLE
CORRECTLY BEFORE OFFERING SERVICE.
MODEL : WD-803(4)0(W)(F)(H)
WD-803(4)0F(H)(B)
WD-1042F(H)(B)
WD-1041(3)F(H)(B)
WD-102(4)1(5)W(F)(H)
WD-102(4)(5)F(H)(B)
WD-1223(5)F(H)(B)
WD-1243(5)F(H)(B)
website : http://www.LGEservice.com
e-mail : http://LGEservice.com/techsup.html

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  Summary of Contents for LG WD-803(4)0(W)(F)(H)

  • Page 1: Washing Machine

    website : http://www.LGEservice.com e-mail : http://LGEservice.com/techsup.html WASHING MACHINE SERVICE MANUAL CAUTION READ THIS MANUAL CAREFULLY TO DIAGNOSE TROUBLE CORRECTLY BEFORE OFFERING SERVICE. MODEL : WD-803(4)0(W)(F)(H) WD-803(4)0F(H)(B) WD-1042F(H)(B) WD-1041(3)F(H)(B) WD-102(4)1(5)W(F)(H) WD-102(4)(5)F(H)(B) WD-1223(5)F(H)(B) WD-1243(5)F(H)(B)
  • Page 2 JUN. 2001 PRINTED IN KOREA P/No.:3828ER3008B...
  • Page 3: Table Of Contents

    CONTENTS 1. SPECIFICATION..........................3 2. FEATURES & TECHNICAL EXPLANATION ................4 3. PARTS IDENTIFICATION ......................6 4. INSTALLATION ..........................7 5. OPERATION ..........................10 6. WIRING DIAGRAM ........................18 7. PROGRAM CHART ........................19 8. TROUBLESHOOTING.........................20 8-1. BEFORE PERFORMING SVICE ..................20 8-2. QC TEST MODE.........................20 8-3.
  • Page 4: Specification

    1. SPECIFICATION WD-1223(5)F(H)(B) WD-803(4)0(W)(F)(H) WD-1243(5)F(H)(B) ITEM WD-102(4)1W(F)(H) WD-1041(3)F(H)B WD-1042F(H) WD-1042F(H)B WD-102(4)1F(H)B WD-803(4)0F(H)B POWER SUPPLY 220V - 240V~, 50Hz PRODUCT WEIGHT 67kg 63kg WASHING 190W 120W SPIN (800rpm) 300W ELECTRICITY CONSUMPTION DRAIN MOTOR WASH HEATOR 2000W WASH 45 rpm REVOLUTION 600/800/1000/1200 rpm 600/800/1000 rpm SPIN SPEED...
  • Page 5: Features & Technical Explanation

    2. FEATURES & TECHNICAL EXPLANATION 2-1.FEATURES Jumbo drum Jumbo drum can wash about 40% more per load than conventional washing machine. A bigger drum improves the wash performance. More economical by Fuzzy Logic System FUZZY Logic System detects the amount of load and water temperature, and then determines the optimum water level and washing time to minimize energy and water consumption.
  • Page 6: Water Level Control

    2-2.DETERMINE WASHING TIME BY FUZZY LOGIC To get the best washing performance optimal time is determined by sensing of water temperature, selected washing temperature and laundry amount. water temperature washing time the best selected FUZZY washing washing rinse time temperature LOGIC performance spin rhythm, time...
  • Page 7: Parts Identification

    3. PARTS IDENTIFICATION Power plug ¥ If the supply cord is damaged, it must be replaced by the manufacturer or its service agents or a similarly qualified person in order to avoid a hazard. Control panel Drawer (For detergent and fabric softener) Drum Door...
  • Page 8: Installation

    4. INSTALLATION Before servicing ask the customer what the trouble is. Check the adjustment (power supply is 220-240V, remove the transit bolts..) Check the troubles referring to the troubleshooting. Decide service steps referring to disassembly instructions. Then, service and repair. After servicing, operate the appliance to see whether it works O K or NOT.
  • Page 9 HOW TO CONNECT INLET HOSE Check that the rubber washer is inside of the valve connector. Connect the inlet hose firmly to prevent leak. CONNECT DRAIN HOSE Make sure that the hose is not twisted. Avoid submerging the end of the hose. The drain hose should be placed under 100cm from the floor.
  • Page 10: Test Operation

    TEST OPERATION Preparation for Press the Press the Press the washing. POWER ( PROGRAM ( (START/PAUSE) button. button. ) button. Connect the power plug to In case of coloreds In case of coloreds the outlet. program. program. Connect the inlet hose. Check the water heating.
  • Page 11: Operation

    5. OPERATION I WD-1223(5)F(H)(B) / WD-1243(5)F(H)(B) WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B Rinse hold Displaying abnormal operation • Rinse hold function can be selected by pressing the rinse • Display the remaining time (Hour : Minute) ) button, and rinse hold lamp turns ON. •...
  • Page 12: Error Display

    How to select a program Error display • 6 programs can be selected by the kind of the laundry. • The display blinks if there is an error. • no inlet : Trouble with water supply. • By pressing the program ( ) button, [Coloreds Whites Rapid Delicate Wool Synthetic] can be •...
  • Page 13 I WD-1021(5)W(F)(H)/WD-1041(5)W(F)(H) Rinse hold Displaying abnormal operation • Rinse hold function can be selected by pressing the rinse • Display the remaining time (Hour : Minute) button, and rinse hold lamp turns ON. • The remaining time is reduced by •...
  • Page 14 How to select a program Error display • 6 programs can be selected by the kind of the laundry. • The display blinks if there is an error. • no inlet : Trouble with water supply. • By pressing the program button, [Coloreds Whites Rapid Delicate...
  • Page 15: Rinse Hold

    I WD-8030(W)(F)(H)/WD-8040(W)(F)(H)/WD-1042F(H) Rinse hold Water temperature selector If you desire to leave fabrics in the machine without Press the button to select water temperature. spinning after rinse to prevent them getting wrinkled, The water temperature [40 C 60 C cold] you may select rinse Hold by pressing the Rinse during coloreds program.
  • Page 16 Wash program selector Start/Pause button Power button 6 programs can be set depending on the Use the button to start or Press the button to turn power type of the laundry. pause wash cycle. on and off. If the power button is pressed. The power turns off Coloreds program is automatically set.
  • Page 17 I WD-8030F(H)B Rinse hold Water temperature selector If you desire to leave fabrics in the machine Press the button to select water temperature. without spinning after rinse to prevent them The water temperature getting wrinkled, you may select rinse Hold by [40 C 50 C 60 C...
  • Page 18 Wash program selector Start/Pause button Power button 6 programs can be set depending on the Use the button to start or Press the button to turn power type of the laundry. pause wash cycle. on and off. If the power button is pressed. The power turns off Coloreds program is automatically set.
  • Page 19: Wiring Diagram

    6. WIRING DIAGRAM I WD-1223(5)F(H)(B) / WD-1243(5)F(H)(B) / WD-1041(2)(3)F(H)B WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B GN/YL(GN) GN/YL(GN) GN/YL(GN) GN/YL(GN) I WD-803(4)0(W)(F)(H) / WD-102(4)1(5)W(F)(H) / WD-1042F(H) (option)
  • Page 20: Program Chart

    7. PROGRAM CHART I WD-8030(4)(W)(F)(H) / WD-102(4)1(5)W(F)(H) / WD-1042F(H) / WD-1223(5)F(H)(B) WD-1243(5)F(H)(B) About 2:23 About I WD-1041(3)F(H)B/803(4)0F(H)B/102(4)2F(H)B/102(4)5F(H)B About About 1:07...
  • Page 21: Troubleshooting

    8. TROUBLESHOOTING 8-1.BEFORE PERFORMING SERVICE Be careful of electric shock or disconnecting the parts while troubleshooting. Voltage of each terminal in AC 220-240V and DC while applying an electric current. 8-2.QC TEST MODE. Pressing RINSE ( ), and SPIN ( ) button simultaneously.
  • Page 22: How To Know The Water Level Frequency

    I WD-803(4)0(W)(F)(H) / WD-803(4)0F(H)(B) / WD-102(4)2F(H)(B) Checking Point Times of press None All lamps turn on 1 time Counterclockwise spin 2 times Low speed Spin 3 times High speed Spin 4 times Inlet valve for pre-wash operation (Cold) 5 times (FOR WD-****FH) Inlet valve for main-wash operation (Hot) 6 times Inlet valve for main-wash operation (Cold)
  • Page 23: Error Display

    8-4. ERROR DISPLAY. I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B)/WD-102(4)1(5)WF(H) / WD-1041(3)F(H)B If you press the Start/Pause button when an error in displayed, any error except will disappear and the machine will change into pause status. In case of if the error is not resolved within 20 sec. In the case of other errors, if the error is not resolved within 4 min.
  • Page 24 ERROR SYMPTOM CAUSE SENSOR • The electric contact between the connectors ERROR (5-pin, male in the wire harness and 5-pin female in the hall sensor) is bad or unstable. Reconnect or repair the contact in the connector. • The connector (6-pin, male, natural) in the wire harness is not connected to the connector (6-pin, female, natural) of PWB assembly (Main) or the electric contact of connectors is bad/unstable.
  • Page 25 I WD-8030(W)(F)(H)/WD-8040W(F)(H)/WD-1042F(H)/WD-803(4)0F(H)B/WD-102(4)2F(H)B If you press the Start/Pause button when an error in displayed, any error except SENSOR PRESSURE S/W ERROR will disappear and the machine will change into pause status. In case of SENSOR PRESSURE S/W ERROR, THERMISTOR ERROR if the error is not resolved within 20 sec.
  • Page 26 ERROR SYMPTOM CAUSE SENSOR • The electric contact between the connectors (1000) Rinse Hold ERROR (5-pin, male in the wire harness and 5-pin female in the hall sensor) is Super Normal no spin bad or unstable. WD-8030F(H)B / WD-8040F(H)B Reconnect or repair the contact in the connector. WD-1022F(H)B / WD-1042F(H)B •...
  • Page 27: Error Diagnosis And Check List

    9. ERROR DIAGNOSIS AND CHECK LIST 9-1.DIAGNOSIS AND ANSWER FOR ABNORMAL OPERATION SYMPTOM GUIDE FOR SERVICE CALL NO POWER Is the power plug connected firmly to 220-240V outlet? Power failure? or Breaker opened? Is the outlet controlled by a switch. Visit to check Water inlet trouble Is no inlet displayed?
  • Page 28 SYMPTOM GUIDE FOR SERVICE CALL Door open trouble When the door opened, Is the started or Error displayed on the on the program TIME DELAY ( program Close the door Didn't you press the DOOR OPEN button when water remained in the tub? 1.
  • Page 29 SYMPTOM GUIDE FOR SERVICE CALL Lather overflow from the Is low-lathering detergent for the drum appliance. washing machine used? (In this condition, wash and spin do not operate LOW SUDSING Is the proper amount of detergent used normally) DETERGENT as recommended? Recommend to reduce the amount of detergent.
  • Page 30: Fault Diagnosis And Troubleshooting

    9-2. FAULT DIAGNOSIS AND TROUBLESHOOTING I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B) / WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B CAUTION 1. Be careful of electric shock or disconnecting the parts while troubleshooting. 2. First of all, check the connection of each part terminal with wiring diagram. 3.
  • Page 31 I WD-803(4)0(W)(F)(H)/WD-102(4)1(5)W(F)(H)/WD-1042F(H) CAUTION 1. Be careful of electric shock or disconnecting the parts while troubleshooting. 2. First of all, check the connection of each part terminal with wiring diagram. 3. Voltage between each terminal is AC 220-240V while applying an electric current. (except secondary part of the transformer and sensors) NO POWER When measuring the voltage of the outlet,...
  • Page 32: No Water Supply

    NO WATER SUPPLY Is the water supply shut-off? Is the tap opened? Open the tap. Check the chamber (Air) When you press both Wash button and and the tube clogged Rinse buttons simultaneously, is the water level frequency below 40? with impurity.
  • Page 33: Softener Does Not Flow In

    SOFTENER DOES NOT FLOW IN Refer to Is water supplied? NO WATER SUPPLY Check the wiring Are receptacles connectly connected to the on the dispenser. Wiring diagram terminals of inlet valve? Is softener put in the correct compartment of Put it in the correct compartment.
  • Page 34: Heating Without Water

    HEATING WITHOUT WATER I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B) / WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B When pressing WASH and RINSE button at the same time after draining, is the water level frequency 252 or more? Replace the sensor (WASH) (RINSE) When pressing WASH , RINSE (pressure).
  • Page 35 DRAIN MALFUNCTIONING I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B) / WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B Is the drain hose twisted or frozen? Repair drain hose. Is the impeller of the drain pump clogged? Remove foreign material. Reconnect or repair the Is the connector disconnected, disassembled? connector.
  • Page 36 WASH HEATER TROUBLE I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B) / WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B PWB ASSEMBLY (MAIN) When checking the voltage between Replace the PWB connector the PWB assembly (Main) during assembly (Main). whites washing ,Is the voltage 220 - 240V 220 - 240V~ After power off,is the resistance of wire (RED-YELLOW) connectors between YELLOW...
  • Page 37 HEATING CONTINUOUSLY ABOVE THE SETTING WATER TEMPERATURE I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B) / WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B When disconnect the connector(1) on the PWB assembly (Main) is the resistance of the natural connectors ( Blue/White, Violet), Replace the thermistor. (Blue, White) between 2.5k to 180k (6322FR2046B) (105 ~0 )?
  • Page 38: Spin Trouble

    SPIN TROUBLE I WD-1223(5)F(H)(B)/WD-1243(5)F(H)(B) / WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B / WD-803(4)0F(H)B Check on the spinning, is the frequency of the Check the sensor water level 248 or more. The frequency can be (Pressure) or hose (Sensor). checked by pressing the WASH If the problem is on the RINSE ( ) buttons at the same time on the...
  • Page 39 I WD-803(4)0(W)(F)(H)/WD-102(4)1(5)W(F)(H)/WD-1042F(H) Check the sensor Press Power button with both Rinse and Spin (Pressure) or hose buttons pressed after power off. Press Start/Pause Spin Rinse (Sensor). button 2 times. Does the drum rotate at low spin If the problem is on the speed? sensor or the hose, replace the sensor or the hose.
  • Page 40: Disassembly Instructions

    10. DISASSEMBLY INSTRUCTIONS Disassemble and repair the parts after pulling out power cord from the outlet CONTROL PANEL PLATE ASSEMBLY (TOP) Two screws are unscrewed on the top plate. The plate assembly (Top) is pulled back and then upward to arrow direction. Hook Hook PANEL ASSEMBLY (CONTROL)
  • Page 41: Dispenser Assembly

    DISPENSER ASSEMBLY DRAWER DRAWER Disassemble the top plate assembly. Pull the drawer to arrow direction. Two screws are unscrewed. The hose clamps and the hose are disassembled. Valve (Hot) The ventilation bellows and the water inlet bellows are disassembled on the tub.
  • Page 42: Inlet Valve

    INLET VALVE Disconnect the wiring connector. Unscrew 2 screws from the back. When reconnecting the connector VALVE#1 (MAIN) White/Black - Black VALVE#2 (PRE) Gray/ White - Black VALVE#3 (HOT) Blue/Red-Black WD-1223FH(B)/1225FH(B)/1243FH(B) WD-1245FH(B) / 1041(3)FH(B) PWB ASSEMBLY (MAIN) WD-803(4)0(W)(F)H WD-102(4)1(5)W(F)H/102(4)1(5)FH(B) I WD-1223(5)F(H)(B) / WD-1243(5)F(H)(B) WD-1042FH(B)/803(4)0FH(B) WD-1041(3)F(H)B / WD-102(4)1(5)F(H)B WD-803(4)0F(H)B...
  • Page 43 LOWER COVER Open the lower cover cap by using coin and remove the lower cover to arrow direction after screw is unscrewed. DOOR When the power cord is plugged, the door can be opened by pressing the DOOR OPEN ) button. Open the door completely.
  • Page 44: Gasket Assembly

    GASKET ASSEMBLY The cabinet gasket clamp is released. Two screws are unscrewed from the cabinet cover. Three screws are unscrewed from the lower cover. The lower cover is disassembled. The control panel is removed. Screw is unscrewed from the cabinet cover. Take apart the tub gasket clamp Make sure that the drain hole of the gasket is put beneath when reassembling the gasket.
  • Page 45 PULLEY, MOTOR, DAMPER The back cover is removed. The belt is pulled off while turning over the pulley. The bolt is unscrewed to the shaft and then the pulley pulled off. (PULLEY) Two screws are unscrewed from the bracket (Motor). The motor is pushed to arrow direction and then it is disassembled.
  • Page 46 PUMP Remove the pump outlet hose. Pump Remove the tub pump hose. Outlet Hose The pump connectors are disconnected, the hose is pulled off. Three screws are unscrewed. The pump is disassembled to arrow direction. Tub Pump Hose HEATER Three screws are unscrewed. The heater M6 bolt is loosened and it is released through the tub cover.
  • Page 47 DOOR HINGE ASSEMBLY Two screw are unscrewed on the door and the door is disassembled. The cabinet cover clamp is removed and the gasket is released. Two screws are unscrewed on the door hinge. The door hinge is disassembled by pressing the door hinge arm inside the cabinet cover.
  • Page 48: Exploded View And Part List

    11. EXPLODED VIEW 11-1.THE EXPLODED VIEW OF CABINET ASSEMBLY A110 A150 A152 A151 A102 A101 A104 A103 A450 A141 A100 A131 A130 A140 A430 A440 A134 A410 A133 A200 A303 A310 A300 HOT (RED) A201 A275 A220 COLD (BLUE) A276...
  • Page 49: The Exploded View Of Control Panel & Dispenser Assembly

    11-2 THE EXPLODED VIEW OF CONTROL PANEL & DISPENSER ASSEMBLY F322 F321 F300 F462 F170 F160 F320 F466 F310 F464 F432 F226 F225 F436 F227 F430 F431 F220 F441 F440 F435 F120 F110 F130 F210...
  • Page 50: The Exploded View Of Drum & Tub Assembly

    11-3 THE EXPLODED VIEW OF DRUM & TUB ASSEMBLY K122 K221 K136 K125 K135 K411 K420 K110 K210 K111 K220 K141 K121 K115 K140 K105 K530 K510 K410 F140 K126 K611 K320 K332 K310 K330 K342 K610 K131 K130 F467 K550 F461 F468...