LG LFX21960ST Training Manual
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LG LFX21960ST Training Manual

LG LFX21960ST Training Manual

French door refrigerator
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LG TRAINING MANUAL
LG TRAINING MANUAL
French Door Refrigerator - Fall 2007
Models:
LFX21960ST
LFX25960xx

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Summary of Contents for LG LFX21960ST

  • Page 1 LG TRAINING MANUAL LG TRAINING MANUAL French Door Refrigerator - Fall 2007 Models: LFX21960ST LFX25960xx...
  • Page 2 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...

  • Page 3: Safety, Cautions, And Warnings

    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.

  • Page 4: Table Of Contents

    Door Frame Removal Door Gasket Clip Release Door Gasket Replacement Door Gasket Clip Replacement Door Frame Replacement Dispenser Filter Freezer Fan and Motor Ice Room Fan Defrost Control Assembly Refrigerator Lamp Freezer Lamp Multi Duct LFX21960ST/LFX25960xx Page 4 of 75 TRAINING MANUAL...
  • Page 5 Test Mode ERROR CODES (Defect Diagnosis) MICOM CIRCUITS AND FUNCTIONS Display Defaults ( F or C, Lock, Filter) Ice Plus Lamp Auto Off Door Open Alarm Buzzer Defrost Mode Initialization Sequence Demo Mode LFX21960ST/LFX25960xx Page 5 of 75 TRAINING MANUAL...
  • Page 6 EXPLODED VIEWS Case Parts Freezer Parts Refrigerator Parts Door Parts Ice and Water Parts Icemaker Parts Dispenser Parts PARTS LIST NOTES APPENDICES Appendix A (Temperature Conversions) App. A-1 Appendix B (Service Bulletins) App. B-1 LFX21960ST/LFX25960xx Page 6 of 75 TRAINING MANUAL...

  • Page 7: Introduction

    There is a special section for Tips & Tricks to make the job easier. Full schematics and parts lists are included. Drawings and photos are used for explanation. Additionally, many of these topics are covered in video training available via Internet at LG CS Academy. (http://www.lgcsacademy.com) LFX21960ST/LFX25960xx...

  • Page 8: Specifications

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

  • Page 9: Features

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

  • Page 10: Warranty

    REFRIGERATOR WARRANTY WARRANTY (May vary by model) 35813 LFX21960ST/LFX25960xx Page 10 of 75 TRAINING MANUAL...

  • Page 11: Installation

    • Install all the shelves, door bins, and accessories in the desired places. Set the desired temperature. • Allow 24 hours for the refrigerator to cool down, stabilize its temperature, and begin making ice. LFX21960ST/LFX25960xx Page 11 of 75 TRAINING MANUAL...

  • Page 12: Unpacking

    The large hole visible is for the type of base grille that presses into place instead of being attached with screws. The feet are also used to align the doors so they hang evenly. (See next page.) LFX21960ST/LFX25960xx Page 12 of 75 TRAINING MANUAL...

  • Page 13: Evening The Doors

    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: Base Grille (Kick Plate)

    If you must scrap a refrigerator, recover the refrigerant and permanently remove the doors. Leave the shelves in place so children cannot crawl in to play. Dispose of the scrapped product by an environmentally acceptable method. LFX21960ST/LFX25960xx Page 14 of 75 TRAINING MANUAL...

  • Page 15: Water Line Connection

    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: Operation

    The temperature in the freezer and the refrigerator can be set independently of one another. LG recommends setting the refrigerator at 37° F (3° C) and the freezer at 0° F (-18° C). Leave the refrigerator at this setting for 24 hours to allow the temperature to stabilize, then adjust the temperature as desired.

  • Page 17: Disassembly

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

  • Page 18: Freezer Door Removal

    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: Freezer Door Replacement

    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 TRAINING MANUAL...

  • Page 20: Door Frame Removal

    REFRIGERATOR DISASSEMBLY DOOR FRAME COVER REMOVAL LFX21960ST/LFX25960xx Page 20 of 75 TRAINING MANUAL...
  • Page 21 Continue across the bottom, up the side, and back across the top of the door until the gasket is free. LFX21960ST/LFX25960xx Page 21 of 75 TRAINING MANUAL...

  • Page 22: Door Gasket Replacement

    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 TRAINING MANUAL...

  • Page 23: Door Frame Replacement

    6. Press the remaining 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: Dispenser

    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 removed. LFX21960ST/LFX25960xx Page 24 of 75 TRAINING MANUAL...

  • Page 25: Freezer Fan And Motor

    Pull the fan blade off the shaft and remove the motor from the bracket. ICE ROOM FAN Remove the grille (steps 1–4 above). Disconnect the wire harness from the grille. Remove the fan assembly by removing two screws. LFX21960ST/LFX25960xx Page 25 of 75 TRAINING MANUAL...

  • Page 26: Defrost Control Assembly

    Press the tabs on both ends of the lamp shield to release it. Unscrew the bulb(s) and replace. Use a 60-watt bulb maximum. Replace the lamp shield and the tabs will click into place. LFX21960ST/LFX25960xx Page 26 of 75 TRAINING MANUAL...

  • Page 27: Freezer Lamp

    Pull the duct away from the back of the refrigerator from the top. Disconnect the lead wire at the bottom of the duct before pulling the duct out any farther. Replacement is the reverse of disassembly. LFX21960ST/LFX25960xx Page 27 of 75 TRAINING MANUAL...

  • Page 28: Icemaker

    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: Icemaker Functions (Modes)

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

  • Page 30: Function Test

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

  • Page 31: Compressor

    6. When replacing the compressor, be careful that dust, humidity, and soldering flux don’t contaminate the inside of the compressor. Contamination in the cylinder may cause noise, improper operation, or lock up. LFX21960ST/LFX25960xx Page 31 of 75 TRAINING MANUAL...

  • Page 32: Ptc Starter (Positive Temperature Coefficient)

    Parts may appear physically identical but could have different electrical ratings. Replace parts by part number and model number. Using an incorrect part could result in damage to the product, fire, injury, or possibly death. LFX21960ST/LFX25960xx Page 32 of 75 TRAINING MANUAL...

  • Page 33: Olp (Overload Protector)

    OLP, do not turn the adjustment screw. Remove the back cover of the mechanical area. Use a flat screwdriver to pry off the cover. Replace the parts as necessary. Reassembly is the reverse of these steps. LFX21960ST/LFX25960xx Page 33 of 75 TRAINING MANUAL...
  • Page 34 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: Troubleshooting

    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: Compressor And Electrical Components

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

  • Page 38: Ptc And Olp

    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: Other Electrical Components

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

  • Page 40: Service Diagnosis Chart

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

  • Page 41: Refrigeration Cycle

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

  • Page 42: Sealed System

    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 42 of 75 TRAINING MANUAL...

  • Page 43: Led Test

    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 displayed. LFX21960ST/LFX25960xx Page 43 of 75 TRAINING MANUAL...

  • Page 44: Error Codes (Defect Diagnosis)

    The refrigerator 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: Micom Circuits And Functions

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

  • Page 46: Ice Plus

    In the event of a power failure, ICE PLUS is cancelled and the product returns to its default settings. LAMP AUTO-OFF To avoid excess heat and the associated damage, the interior lamps will turn off automatically when the door is left open for more than 7 minutes. LFX21960ST/LFX25960xx Page 46 of 75 TRAINING MANUAL...

  • Page 47: Door Open Alarm

    Defrosting stops automatically when the sensor detects a temperature over 46.4° F (8° C). If the temperature does not reach 46.4° F (8° C) within 2 hours, the defrost mode is malfunctioning. (See diagnosis, page 51.) LFX21960ST/LFX25960xx Page 47 of 75 TRAINING MANUAL...

  • Page 48: Initialization Sequence

    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 MANUAL...

  • Page 49: Pcb Circuits

    IC1 (MICOM). Be sure to use specified replacement parts, since calculating time by the IC1 may be changed. If changed, the OSC1 SPEC will not work. LFX21960ST/LFX25960xx Page 49 of 75 TRAINING MANUAL...

  • Page 50: Reset Circuit

    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: Load Drive Circuit

    ~ 16V 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: Door Open Detection Circuit

    The circuit above reads 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: Refrigerator Damper Circuit

    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: Temperature Compensation Table

    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: Freezer Sensor Resistance Specification

    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: Schematics

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

  • Page 57: Main Board Layout

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

  • Page 58: Main Board Parts List

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

  • Page 59: Display Board Schematic

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

  • Page 60: Display Board Parts Layout

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

  • Page 61: Exploded Views

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

  • Page 62: Freezer Parts

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

  • Page 63: Refrigerator Parts

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

  • Page 64: Door Parts

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

  • Page 65: Ice And Water Parts

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

  • Page 66: Icemaker Parts

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

  • Page 67: Dispenser Parts

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

  • Page 68: Parts List

    REFRIGERATOR PARTS PARTS LIST Always order parts by Part Number, Model Number, and Serial Number. A = LFX21960ST B = LFX25960ST C = LFX25960SW D = LFX25960TT Model Loc. Part# Description 103A 3650JA2061A Handle, Rear 103A 3650JA2061W Handle, Rear 103A...
  • Page 69 Door Foam Assembly, Freezer 203A 4987JA2008E Gasket Assembly, Door 203A 4987JA2008J Gasket Assembly, Door 205A 5004JJ1061B Basket, Door 205B 5004JA2017A Basket, Tilt 205B 5006JJ2013A Cap, Cover 205C 5004JA2017B Basket, Tilt 205C 5006JJ2013B Cap, Cover LFX21960ST/LFX25960xx Page 69 of 75 TRAINING MANUAL...
  • Page 70 Ring 262H 4775JJ2017D Hinge Assembly, Center 262H 4775JJ2017H Hinge Assembly, Center 262H 4775JJ2017R Hinge Assembly, Center ABCD 271A 4775JJ2014B Hinge Assembly, Upper ABCD 271B 4510JA3004A Lever, Hinge ABCD 271C 4775JJ2014A Hinge Assembly, Upper LFX21960ST/LFX25960xx Page 70 of 75 TRAINING MANUAL...
  • Page 71 5421JJ1003B Evaporator Assembly 303B 6748C-0002C Thermistor, PTC 303C 6750C-0004R Overload Protect 303C 6750JA3001B Overload Protect 304A 3550JA2042B Cover, PTC 304A 3550JA2158A Cover, PTC 310B 4J00977N Pipe, Compressor Sealing ABCD 312A 5040JA3071A Damper, Compressor LFX21960ST/LFX25960xx Page 71 of 75 TRAINING MANUAL...
  • Page 72 ABCD 407B 4810JJ0003A Bracket, Motor ABCD 408A 5300JK1005D Heater, Sheath 409B 6912JB2004K Lamp, Incandescent 409B 6912JK2002C Lamp, Incandescent ABCD 409D 3034JA1009A Reflector, Lamp ABCD 410A 6621JK2002D Drawing, Assembly 410G 0CZZJB2012K Capacitor, Film, Box LFX21960ST/LFX25960xx Page 72 of 75 TRAINING MANUAL...
  • Page 73 5230JA2003A Filter, Head ABCD 625A 3550JA2184A Cover, Tube ABCD 626A 3550JA2279A Cover, Filter ABCD 627A 4930JA3054A Holder, Pipe ABCD 630A 3581JA1182A Door Assembly, Freeze Room ABCD 630B 5433JA2071A Door Foam Assembly, Home Bar LFX21960ST/LFX25960xx Page 73 of 75 TRAINING MANUAL...
  • Page 74 Screw, Customzied ABCD 4J00415D Screw, Customzied ABCD 4J00415D Screw, Customzied ABCD 4J00415D Screw, Customzied ABCD 1SZZJA3016A Screw, Customzied ABCD 1SZZJA3011D Screw, Customzied 5078JJ1035A Cap, Decor Refrigerator 1SZZJA3011B Screw, Customzied ABCD FAB30025701 Screw, Customzied LFX21960ST/LFX25960xx Page 74 of 75 TRAINING MANUAL...

  • Page 75: Notes

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

  • Page 76: Appendices

    60.8 -8.3 62.6 -7.8 64.4 -7.2 66.2 -6.7 -6.1 69.8 -5.6 71.6 -5.0 73.4 -4.4 75.2 -3.9 -3.3 78.8 -2.8 80.6 -2.2 82.4 -1.7 84.2 -1.1 -0.6 87.8 89.6 91.4 93.2 96.8 98.6 100.4 102.2 LFX21960ST/LFX25960xx App. A-1 TRAINING MANUAL...
  • Page 77 It is current as of the time of printing 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.
  • Page 78 REFRIGERATOR REFRIGERATOR APPENDICES APPENDICES LFX21960ST/LFX25960xx LFX21960ST/LFX25960xx App, B - 2 App, B - 2 TRAINING MANUAL TRAINING MANUAL...
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  • Page 128 2007 French Door Training...

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