SERVICE MANUAL Thermador Pro Grand® Range
This manual contains information that is necessary for servicing the following Thermador Pro Grand Ranges: PD304BS PD364GDBS PD364GEBS PD364GLBS PD366BS PD484GED PD484GGBS PD486GDBS PD486GEBS PD486GLBS
Due to the complexity and the risk of high-voltage electrical shock, customers should not service their appliances.
Models: PD304BS, PD364GDBS, PD364GEBS PD364GLBS, PD364GLBS PD486GDBS, PD486GEBS, PD486GLBS
The information provided in this document is intended for trained, qualified personnel only. The proper function and the safety of the appliance can be affected by an improper repair, and even serious threats to life or physical condition may arise. BSH Home Appliances Corporation is not liable for damages caused by improper repairs performed by unauthorized parties. Local codes and standards apply and must be observed. Contact Technical Support for further assistance. NOTE: The illustrations in this manual are “typical” representations of 30, 36 & 48 inch Dual Fuel Ranges. The model you are servicing may appear different, the service procedure is common for all.
Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
TABLE OF CONTENTS 1 General ..................................................................................................... 5
3.3
Rangetop Flame Characteristics ................................................................. 13
3.4
Testing Rangetop Burner Ignition................................................................ 14
3.4.1
Testing Ignition for HI, Medium, and Low Settings............................... 14
3.4.2
Testing Ignition for XLO Setting ........................................................... 14
1.1
Applicable Models ......................................................................................... 5
1.2
Data Rating Plate .......................................................................................... 5
3.5
Adjusting Grill Burner Flame with the Air Shutter ........................................ 14
1.3
Wiring Diagram ............................................................................................. 5
3.6
Adjusting Rangetop Burner Valves Manually .............................................. 15
1.4
Technical Documents to Read Prior to Servicing .......................................... 6
3.6.1
Special Tools Needed .......................................................................... 15
1.5
Recommended Tools and Supplies .............................................................. 6
3.6.2
Adjusting the Bypass Screws............................................................... 15
1.6
Important Safety Information ......................................................................... 6
3.7
Troubleshooting Burner, Flame, Ignition, and Elements ............................. 16
1.6.1
Safety Symbols Used In This Manual .................................................... 6
3.7.1
Burner and Flame Diagnostics for Rangetop Burners.......................... 16
1.6.2
Safety Precautions to Know Prior to Servicing....................................... 6
3.7.2
Ignition Diagnostics for Rangetop Burners........................................... 16
2 Operation.................................................................................................. 9
3.7.3
Element Diagnostics ............................................................................ 18
2.1
Knobs and Controls....................................................................................... 9
3.7.3.1
Safety Practices for Element Diagnostics ..................................... 18
2.1.1
Standard Burner Knob ........................................................................... 9
3.7.3.2
Element Diagnostic Tips ............................................................... 18
2.1.2
ExtraLow Burner Knob ........................................................................... 9
3.7.3.3
Element Cycle/Circuit Specification .............................................. 18
2.1.3
Griddle Control Knob ............................................................................. 9
2.1.4
Grill Control Knob................................................................................. 10
2.1.5
Temperature Selector Knob ................................................................. 10
2.1.6
Five-Position Oven Function Selector Knob......................................... 10
2.1.7
Six-Position Oven Function Selector Knob .......................................... 10
2.1.8
Oven Lamp Switch............................................................................... 11
3.8
Fault Codes................................................................................................. 19
4 Service and Repair ................................................................................ 21 4.1
Preparing the Range for Servicing .............................................................. 21
4.2
Accessing Components under the Maintop................................................. 21
4.2.1
Removing Knobs, Grates, Trim, Burner Assemblies............................ 21
4.2.2
Removing Spill Trays ........................................................................... 23
4.2.3
Removing Heat Shields ....................................................................... 23
4.2.4
Removing the Burner Support Rail ...................................................... 24
2.2
LED Indicators............................................................................................. 11
2.3
Automatic Re-Ignition.................................................................................. 11
2.4
Operation During a Power Outage .............................................................. 11
2.5
Maintop Components and Burner Assembly............................................... 11
4.3.1
Griddle with Removable Brackets – Removal and Replacement ......... 26
3 Testing, Adjusting, Troubleshooting Burners and Ignition .............. 12
4.3.2
Griddle with Fixed Brackets – Removal and Replacement .................. 30
3.1
Before Testing............................................................................................. 12
3.2
Rangetop Burner Characteristics ................................................................ 12
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4.3
4.4
Griddle Removal and Replacement ............................................................ 26
Grill Components – Removal and Replacement ......................................... 32
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
4.4.1
Grill Flame Spreader Removal and Replacement................................ 33
4.5.20 Plunger Switch Removal and Replacement ......................................... 62
4.4.2
Grill Burner Removal and Replacement............................................... 34
4.5.21 Griddle and Grill Thermostat Removal and Replacement .................... 63
4.4.3
Grill Hot Surface Igniter Removal and Replacement............................ 35
4.5.22 Control Panel and Bullnose Removal and Replacement ..................... 64
4.4.4
Grill Electrode Removal and Replacement .......................................... 35
4.4.5
Grill Thermostat Removal and Replacement ....................................... 36
4.6.1
Backguard and Island Trim Removal and Replacement ...................... 68
4.4.6
Grill Orifice and Elbow Connector Removal and Replacement ............ 37
4.6.2
Back Panel Removal and Replacement............................................... 69
Removal and Replacement of Top-Accessible Components ...................... 38
4.6.3
Crossmember Cover Removal and Replacement................................ 70
4.5
4.6
Removal and Replacement of Back-Accessible Components .................... 68
4.5.1
Jet Holder Assembly Removal and Replacement ................................ 38
4.6.4
Terminal Block Removal and Replacement ......................................... 70
4.5.2
Standard Valve Removal and Replacement ........................................ 40
4.6.5
Electrical Wiring Connections at the Terminal Block............................ 71
4.5.3
Microswitch Removal and Replacement .............................................. 41
4.6.6
Cooling Fan Removal and Replacement ............................................. 71
4.5.4
Solenoid Valve for XLO Burner – Removal and Replacement ............. 42
4.5.5
Solenoid Valve for Grill – Removal and Replacement ......................... 43
4.5.6
XLO Valve Removal and Replacement................................................ 44
4.5.7
Potentiometer Removal and Replacement........................................... 47
4.7.1
Oven Temperature Sensor Removal and Replacement ...................... 74
4.5.8
Manifold Removal and Replacement ................................................... 48
4.7.2
Oven Lamp and Bulb Removal, Replacement, and Diagnostics.......... 75
4.5.9
Oven Lamp Transformer Removal and Replacement.......................... 50
4.5.10 Oven Temperature Selector Removal and Replacement..................... 51
4.6.6.1 4.6.7 4.7
Air Interlock Switch Removal and Replacement ........................... 72
Thermal Fuse Removal and Replacement........................................... 73
Removal and Replacement of Front-Accessible Components .................... 74
4.7.2.1 4.7.3
Oven Light Diagnostics ................................................................. 75
Oven Door Removal, Installation, and Alignment................................. 77
4.5.11 Five-Position Oven Function Selector Removal and Replacement...... 52
4.7.3.1
Removing the Door ....................................................................... 77
4.5.12 Oven Temperature Gauge Removal and Replacement ....................... 53
4.7.3.2
Installing the Door ......................................................................... 77
4.5.13 Regulator Removal and Replacement ................................................. 54
4.7.3.3
Aligning the Door .......................................................................... 78
4.5.14 Control Board Removal and Replacement........................................... 55
4.7.4
Convection Components – Removal and Replacement....................... 79
4.5.14.1 Control Board Removal and Replacement (Large Oven).............. 55
4.7.5
Broil Burner Removal and Replacement .............................................. 83
4.5.14.2 Control Board Removal and Replacement (Small Oven).............. 56
4.7.6
Bake Element Components – Removal & Replacement (Large Oven) 86
4.5.15 Simmer Control Board Removal and Replacement ............................. 57
4.7.7
Bake Element Components – Removal & Replacement (Small Oven) 88
4.5.16 Hot Surface Igniter Board Removal and Replacement ........................ 58
4.7.8
Door Handle Components – Removal and Replacement .................... 89
4.5.17 LED Indicator Removal and Replacement ........................................... 59
4.7.9
Door Hinge Removal and Replacement............................................... 90
4.5.18 Ignition (Spark) Module Removal and Replacement............................ 59
4.7.10 Door Gasket Removal and Replacement............................................. 93
4.5.19 Door Latch Removal and Replacement ............................................... 60
4.7.11 Kick Panel Removal and Replacement ................................................ 94
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
5 Before Returning Appliance to Service............................................... 94 6 Clean-Up ................................................................................................. 95 7 Additional Resources............................................................................ 95 7.1
QuickFinder................................................................................................. 95
7.2
Technical Support ....................................................................................... 95
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
1
GENERAL
Thermador Pro Grand dual fuel ranges may include such features as convection bake and convection broil, a 6-pass / 1630-watt electric griddle, a gas grill, 6-pass bake and 8-pass broil elements for the large oven, 6-pass bake and broil elements for the small oven, Star® burners, and two ExtraLow® simmer burners. Compatible with natural gas, the range is convertible to LP gas using the PLPKIT kit.
1.1 Applicable Models This manual contains information that is necessary for servicing the following Thermador Pro Grand dual fuel ranges:
PD304BS/01-13 PRD304EG PD304BS PD364GDBS/01-02 PRD364EDG PD364GDBS PD364GEBS/01-13 PRD364EDPG PD364GEBS PRD364ELG PD364GLBS/01-12 PD364GLBS PRD366EG PD366BS/01-12 PD366BS PRD366EPG PD484GED/01 PD484GED PRD484ECG PD484GGBS/01 PD484GGBS PRD484EEG PD486GDBS/01 PD486GDBS PRD486EDG PD486GEBS/01-14 PD486GEBS PRD486EDPG PD486GLBS/01-11 PD486GLBS PRD486ELG
■ ■
Due to the complexity and the risk of high-voltage electrical shock, customers should not service their appliances. The information provided in this document is intended for trained, qualified personnel only. The proper function and the safety of the appliance can be affected by an improper repair, and even serious threats to life or physical condition may arise. BSH Home Appliances Corporation is not liable for damages caused by improper repairs performed by unauthorized parties. Local codes and standards apply and must be observed. Contact Technical Support for further assistance at (800) 444-9091.
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1.2 Data Rating Plate The data rating plate which shows the model, serial, and FD number is located at the bottom of the range behind the kick panel, as shown in Figure 1. Remove the kick panel to access it. The information on the data rating plate is required when calling for technical or customer service. The first two digits of the FD number indicate the year the appliance was produced. To get the year, add 20 to the first two digits (for example, an FD number beginning with 87 was produced in 2007; a number that begins with 88 was produced in 2008). The last 2 digits of the FD number indicate the month the product was produced (for example, 06 indicates the appliance was produced in June).
1.3 Wiring Diagram The wiring diagram is located at the back side of the kick panel (see Figure 1).
Figure 1: Data Rating Plate and Wiring Diagram Locations
1 2
Data rating plate (behind kick panel) Wiring diagram (back side of kick panel)
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
1.4 Technical Documents to Read Prior to Servicing
1.6 Important Safety Information
Before you start servicing, check QuickFinder for all documents and information associated with this specific appliance and/or parts.
Before starting to service an appliance, familiarize yourself with all safety information and precautions contained in this manual.
1.5 Recommended Tools and Supplies
The following are recommended to use when servicing this appliance:
m Caution
Power Drivers If using a power driver, set the clutch to the lowest setting Phillips screwdrivers Flat blade screwdrivers: large, small Precision flat-blade screwdriver with a high-strength blade, 1/8-inch [3.0mm] wide, .020-inch [0.50mm] thickness tip Drivers: T-27, T-20, T-10 1/4 inch nut driver or 1/4 inch socket wrench / ratchet 20 mm socket Adjustable wrenches (2) Open-end wrench sizes: 1/4 inch, 9 mm, 11 mm, 1/2 inch, 9/16 inch, 5/8 inch, 3/4 inch, 5/16 inch, 11/32 inch, Pipe wrench Socket wrench / ratchet 11/32 inch Swivel head driver with an 11/32 inch, deep-well socket Needle-nose pliers Hammer Protective gloves Gas leak test equipment Pipe sealant Small mirror Air sled or dolly Protective eye wear (such as glasses, goggles) Flashlight Amp meter Thermometer with thermocouple leads Multimeter
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1.6.1
Safety Symbols Used In This Manual
Warnings alert you to dangers that may result in bodily injury or death.
m Caution
Cautions alert you to actions that may result in damage to the product, or property. 1.6.2
Safety Precautions to Know Prior to Servicing
Before You Start Servicing the Appliance Before disassembly, removal or installation of any component, do the following: ■ Turn off electrical power by removing the power cord from the electrical outlet, and putting the circuit breaker in the OFF position (or removing the fuse) ■ Turn off the gas supply to the appliance ■ Make sure the range and components are cool before removing or servicing them ■ Wear protective clothes: long sleeves, gloves, safety glasses Replacement Parts Use only authorized replacement parts for this appliance. Use of substitutions may defeat compliance with safety standards set for home appliances, will void the warranty, and may create safety hazards resulting in bodily injury, death, or damage.
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
Fire / Explosion Hazards ■ Make sure the gas valve at the wall is closed before removing and installing any gas components. ■ Do not store or use any flammable vapors, liquids, or combustible materials in the vicinity of this appliance. ■ Do not use water on grease fires. Turn appliance off and smother the fire with baking soda or use a dry chemical or foam-type extinguisher.
Griddle and Grill Hazard The griddle / grill plate must always be correctly in place when it is on.
What to Do If You Smell Gas ■ Do not try to light any appliance ■ Do not touch any electrical switch ■ Do not use any phone or cell phone in the building Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
Testing for Gas Leaks ■ Do not ever use a flame to test for gas leaks, as doing so may result in explosion, injury, death, and/or damage to the appliance and property. ■ With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. The only exceptions that may require the electrical power to be on are for the XLO valves – for these, use extreme caution when performing gas leak testing.
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Electrical Hazards ■
■
■ ■ ■
Before servicing the appliance, remove electrical power by disconnecting the power cord from the wall receptacle, by shutting off the circuit breaker, or by disconnecting the proper fuse. If tests have to be conducted while the appliance is live, always use a residual-current-operated circuit-breaker. The protective conductor connection must not exceed the recommended values. When repairs are complete, perform a function test in accordance with the appropriate regulations. Do not under any circumstances cut or remove the separate ground wire or the third (ground) prong from the power cord plug. Improper grounding or reverse polarization will cause malfunction (such as continuous sparking of the igniters), which can damage the appliance and create an electrical shock hazard. Make sure the circuit is properly grounded and polarized in accordance with applicable local codes and ordinances. Receptacle replacement shall be in accordance with the National Electric Code.
Hot Surfaces To avoid burns and injury, do not handle components and surfaces that are hot, such as the rangetop burner assemblies, maintop, griddle/grill, gas burners, electric elements, hot surface igniters, heat deflector, and interior oven surfaces, or the exterior area immediately surrounding the door.
Sharp Components This appliance has sheet metal and other components which often have sharp edges. When working on this appliance, avoid cutting yourself and other injury by handling these parts with care and using adequate protective measures, such as gloves.
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
In Case of Power Outage
Prior to Returning Appliance to Service
1. If for any reason a control knob is on when there is any failure or removal of electrical power from the appliance (such as a power outage), immediately turn all control knob(s) to the OFF position.
Prior to returning the appliance to service, make sure that:
2. Ventilate by opening a door or window, and wait at least 5 minutes for all the gas to dissipate. 3. If you smell gas, refer to the applicable safety precautions stated in this manual.
Clean-up Hazards ■ Don’t allow any cleaning or polishing solutions/compounds, disinfectants or bleaches to remain in contact with the stainless steel surfaces for long periods, or after clean-up. These may contain chemicals or materials which could release harmful inhalants and can damage the appliance. After cleaning or polishing, always rinse the cleaning/polishing materials with clear water and wipe dry with a clean soft, non-abrasive cloth. ■
Clean the range with caution. Do not use flammable cleaners to clean the range. Avoid steam burns; do not use a wet sponge or cloth to clean the range while it is hot. Do not use any type of aerosol cleaner on or around the rangetop when hot. Some cleaners produce noxious fumes if applied to a hot surface. Follow directions provided by the cleaner manufacturer.
Fiberglass Insulation Wear gloves when handling fiberglass insulation.
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■
All electrical connections are correct and secure
■
All safety grounds (internal and external) are correctly and securely connected
■
All gas connections are secure and have been leak tested using a gas leak detector or bubble test.
■
All panels and components are properly and securely reassembled
m Caution
Code Compliance Local codes vary. Installation, electrical connections, gas connections, and grounding must comply with all applicable codes. TESTED IN ACCORDANCE WITH ANSI Z21.1, THE STANDARD FOR HOUSEHOLD COOKING GAS APPLIANCES. IN CANADA TESTED IN ACCORDANCE WITH CAN/CGA1.1 – M81, THE STANDARD FOR DOMESTIC GAS RANGES. Check your local building codes for the proper method of installation. In the absence of local codes, this unit should be installed in accordance with the National Fuel Gas Code No. Z223.1/ NFPA 54 current issue and the National Electrical Code ANSI/NFPA No. 70 current issue or the Can – B149 Installation Codes for Gas Burning Appliances and C22.1 Canadian Electrical Code Part 1. It is the responsibility of the owner and the installer to determine if additional requirements apply in specific installations.
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
2
OPERATION
2. In XLO mode, the knob can be set between SIM and XLO for a variable range of low heat (see Figure 3).
2.1 Knobs and Controls The control knobs each have an icon to identify the location on the range. The two standard burners are located on the right side of the control panel (see Figure 2). The two ExtraLow (XLO) burners are located on the left side (see Figure 3). 2.1.1
Standard Burner Knob
1. Press a control knob in, and turn counter-clockwise to HI setting. The igniter for the burner clicks while sparking until flame ignition. Burner should ignite within 4 seconds. 2. For the standard burners, rotate the knob to any setting between HI and SIM. NOTE: The blue LED indicator lights up when burners are lit.
Figure 3: XLO Burner Control Knob
2.1.3
Griddle Control Knob
The griddle knob controls the temperature to the griddle, from 150° F to 500° F (see Figure 4). Press and turn the knob clockwise to select a setting.
Figure 2: Standard Burner Control Knob
2.1.2
ExtraLow Burner Knob
When in XLO mode - the very lowest flame setting, the flame cycles on for approximately 8 seconds and then turns off for 52 seconds of each minute. 1. Press a control knob in, and turn counter-clockwise to HI setting. The igniter for the burner clicks while sparking until flame ignition. Burner should ignite within 4 seconds.
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Figure 4: Griddle Control Knob
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
2.1.4
Grill Control Knob
This knob controls the temperature to the grill. Press the control knob and rotate it counterclockwise to the LITE position. After the flame is completely around the burner, adjust the knob to the desired heat setting between HI and LO.
2.1.6
Five-Position Oven Function Selector Knob
For the small oven of 48-inch ranges only, use this knob for bake, convection bake, broil, and speed-clean (see Figure 7).
Figure 7: Five-Position Oven Function Selector Knob Figure 5: Grill Control Knob
2.1.7
2.1.5
For the large oven of 48-inch ranges and for the oven of all 30-inch and 36-inch ranges, use this knob for bake, convection bake, broil, convection broil, and speed-clean (see Figure 8).
Temperature Selector Knob
Use this knob for setting the oven temperature, broil, and speed-clean mode. The small oven does not have the speed-clean feature. See Figure 6.
Six-Position Oven Function Selector Knob
Figure 8: Six-Position Oven Function Selector Knob Figure 6: Temperature Knobs – Small Oven (Left), Large Oven (Right)
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
2.1.8
Oven Lamp Switch
2.5 Maintop Components and Burner Assembly
There is an oven lamp switch for each oven.
Figure 9: Oven Light Switch
2.2 LED Indicators The LED indicators illuminate per current cycle. They are also used to indicate fault codes (see Fault Codes, page 19).
Figure 10: LED Indicators
2.3 Automatic Re-Ignition Each Star burner has its own electronic igniter that sparks when the burner is turned on. If one or more burner blows out, the respective igniter/electrode automatically re-ignites the flame.
2.4 Operation During a Power Outage When there is a removal of electrical power, the XLO burners, griddle, and grill cannot be used. Do not attempt to light them manually during a power outage.
m Caution
Power Outage Precautions ■ ■
Ventilate well by opening a door or window, and wait at least five minutes until all the gas dissipates. If you smell gas, comply with the warnings and precautions in the Important Safety Information section (page 6) of this manual.
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Figure 11: Maintop Components and Burner Assembly
1 2 3 4 5 6
Burner cap Venturi tube Burner base (brass) Trim for spill tray Spill tray Nut
7 8 9 10 11 12
Heat shield Burner support rail Wire guard clip Jet holder assembly Spring Igniter plug (electrode)
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
3
TESTING, ADJUSTING, TROUBLESHOOTING BURNERS AND IGNITION
Servicing Burners and Ignition
3.2 Rangetop Burner Characteristics If one or more rangetop burner blows out, the respective igniter electrode automatically re-ignites the flame. The flame should burn through each burner port, completely around the burner cap (see Figure 12).
Burner and ignition servicing must be performed by a qualified technician. Improper adjustments may be dangerous, cause damage or harmful by-products, and may void the appliance warranty.
Ignition Hazard Do not touch burners when the igniters are active (sparking).
3.1 Before Testing
Figure 12: Burner Ports
1
Before testing rangetop burners and ignition, do the following: 1. Re-install any loose components that may have been removed earlier, such as burner caps, griddle, and grates. Be certain that burner caps seat properly into the burner bases, burner bases and Venturi tubes are aligned correctly, and that the ignition wires are properly positioned. 2. To test for gas leaks, make sure the electrical power is removed and the manual gas shut-off valve is open, and then carefully check range components and gas supply for leaks using a gas leak detector or bubble test.
Burner port
It is normal to hear the following during burner operation:
A slight sound that is associated with gas combustion and ignition. There should not be a loud noise.
A clicking noise every time the gas cycles, coming from the solenoid valves of the two left burners
If using LP gas, a slight “pop” sound may be heard at the burner ports a few seconds after the burner has been turned off
3. After gas checks are complete and before testing, connect the range to the electrical power supply.
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
3.3 Rangetop Flame Characteristics Natural gas: The Star burner flame color should be blue with no yellow on the tips (see Figure 13). It is not uncommon to see orange in the flame color; this indicates the burning of airborne impurities in the gas, and will disappear with use. See Figure 14 for additional flame characteristics. LP gas: Slight yellow tips on the primary flame cone are normal and may appear after a few minutes. The flame should be stable with no excessive noise or fluttering. Orange colored streaks in the flame are produced from burning airborne debris, which is normal at startup, and should dissipate in a few minutes (see Figure 14). When the flame is properly adjusted, it should burn completely around the burner cap, at each burner port (see Figure 12).
Figure 14: Additional Flame Characteristics
NOTE: If rangetop burner/flame characteristics are not adequate, see Troubleshooting Burner, Flame, Ignition, and Elements, page 16.
Figure 13: Correct Flame Color and Characteristics for Natural Gas
1 2 3 4
Dark blue Secondary cone Light blue Primary cone
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
3.4 Testing Rangetop Burner Ignition
Ignition Hazard Do not touch the rangetop burners when the igniters are sparking. For each burner, push the control knob in and then turn counterclockwise to HI. The igniter should produce a clicking sound as the burner is sparking, and the burner should light within four seconds. 3.4.1
Testing Ignition for HI, Medium, and Low Settings
Set the burner knob to HI, and observe flame characteristics (see Figure 13 and Figure 14). If any burner flame burns primarily yellow, verify if the burner cap is positioned properly on the burner base, and then re-test. Repeat test for MEDIUM and SIM settings. If flame characteristics do not improve, call Thermador technical support at (800) 444-9091. 3.4.2
Testing Ignition for XLO Setting
The left-front and left-back burners have the XLO feature. Set the burner knob to a setting between SIM to XLO and observe if the flame cycles correctly – it should be on for approximately 8 seconds, and then off for approximately 52 seconds of each minute.
3.5 Adjusting Grill Burner Flame with the Air Shutter [Models with grill only]: The grill’s gas burner has an air shutter system that is factory pre-set to burn optimally, but depending on the quality of the gas available, may require adjustment (see Figure 15).
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Figure 15: Typical Air Shutter
1 2 3
Air shutter Adjustment screw Opening
1. First remove the grill burner from the grill burner box (see Grill Components – Removal and Replacement, page 32). 2. Loosen the adjustment screw, and then rotate the air shutter to modify the opening as follows: If the flame is lifting or blowing, or is not carrying over, rotate the shutter clockwise to set the opening to a more closed position. If the flame is too yellow, rotate the shutter counter-clockwise to set the opening to a more open position. 3. Tighten the adjustment screw. 4. Re-install the grill burner (see Grill Components – Removal and Replacement, page 32). 5. Test to evaluate the flame characteristics. 6. Repeat procedure as needed until flame characteristics are optimal.
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Service Manual for Thermador Dual-Fuel Ranges - 30, 36 and 48 Inch
3.6 Adjusting Rangetop Burner Valves Manually
3.6.2
Adjusting the Bypass Screws
1. Turn off electrical power by unplugging the power cord, or putting the circuit breaker in the OFF position. 2. Remove knobs from valve stems by slowly pulling knobs straight out, away from control panel. 3. For newer models: Remove and retain the two bezel mounting screws and remove the bezel. 4. For older models: Valve screws can be accessed directly through the control panel, without removing the bezel mounting screws. 5. To engage the valve screw, insert the precision screwdriver with a 1/8 inch blade into the same hole in the bezel that was created by the removal of the right side mounting screw (see Figure 18, page 16). Figure 16: Bypass Screw on Valve (View with Control Panel Removed for Clarity)
1
Bypass screw on XLO valve and standard valve
Although pre-adjusted, if you need to set the XLO valves and standard valves for the lowest possible flame setting, then manually adjust the bypass screws on the valves. 3.6.1
6. Turn the valve screw clockwise just until "bottom out" position is reached. Do not over-tighten the valve screw (see Figure 18). NOTE: The two valves for XLO operation (farthest left on control panel) must be in the OFF position for proper access to the valve screws through clearance holes in the XLO potentiometers. NOTE: The griddle/grill is controlled by a thermostat and does not have a valve that requires adjustment.
Special Tools Needed
To reposition the bypass screws for minimum flow settings on manual valves, use a precision high-strength blade screwdriver, with a 1/8 inch [3.0mm] wide, .020-inch [0.50mm] thickness tip.
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Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. For XLO valves (not standard valves), you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on XLO valves.
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3.7 Troubleshooting Burner, Flame, Ignition, and Elements 3.7.1
Burner and Flame Diagnostics for Rangetop Burners
If a rangetop burner clicks (sparks) constantly or if burner doesn’t light correctly and/or has inadequate burner/flame characteristics (per Rangetop Burner Characteristics, page 12 and Rangetop Flame Characteristics, page 13), then do the following:
Figure 17: Removing the Bezel Mounting Screws
1
Bezel mounting screws (2)
Check if the manual shut-off valve is open and the unit is receiving gas. Check if the burner cap is properly aligned on the burner base. Check if the burner port is open and not clogged or blocked. Check if the igniter electrode is free from debris and is sparking. If it is suspect that air is in the gas supply lines and system, you can purge the remaining air by operating one of the burners for several minutes. Check if a fuse has blown or a circuit breaker has tripped. For constant sparking, check wiring connections at ignition (spark) module and electrode, and also check grounding Refer to the Ignition Diagnostics, page 16. Call Thermador technical support at (800) 444-9091 for assistance if any burners fail to light, or any burners continue to burn yellow. 3.7.2
Ignition Diagnostics for Rangetop Burners
The following flowchart applies in the event a burner fails to ignite.
Figure 18: Accessing the Bypass Screw on the Valve
1
Bypass screw access location (shown with bezel mounting screws and bezel removed)
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Before performing steps in the Rangetop Burner Ignition - Diagnostic Flowchart (Figure 19, page 17), remove electrical power from appliance during disassembly and during removal and installation procedures. Restore electrical power when testing the unit if it is re-assembled.
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Figure 19: Rangetop Burner Ignition - Diagnostic Flowchart
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3.7.3
Element Diagnostics
Use the Element Cycle/Circuit Specification chart for troubleshooting all elements as well as the hot surface igniter (HSI) for the grill. 3.7.3.1 Safety Practices for Element Diagnostics Observe all pertinent safety practices such as warnings, cautions and instructions contained in the Safety Precautions to Know Prior to Servicing section of this manual (page 6), throughout this manual, and the Installation Manual. Ensure compliance with all applicable codes. 3.7.3.2
Element Diagnostic Tips
Wiring Diagram The electrical wiring diagram is located behind the kick panel of the range (see Wiring Diagram, page 5). Resistance Reading You can perform a resistance reading on an element with the electrical power to the range turned off. Amperage Reading for all Elements and Grill HSI: For an element, check either of the wires with an amp meter and amp clamp. For the grill HSI, check at one of its wire connectors, as the gas burner attached to HSI will ignite. NOTE: Although the grill HSI may be glowing, if not enough current is running through it, the safety valve may fail. Alternatively, you can check the element and grill HSI from the corresponding I/O relay terminals on the control board. Alternatively, you can check an element and grill HSI from the hot terminals (L1, L2) and neutral terminal at the terminal block.
3.7.3.3 Cavity
Watts
Volts
Amps
Ohms
18 inch
Bake (Bake element)
Active
4000
240
16.7
14.4
18 inch
Broil (Broil element)
Active
2600
240
10.8
22.2
30 inch
Bake (Bake element)
Active
6000
240
25.0
43.2
30 inch
Broil (Broil element) Convection Bake (Bake and Broil elements are on during Preheat mode. Bake, Broil, and Convection elements are on in active mode, although Broil is only on for 4 seconds of every minute for browning)
Active
4000
240
16.7
14.4
Preheat
6000
240
25.0
43.2
Active
8750
240
36.5
113.0
30 inch
Convection Broil (Broil and convection elements)
Preheat
4750
240
19.8
49.7
Speed Clean (Broil and Bake elements)
Active
4750
240
19.8
49.7
30 inch
Active
6000
240
25.0
43.2
36 inch
Bake (Bake element)
Active
6000
240
25.0
43.2
36 inch
Broil (Broil element) Convection Bake (Bake and Broil elements are on during Preheat mode. Bake, Broil, and Convection elements are on in active mode, although Broil is only on for 4 seconds of every minute for browning) Convection Broil (Broil & convection elements on for Preheat and active modes) Speed Clean (Broil and Bake elements) Griddle (Griddle element) NOTE: For specific 36-inch and 48-inch models. Grill Hot Surface Igniter (HSI) NOTE: For specific 36-inch and 48-inch models.
Active
4000
240
16.7
14.4
Preheat
6000
240
25.0
43.2
Active
8750
240
36.5
113.0
Preheat
4750
240
19.8
49.7
Active
4750
240
19.8
49.7
Active
6000
240
25.0
43.2
Active
1600
120
13.3
9.0
Active
120 to 48
120
0.4 to 1.0
300 to 120
30 inch
36 inch
36 inch 36 inch N/A
Temperature Reading N/A
Do not remove the thermocouple prematurely when the oven is hot.
Element Cycle/Circuit Specification Cycle (Element/s)
Mode
Test oven temperature using a thermometer with a thermocouple lead. If you leave the thermocouple in the oven during a speed clean cycle, keep in mind it will take a few hours before the oven is cool enough if you plan to retrieve the thermocouple.
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3.8 Fault Codes When a fault is detected, this appliance will display a fault code (see Figure 23, on page 20). The fault codes are represented by the manner in which two blue LED indicators are blinking. Depending on the range model, the blue LEDs that blink are located either horizontally or vertically on the control panel. The horizontal positioned blue LEDs (see Figure 20 and Figure 21) will first blink on the left and then the right, and the vertical positioned blue LEDs (see Figure 22) will first blink on the top and then the bottom. For example, if the first LED blinks 4 times followed immediately by the second LED blinking 3 times, that represents a fault code of 43 on the chart (see Figure 23, on page 20). Figure 21: Three Horizontal LED Indicators (Only Blue LEDs Blink)
Figure 20: Two Horizontal LED Indicators Figure 22: Two Vertical LED Indicators
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Figure 23: Fault Codes
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4
SERVICE AND REPAIR
3. Remove all trim from the maintop (see Figure 24).
4.1 Preparing the Range for Servicing For most servicing of this appliance (for example, involving disassembly, or component removal / installation), you will need to do the following prior to starting: ■
Turn off the gas supply to the range by closing the gas valve at the wall
■
Turn off the electrical power to the range by removing the power cord from the electrical outlet, and putting the circuit breaker in the OFF position (or removing the fuse)
■
Make sure the range components are not hot before servicing
■
Wear protective clothes: long sleeves, gloves, safety glasses
Figure 24: Trim
4. Remove all Star burner caps (see Figure 25). 5. Use a 20 mm socket to remove the Venturi tube from the receptacle in the brass burner base (see Figure 25).
If testing the appliance requires the use of electrical power and/or an open gas supply, exercise extreme caution.
4.2 Accessing Components under the Maintop This section contains the steps required to gain access to the components located under the maintop(s). 4.2.1
Removing Knobs, Grates, Trim, Burner Assemblies
To access and service components located underneath the maintops (see Figure 11), first remove the knobs, grates, trim, and burner assemblies. Then remove spilltrays, heat shields, and burner support rail(s). 1. [Optional – only if a component attached to a knob needs replacing] Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 2. Remove all grates.
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Figure 25: Star Burner Assembly
1 2 3 4
Burner cap Igniter plug (electrode) – with spring Burner base (brass) Venturi tube
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6. Slowly lift to remove the burner base (see Figure 25, page 21).
m Caution Fragile Component The igniter plug is a ceramic component that can be brittle and crack easily. 7. While lifting the brass burner base, carefully depress the locking tab on the female terminal of the igniter wire, and gently pull to detach from the igniter plug (see Figure 26 and Figure 27).
Figure 27: Ignition Plug with Spring
Figure 26: Igniter Wire Locking Tab
1
Tab (press it to detach wire from electrode)
8. [Only if the ignition plug needs replacing]: Remove and retain the spring from the ignition plug by rotating the ignition plug clockwise while simultaneously holding the spring with a flat blade screwdriver to prevent its rotation (so that the spring is unscrewed from the plug). You may need to push the spring upward with the screwdriver in order to remove it from the ignition plug (Figure 28).
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Figure 28: Rotating the Ignition Plug to Detach Spring
9. [Only if the ignition plug needs replacing]: After the spring is detached, remove the igniter plug from the burner base.
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4.2.2
Removing Spill Trays
4.2.3
Removing Heat Shields
m Caution Fragile Component Porcelain enamel spill trays are fragile, so do not over-torque spill tray screws to avoid damaging the porcelain. 1. Push each ignition wire downward through its respective receptacle, as you carefully lift out each spill tray (see Figure 29 and Figure 30).
Figure 31: Typical Heat Shields
Sharp Components – Gloves Recommended Use gloves when removing or installing a heat shield, as the edges may be sharp.
Figure 29: Typical Spill Tray
Figure 30: Removing the Spill Trays (Ignition Wire Shown)
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1. Remove and retain the screws that secure the heat shield onto the range. 2. Use gloves while you carefully lift and remove the heat shield(s). See Figure 32.
Figure 32: Removing the Heat Shield
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4.2.4
Removing the Burner Support Rail
This procedure is for the removal of the burner support rail with the jet holder assemblies attached, which may be necessary in order to gain access to components under the maintop that need servicing. If a jet holder assembly needs to be removed from the burner support rail or needs to be replaced, see Jet Holder Assembly Removal and Replacement, page 38. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
4. Using a 9/16th inch wrench, unscrew the hex nut to remove the other end of the gas tubes from their respective valve as follows:
[XLO valves]: Use a 1/2 inch wrench to hold the bolt on the solenoid valve, while unscrewing the gas tube hex nut with a 9/16th inch wrench. Be careful not to bend the gas tubes (see Figure 80).
[Standard valves]: Use a 9/16th inch wrench to remove the gas tubes from the standard valves. Be careful not to bend the gas tubes.
5. Push each ignition wire downward through its receptacle in the burner support rail.
Figure 33: Burner Support Rail
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Using a 9/16th inch wrench, unscrew the hex nuts to remove the gas tubes from the jet holder assemblies. Be careful not to bend the gas tubes (see Figure 34).
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Figure 34: Removing Gas Tube from Jet Holder Assembly
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6. Make note of which way the burner support rails are placed on the range chassis before removing, so you can re-install in the correct position in relation to the jet holder assemblies and gas tubes.
Sharp Component – Gloves Recommended The burner support rail has sharp edges. Avoid injury by using gloves when removing or installing burner support rails.
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test.
Figure 35: Removing Burner Support Rail from Range Chassis
7. Using a large flat-blade screwdriver, push one side of the burner support rail to the other side of the chassis, until the 2 prongs come out from their slots on the chassis (see Figure 35). Then remove burner support rail with the two jet holder assemblies attached (see Figure 36).
Figure 36: Burner Support Rail with Jet Holder Assembly Attached
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4.3 Griddle Removal and Replacement Depending on the model and index number of the range, there are two different procedures for the griddle removal that are presented here (the primary differences between them are the brackets used): Griddle with Removable Brackets – Removal and Replacement, and Griddle with Fixed Brackets – Removal and Replacement., page 30. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 4.3.1
Griddle with Removable Brackets – Removal and Replacement
Griddle Hazard The griddle plate must always be correctly in place when it is on. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Complete steps for Accessing Components under the Maintop, page 21. 3. Remove the griddle plate and grease tray (see Figure 38).
Fiberglass Wear gloves when handling fiberglass insulation
Figure 38: Griddle Plate and Grease Tray
1 2
Griddle plate Grease tray
4. Remove and retain the two screws from each of the two element support brackets (see Figure 37). Figure 37: Element Support Brackets and Screws
1 2
Screws (2) Element support brackets (1 of 2 shown)
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5. For both right-side and left-side brackets (see Figure 39), remove and retain the following two screws: ■ The screw securing the element flange onto the bracket (see Figure 40) ■
The screw securing the bracket onto the back frame (see Figure 41)
6. Remove right and left brackets by lifting the pins out of the slots on the element tray (see Figure 39). NOTE: Depending on the model and FD number, some ranges will not use the bracket shown in Figure 39).
Figure 40: Removing Element Flange from Bracket
1
Location of screw on element flange that secures the element flange to the bracket
Figure 39: Bracket
1 2 3
Screw location (attaches to back frame) Screw location (attaches to element flange) Pins (2)
Figure 41: Removing Bracket from Back Frame
1
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Screw holding bracket onto the back frame
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7. Remove the thermostat bulb by carefully pulling it out of the retaining bracket (see Figure 42). If necessary, you can remove and retain the two screws from the retaining bracket to remove in order to facilitate the removal of the bulb. NOTE: After removing the thermostat bulb from retaining bracket, do not push the bulb through the receptacle in the element tray yet.
Figure 42: Removing the Thermostat Bulb from Retaining Bracket
1 2
Retaining bracket Thermostat bulb
8. Disconnect the 1/4 inch spade connectors of both (right and left) element wires. You may have to pull the element wires out a bit to access the connectors – while doing this, be careful not to damage the element wires. 9. Remove the two screws from the element tray (see Figure 43). The insulation support bracket is now detached from under the element tray (see Figure 44, page 29).
Figure 43: Screws on the Element Tray
1
Screws (2) holding element to tray
Fiberglass Wear gloves when handling fiberglass insulation
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Figure 44: Detaching the Insulation Support Bracket
10. While lifting up the element tray slightly, carefully push the bulb through the circular receptacle in the element tray (see Figure 45).
Figure 45: Receptacle for Removing Thermostat Bulb
11. While removing the insulation (see Figure 46), be careful not to pull on the thermostat bulb.
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Figure 46: Removing the Insulation
12. Remove the insulation support bracket by pulling its two prongs out of the slots in the retaining plate (see Figure 47).
Figure 47: Insulation Support Bracket
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4.3.2
Griddle with Fixed Brackets – Removal and Replacement
Fiberglass Wear gloves when handling fiberglass insulation
Griddle Hazard The griddle plate must always be correctly in place when it is on. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Complete steps for Accessing Components under the Maintop, page 21. 3. Remove the griddle plate and grease tray (see Figure 38, page 26). 4. Carefully remove the bulb from the fixed retaining bracket (see Figure 48).
Figure 48: Removing Thermostat Bulb from Retaining Bracket
1 2 3
Retaining bracket Thermostat bulb Receptacle for removing bulb
NOTE: After removing the thermostat bulb from retaining bracket, don’t push the bulb through the receptacle in the element tray yet. 5. Disconnect the 1/4 inch spade connectors of both right and left element wires. You may have to pull the element wires out a bit to access the connectors – while doing this, be careful not to damage the element wires.
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6. If the element needs replacing, it snaps out of the fixed brackets on the element tray (see Figure 49).
8. Detach the insulation support bracket from under the element tray (see Figure 51).
7. Remove the two screws from the element tray (see Figure 50).
Figure 51: Detaching Insulation Support Bracket Figure 49: Fixed Element Brackets
9. While lifting up the element tray slightly, carefully push the bulb through the circular receptacle in the element tray (see Figure 48, page 30).
Fiberglass Wear gloves when handling fiberglass insulation
Figure 50: Locations of Screws on Element Tray
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10. While removing the insulation (see Figure 52), be careful not to pull on the thermostat bulb.
4.4 Grill Components – Removal and Replacement When diagnosing problems with the grill, also see Hot Surface Igniter Board Removal and Replacement, page 58. For adjustment of the grill burner flame, see Adjusting Grill Burner Flame with the Air Shutter, page 14. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing any of these components.
Grill Hazards ■ The grill plate must be correctly in place whenever the grill is on ■ Do not service the grill when it is hot
Figure 52: Removing the Insulation
11. Remove the insulation support bracket by pulling its two prongs out of the slots in the retaining plate (see Figure 53).
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Complete steps for Accessing Components under the Maintop, page 21. 3. Remove the grill plate and grease tray (see Figure 54).
Figure 54: Grill Plate and Grease Tray Figure 53: Insulation Support Bracket
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1 2
Grill plate Grease tray
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4. Remove and retain the screws from the two burner box mounting brackets (see Figure 55). 5. Lift up the grill burner box slightly, and then detach the HSI wire connector and the electrode spade connector from underneath the burner box (see Figure 55).
4.4.1
Grill Flame Spreader Removal and Replacement
6. Remove and retain the two screws securing the flame spreader on the grill burner box (see Figure 56), and then remove the flame spreader (see Figure 57, page 33).
Figure 56: Grill Burner Box with Flame Spreader Installed
Figure 55: Grill Burner Box (View of from Underneath)
1 2 3 4 5 6 7
1, 3 2
Flame spreader screw locations Flame spreader
Solenoid valve for grill (attached to gas flex line) Burner box mounting brackets(2) Electrode terminal (connecting wire not shown) HSI wire connector Grill burner (only Venturi tube section is visible) Air shutter (shown with orifice visible inside) Elbow connector (attached to orifice)
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Figure 57: Flame Spreader Removed (Grill Burner Shown)
4.4.2
Grill Burner Removal and Replacement
Figure 58: Removing the Grill Burner
1 2
Tab at end of grill burner Slot on burner box
7. Lift the grill burner out of the burner box slightly upward, in the direction towards the open end of the burner box – so that the tab end is disengaged from the slot in the burner box. See Figure 58. NOTE: For adjustment of the grill burner flame, see Adjusting Grill Burner Flame with the Air Shutter, page 14.
Figure 59: Grill Burner
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4.4.3
Grill Hot Surface Igniter Removal and Replacement
4.4.4
Grill Electrode Removal and Replacement
On the grill, the electrode functions as a flame sensor – that is, if the electrode does not heat up enough in a short time frame, the electrode will close the solenoid valve to avoid gas build-up in the grill burner. See Figure 62.
Figure 60: Grill Hot Surface Igniter (HSI)
8. Make sure the HSI wire connector has been detached from under the burner box (per step 5). 9. Remove and retain the screw that secures the HSI onto the burner box chassis (see Figure 61), and then gently pull the HSI out (see Figure 60).
Figure 62: Electrode
1 2
Electrode terminal Location of screw that secures electrode onto electrode bracket
10. Make sure the electrode spade connector has been detached from the electrode terminal (from under the burner box). 11. Remove and retain the screw that secures the electrode onto the electrode bracket (see Figure 61 and Figure 62), and then remove the electrode.
Figure 61: Screws for Removing the HSI and Electrode
1 2
Electrode screw (shown securing electrode onto electrode bracket) HSI screw (shown securing HSI onto burner box)
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4.4.5
Grill Thermostat Removal and Replacement
The removal and replacement of the grill thermostat requires removing the bulb from the burner box (per this procedure). It also requires removal of the thermostat switch at the control panel (see Griddle and Grill Thermostat Removal and Replacement, page 63). 12. Remove and retain the screw that secures the side panel of the burner box, and then remove the side panel. The left side panel acts as a shield for the sensor bulb. See Figure 63 and Figure 64.
Figure 64: Thermostat Sensor Bulb (Shown with Left Side Panel of Burner Box Removed)
1 2 3 4
Figure 63: Left Side Panel of Grill Burner Box (Shown Attached)
1 2
Screw securing side panel onto burner box Left side panel of burner box
13. Gently remove the sensor bulb by sliding it out of the bracket (the bracket does not have to be removed). See Figure 64.
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Bracket Sensor bulb Capillary tube Portal for sensor bulb
m Caution
You can extend the capillary tube of the thermostat to the needed length, however be careful not to twist or bend it, or it may impede the component’s ability to operate properly.
14. Carefully slide the sensor bulb and capillary tube through the portal in the burner box chassis (see Figure 64). 15. If you have not already done so prior, detach the thermostat switch from the control panel (see Griddle and Grill Thermostat Removal and Replacement, page 63), and then remove the grill thermostat assembly from the range.
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4.4.6
Grill Orifice and Elbow Connector Removal and Replacement
16. From inside the burner box, remove and retain the two screws securing the burner support (which houses the orifice and elbow connector) onto the front of the burner box (see Figure 65 and Figure 66), and then remove the burner support (see Figure 67).
Figure 67: Burner Support Removed with Orifice and Elbow Connector Attached
Figure 65: Screws for Connecting Piece
1
Screw locations (2) securing the burner support onto the burner box
1 2 3 4 5 6
Elbow connector (shown attached to gas flex line) Burner support Screw hole – for screw from grill burner tab Screw holes (2) – for screws from burner box Orifice Holes on for burner support screws (2)
Figure 68: Elbow Connector Figure 66: Burner Support
1 2
Portal for orifice Screw holes (2)
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Figure 69: Typical Orifice
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17. When installing, be sure the orifice is aligned correctly inside the air shutter section of the grill burner, and that the burner support is secured properly onto the tab end of the grill burner (Figure 70).
4.5 Removal and Replacement of Top-Accessible Components
TIP: Correct alignment of the orifice straight into the burner’s Venturi tube maximizes air input for best burner performance.
This section contains removal and replacement procedures for the top-accessible components, located under the maintop.
NOTE: If converting the range for use with LP gas, make sure to use the orifice provided in the LP conversion kit (PLPKIT).
4.5.1
Jet Holder Assembly Removal and Replacement
This procedure is for removing and replacing the jet holder assembly from the burner support rail. The assembly includes the jet holder, as well as the orifice (jet) which is an integral part of the assembly, and is not available separately. NOTE: The orifice (jet) should not be removed. NOTE: If ordering a replacement jet holder assembly, retain the wire clip for use with the replacement assembly. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 70: Orifice—Burner Support—Elbow Connector Assembly Attached to Air Shutter and Grill Burner Tab Figure 71: Jet Holder (left) and Wire Guard Clip (Right)
Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Sharp Components – Gloves Recommended ■ ■
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The burner support rail may have sharp edges. Avoid injury by handling with care. It is recommended to use gloves when removing or installing the burner support rail.
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove both gas tubes attached to both jet assemblies on the burner support rail you are to remove (see Figure 34, page 24). NOTE: Although the jet holder can be replaced without removing the burner support rail, it is recommended to always remove the burner support rail prior to replacing the jet holder, so that proper alignment can be verified by seeing the jet holder and wire guard clip placement. 4. Remove burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 5. To detach the jet assembly from the burner support rail, use an adjustable wrench to remove the nut (see Figure 72).
7. When installing the jet holder, do the following: NOTE: Before attaching the wire guard clip, first install the jet holder onto the burner support rail and tighten the nut, so that the clip doesn’t get caught between the base of the jet and the rail.
When installing a jet holder, make sure it seats into the correct groove on the rail, so that it faces the right direction. Install the nut with the hollowed end touching the rail, and make sure the nut is fastened tightly. Install the wire guard clip correctly onto the jet holder – so that at the lower end it won’t interfere when the gas tube is installed – and so that at the upper end the clip is seated under the two protruding wings of the jet holder (but not caught in between the jet and the rail). See Figure 73.
Figure 73: Jet Holder Assembly and Wire Guard Clip Figure 72: Removing the Nut on the Burner Support Rail
6. Replace the jet holder assembly if needed. Be sure to retain and re-use the wire guard clip if you are ordering a replacement jet holder assembly.
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1 2 3 4
Wing (1 of 2 shown) on jet holder Wire guard clip Threaded connection for gas tube Orifice (jet)
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Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. 4.5.2
Standard Valve Removal and Replacement
The standard valves are for the non-XLO burners only [right side, and also on some models for the left (but not far-left) side]. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
6. Using a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet, remove and retain the valve screw (that secures the standard valve onto the manifold) by accessing it from under the chassis base, through the corresponding access hole (the oven door must be opened or removed (see Figure 75 and Figure 76). Be careful not to lose the rubber washer attached to the screw. 7. Remove the standard valve and (connected) microswitch from the manifold (see Figure 77, page 41). Be careful not to lose the red rubber washer attached to the standard valve. 8. Detach the standard valve from the microswitch by removing and retaining the screw and then pulling the microswitch off the alignment pin on the standard valve (see Figure 77, page 41). NOTE: You do not have to detach the wires connected to the microswitch terminals if you are just servicing the standard valve. 9. Replace the standard valve if needed.
Figure 74: Typical Standard Valve
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. Using a 9/16th inch wrench, remove the gas tube by unscrewing the hex nuts connected to the standard valve and to the jet holder assembly. Be careful not to bend the gas tube. 5. If a burner support rail obstructs access to the standard valve, then remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24.
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Figure 75: Valve Access Holes on Typical Range
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Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. 4.5.3
Microswitch Removal and Replacement
The microswitches are for the standard (non-XLO) burners only. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 76: Removing the Valve Screw
Figure 78: Microswitch
Figure 77: Standard Valve Connected to Microswitch
1
Screw connecting microswitch to standard valve
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If a burner support rail obstructs access to the microswitch, then remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 5. Using a 9/16th inch wrench, remove the gas tube by unscrewing the hex nuts connected to the standard valve and to the jet holder assembly. Be careful not to bend the gas tube.
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10. Use a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet to remove and retain the valve screw by accessing it from under the chassis base, through the corresponding access hole. The oven door must be opened or removed (see Figure 75 and Figure 76). Be careful not to lose the rubber washer attached to the screw. 6. Remove the standard valve and microswitch (connected together) from the manifold (see Figure 77). Be careful not to lose the red rubber washer attached to the standard valve. 7. First make a note of how the wires (piggyback and single) are connected to the terminals on the microswitch before detaching the wires from the terminals (see Figure 77). NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 8. Detach the standard valve from the microswitch by removing and retaining the screw, and then pulling the microswitch off the alignment pin on the standard valve (see Figure 77, page 41). 9. Replace the microswitch if needed.
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component removed, replaced, or otherwise serviced using gas leak detector or bubble test.
4.5.4
Solenoid Valve for XLO Burner – Removal and Replacement
This procedure is for the solenoid valves for the XLO burners. For the procedure for the grill solenoid, see Solenoid Valve for Grill – Removal and Replacement, page 43. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 79: Solenoid Valve with O Ring
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove knob from solenoid valve stem by slowly pulling knob straight out, away from control panel. 4. If obstructing access to the solenoid, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 5. Use a 1/2 inch wrench to hold the nut on the solenoid valve, while unscrewing the gas tube hex nut with a 9/16th inch wrench. 6. Then unscrew the other side of the gas tube attached to the jet holder assembly and remove the gas tube. Be careful not to bend the gas tube (see Figure 80). 7. First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals.
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NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 8. Use an adjustable wrench to unscrew the large hex nut on the solenoid and remove the solenoid valve from the XLO valve. Be careful not to lose the plastic O ring inside the large hex nut of the solenoid valve, as it may fall out easily (see Figure 79, page 42). 9. Replace solenoid valve if needed.
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test.
4.5.5
Solenoid Valve for Grill – Removal and Replacement
Access for the solenoid valve for the grill is under the maintop. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. For the procedure to remove and replace the solenoid valve for the XLO burners, see Solenoid Valve for XLO Burner – Removal and Replacement, page 42. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the solenoid, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. At the solenoid valve outlet, use a wrench to detach the gas flex tube – remove and retain the compression nut and the sleeve from the gas flex tube (see Figure 81, page 44). 5. At the solenoid valve inlet, detach the gas flex tube that connects the solenoid valve to the elbow connector fitting on the manifold (the elbow connector fitting is supplied as part of the manifold assembly). See Figure 81, page 44. 6. Replace the solenoid valve if needed.
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 80: Removing Gas Tube from the Solenoid Valve
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4.5.6
XLO Valve Removal and Replacement
The XLO valves are for the left-most front and left-most rear (simmer) burners only. When replacing the XLO valve, on some models you may need to remove the potentiometer together with the XLO valve, while on other models you may snap the potentiometer off the XLO valve. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 81: Solenoid Valve and Respective Fittings for Grill Burner
1 2 3 4 5 6
Gas flex tube Compression nut Sleeve Solenoid valve outlet (to gas flex tube / grill burner) Solenoid valve Solenoid valve inlet (connected to gas flex tubing that extends to manifold elbow connector fitting)
Figure 82: Typical XLO Valve
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. If a burner support rail obstructs access to the XLO valve, then remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 5. While using a 1/2 inch wrench to hold the nut on the solenoid valve, unscrew the gas tube hex nut with a 9/16th inch wrench. Then unscrew the other side of the gas tube attached to the jet holder assembly and remove the gas tube. Be careful not to bend the gas tube (see Figure 80, page 43).
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6. First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Use an adjustable wrench to unscrew the large hex nut on the solenoid and remove the solenoid valve from the XLO valve. Be careful not to lose the plastic O ring positioned inside the large hex nut of the solenoid valve, as it may fall out easily (see Figure 79). 8. Use a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet to remove and retain the valve screw (that secures the XLO valve onto the manifold) by accessing it from under the chassis base, through the corresponding access hole. The oven door must be opened or removed (see Figure 75 and Figure 76). Be careful not to lose the rubber washer attached to the screw.
9. Gently lift the protruding part of the XLO valve out of the receptacle on the manifold (don’t lose the red rubber washer attached to the XLO valve), and slightly bring out the (connected) XLO valve–-potentiometer assembly from under the front panel.
Figure 84: Solenoid—XLO Valve—Potentiometer Assembly
1 2 3 4
Solenoid valve XLO valve Simmer potentiometer Side connector (to simmer potentiometer)
Figure 83: Valve Access Holes on Typical Range (XLO Valve Access Shown)
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10. Remove the white plastic side connector from the potentiometer by pressing on the connector tab. (see Figure 85). 11. Replace the XLO valve if needed. 12. Detach the XLO valve from the potentiometer by using a small flat-blade screwdriver to gently remove the XLO valve from the potentiometer standoffs. Then slide the potentiometer off the valve stem (see Figure 86).
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. For XLO valves, you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on XLO valves with the electrical power on.
Figure 86: Removing the XLO Valve from the Potentiometer
Figure 85: Side Connector Tab
1
Harness connector tab
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4.5.7
Potentiometer Removal and Replacement
Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. The potentiometer (also known as the simmer control potentiometer or XLO potentiometer) is used to control the simmer function of the XLO burners. The potentiometer should not be confused with the temperature selector switch, which is sometimes also referred to as a potentiometer.
Figure 87: Typical Potentiometers
This procedure is for removing and replacing the potentiometer when accessed from the top of the range (under the maintop). The potentiometer can also be removed and replaced easily through the front of the range (after the front panel has been removed), however front panel removal also requires access from the top of the range. NOTE: If the control panel has already been removed per Control Panel and Bullnose Removal and Replacement procedure on page 64, you can easily remove the potentiometer by detaching the plastic wire connector at the potentiometer and then pulling the potentiometer off of the XLO valve (it should snap off). If the potentiometer to be replaced is located behind the manifold support bracket, first remove and retain the screws on the bracket, and then remove the bracket before pulling the potentiometer off (see Figure 90, page 49). 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21.
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2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. If obstructing access to the potentiometer—XLO valve—solenoid assembly, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 5. Use a 1/2 inch wrench to hold the nut on the solenoid valve, while unscrewing the gas tube hex nut with a 9/16th inch wrench. Then unscrew the other side of the gas tube attached to the jet holder assembly and remove the gas tube. Be careful not to bend the gas tube (see Figure 80). 6. First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Use an adjustable wrench to unscrew the large hex nut on the solenoid and remove the solenoid valve from the XLO valve. Be careful not to lose the plastic O ring positioned inside the large hex nut of the solenoid valve, as it may fall out easily (see Figure 79). 8. Use a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet to remove and retain the valve screw by accessing it from under the chassis base, through the corresponding access hole. The oven door must be opened or removed (see Figure 75 and Figure 76). Be careful not to lose the rubber washer attached to the screw. 9. Gently lift the protruding part of the XLO valve out of the receptacle on the manifold (don’t lose the red rubber washer attached to the XLO valve), and slightly bring out the (connected) XLO valve/potentiometer assembly from under the front panel. Be aware of the side connector that is attached.
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10. Remove the white plastic side connector from the potentiometer by pressing on the connector’s tab. (see Figure 85). 11. Detach the XLO valve from the potentiometer by using a small flat-blade screwdriver to remove the XLO valve from the potentiometer standoffs. Then slide the potentiometer off the valve stem (see Figure 86). 12. Replace the potentiometer if needed.
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. If potentiometer was accessed by removing an XLO valve, you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on XLO valves with the electrical power on. 4.5.8
Manifold Removal and Replacement
NOTE: The manifold is sold as an assembly, which comes with XLO and standard valves pre-installed. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove burner support rails (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Remove the regulator from the manifold (see Regulator Removal and Replacement, page 54). 5. Remove all knobs from their valve stems by slowly pulling knobs straight out, away from control panel. 6. At each of the locations shown in Figure 123 on page 65, remove and retain two screws inside each bezel (see Figure 89) to detach the manifold support brackets at the back of the control panel (see Figure 90 on page 49).
Figure 88: Typical Manifold
Although range components can usually be accessed and replaced without removing the manifold, this procedure is provided if the manifold for the maintop burners needs to be replaced, for example, if damage is sustained due to a gas leak in the manifold, or if the threading on the manifold is bad after removing the regulator.
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Figure 89: Screws that Attach to Manifold Support Bracket
1
Screws (2) that attach to manifold support bracket
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7. Detach all wire connectors to the LED indicators and temperature gauge, and make a note of how all the wires are connected. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 8. Remove the control panel (see Control Panel and Bullnose Removal and Replacement, page 64). 9. Remove the oven door(s). See Removing the Door, page 77. 10. Remove and retain the two screws from each manifold support bracket that attach to the manifold, and then remove the support brackets from the manifold (see Figure 90). 11. Disconnect the wire connectors from the potentiometers and then detach the potentiometer from the XLO valve by using a small flatblade screwdriver to gently separate the XLO valve from the potentiometer standoffs (see Figure 86, page 46). 12. Slide the potentiometers off the XLO valve stems, and retain the potentiometers. 13. Detach the wire connectors to the two solenoid valves, and to all the microswitches. Make a note of how the wires are connected. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone) 14. Remove gas tubes from standard valves: Use a 9/16th inch wrench to remove the gas tubes by unscrewing the hex nuts connected to the standard valves and to the jet holder assemblies. Be careful not to bend the gas tubes. 15. Remove gas tubes from solenoid valves: Use a 1/2 inch wrench to hold the nut on a solenoid valve, while unscrewing the attached gas tube hex nut with a 9/16th inch wrench (see Figure 80, page 43). Then remove the other side of the gas tube attached to
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the jet holder assemblies and remove the gas tubes. Be careful not to bend the gas tubes.
Figure 90: Manifold Support Bracket (Shown with Control Panel Removed)
1 2 3
Screws (2) holding manifold support bracket onto manifold Manifold support bracket Holes on manifold support bracket (2) for receiving screws from bezel
16. Remove the two solenoid valves (see Solenoid Valve for XLO Burner – Removal and Replacement , page 42). 17. Detach microswitches from all XLO and standard valves: Remove and retain the small screw that holds the microswitch onto the valve, and then pull the microswitch off the alignment pin on the valve (see Figure 77, page 41). NOTE: If replacing a manifold assembly (which has XLO and standard valves pre-installed), you do not have to remove or reuse the standard and XLO valves from the old manifold.
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18. Now remove and retain the screw holding the manifold pipe onto the bracket (near the regulator). You do not have to remove the screw holding the bracket onto the chassis. See Figure 91. 19. Gently lift the manifold out through the area where the control panel was removed. Be careful of the wire harnesses, control boards, and other components.
4.5.9
Oven Lamp Transformer Removal and Replacement
To diagnose problems with the oven light, see Figure 147, page 76. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test.
Figure 92: Typical Oven Lamp Transformer
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the oven lamp transformer, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail, page 24. 4. First make a note how the wires are connected to the transformer terminals before detaching the wire connectors.
Figure 91: Manifold Pipe Bracket on Chassis Base
1 2
Bracket Manifold pipe
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NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 5. Remove and retain the two screws securing the transformer onto the range chassis. 6. Replace the transformer if necessary.
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4.5.10 Oven Temperature Selector Removal and Replacement For 48-inch ranges, there is a dedicated oven temperature selector for each of the two ovens. This procedure covers the removal and replacement for both oven temperature selectors. Depending on the FD number and model, the oven temperature selector may or may not be fastened with a clip-shaped bracket (see Figure 94).
Figure 95: Large Oven Temperature Selector (Typical Models Shown)
Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 93: Small Oven Temperature Selector (Typical Models Shown)
Figure 96: Front and Back of Large Oven Temperature Selector (Typical Model Shown with Retaining Bracket)
1
Figure 94: Front and Back of Small Oven Temperature Selector (Typical Model Shown with Retaining Bracket)
1
Retaining bracket
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Retaining bracket
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. If obstructing access to the oven temperature selector, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail, page 24.
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5. From the back of the control panel, first make a note of how the wires are connected to the oven temperature selector terminals, and then remove the wire connectors from the terminals (see Figure 94 and Figure 96 on page 51). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 6. At the front of the control panel, remove and retain the two screws through the bezel that attach to the oven temperature selector (see Figure 97), and then remove the bezel.
4.5.11 Five-Position Oven Function Selector Removal and Replacement The Five-Position Oven Function Selector switch is for the large oven on 48-inch ranges only. Depending on the range model and FD number, the Five-Position Oven Function Selector switch may or may not be fastened with a clip-shaped bracket (see Figure 99). NOTE: When installing the Five-Position Oven Function Selector, make sure to attach the wire connector correctly onto all of the pins. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
7. At the back of the control panel, remove the oven temperature selector, and replace it if necessary.
Figure 98: Five-Position Oven Function Selector (Typical Models)
Figure 97: Screw Locations on Bezel
1
Location of screws (2)
Figure 99: Front and Back of Five-Position Oven Function Selector (Typical Model Shown with Retaining Bracket)
1
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Retaining bracket
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. If obstructing access to the five-position oven function selector, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail, page 24. 5. At the back of the control panel, disconnect the plastic multi-pin connector from the pins on the five-position oven function selector (see Figure 99). 6. At the front of the control panel, remove and retain the two T-20 screws on the bezel which are attached to the five-position oven function selector (see Figure 100), and then remove the bezel.
4.5.12 Oven Temperature Gauge Removal and Replacement For 48-inch model ranges, the temperature gauge is for the large oven only. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 101: Oven Temperature Gauge
Figure 100: Screws on Bezel of Oven Function Selector
7. At the back of the control panel, remove the five-position oven function selector and replace it if necessary.
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the temperature gauge, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. At the back side of the control panel, detach the four-pin wire connector from the gauge (see Figure 102). 5. Remove and retain the two nuts with lockwashers from their respective studs, and then remove the mounting bracket (see Figure 102). 6. Push the gauge outward (towards the front of the range) to remove it. 7. Replace the gauge if necessary.
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4.5.13 Regulator Removal and Replacement Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. NOTE: When replacing the regulator, if the range has been converted for use with LP gas, make sure to install the correct regulator (cap) fitting. Refer to the instructions in the PLPKIT kit for details.
Figure 102: Oven Temperature Gauge (Back Side Shown)
1 2 3 4
Nuts with lockwashers (2) on studs (2) Temperature gauge Mounting bracket Four-pin wire connector Figure 103: Regulator with Typical Fittings and Gas Flex Line
1 2 3 4 5 6 7 8 9
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Gas flex line Hex nut on gas flex line Flared adapter Large nut on regulator Regulator Connecting pipe T-connector Manifold pipe Flared adapter
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the regulator, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Use two wrenches (open-end, or adjustable) and hold the large nut on the regulator steady with one wrench, while you simultaneously rotate the flared adapter with the other wrench – until you can remove the flared adapter from the regulator (see Figure 103). 5. Use a wrench to hold the connecting pipe, while you simultaneously rotate the regulator until you can detach it (see Figure 103). 6. Replace the regulator if needed. NOTE: When replacing the regulator or associated fittings, use pipe sealant on pipe threads only - such as the manifold pipe to T-connector, T-connector to connecting pipe, connecting pipe to regulator, and regulator to flared adapter (threaded end only).
Never use pipe sealant on flair connections or pressure fittings, such as the flared end of the flared adapter. 7. When replacing the regulator, make sure it is positioned correctly with its cap fitting facing upward, as shown in Figure 103.
4.5.14 Control Board Removal and Replacement The 48-inch range has a control board for each of the two ovens. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 4.5.14.1
Control Board Removal and Replacement (Large Oven)
This procedure is for the oven control boards of 36-inch and 30-inch ranges, as well as for the large oven control boards of 48-inch ranges. For replacing the small oven control board of 48-inch ranges, see Control Board Removal and Replacement (Small Oven), page 56. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the large oven control board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Remove and retain the screws holding the control board shield onto the range chassis and then remove the control board shield (see Figure 104). 5. Remove all multi-pin wire connectors from the control board as well as the spade connector of the ground wire (see Figure 104). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone).
Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test.
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m Caution Fragile Components Be careful not to exert too much pressure on the standoffs or the control board, as these are fragile components. 6. Using a needle nose pliers, disengage the control board from all the plastic standoffs by lightly pressing the tiny protruding clip on each standoff, while simultaneously pulling the control board off the standoff. 7. Replace the control board only if needed.
4.5.14.2
Control Board Removal and Replacement (Small Oven)
This procedure is for the oven control boards of the small ovens on the 48-inch ranges only. For replacing the control boards on the large ovens of 48-inch ranges or the ovens of 30-inch and 36-inch ranges, see Control Board Removal and Replacement (Large Oven), page 55. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the small oven control board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Remove all wire connectors from the control board relays, terminals, and multi-pin connectors (see Figure 104 and Figure 105). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone).
m Caution Fragile Components Be careful not to exert too much pressure on the standoffs or the control board, as these are fragile components. Figure 104: Control Boards and Shield on Typical 48-Inch Range
1 2 3
Control board for large (main) oven Control board shield with fault code instructions Control board for small (auxiliary) oven
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8. Using a needle nose pliers, disengage the control board from all the plastic standoffs by lightly pressing the tiny protruding clip on each standoff, while simultaneously pulling the control board off the standoff. 9. Replace the small oven control board only if needed.
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5. Using a needle nose pliers, disengage the control board from all the plastic standoffs by lightly pressing the tiny protruding clip on each standoff, while simultaneously pulling the simmer board off the standoff (see Figure 106). 6. Remove and replace the simmer control board if needed.
NOTE: Please explore other possible causes before replacing the simmer control board. Approximately 75% of all simmer control boards returned to the factory turn out to be ok.
Figure 105: Control Board for Small Oven
4.5.15 Simmer Control Board Removal and Replacement Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the simmer control board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Remove and retain the screw to detach the ground wire from the chassis (see Figure 106).
m Caution
Figure 106: Simmer Control Board
1 2 3
Multi-pin wire connectors (2) Standoffs (4) Ground wire (shown attached to screw on chassis)
Fragile Components Be careful not to exert too much pressure on the standoffs or the simmer control board, as these are fragile components.
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4.5.16 Hot Surface Igniter Board Removal and Replacement The hot surface igniter (HSI) control board is for the HSI on the gas grill burner (see Grill Hot Surface Igniter Removal and Replacement, page 35). Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the HSI board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24.
Figure 107: Typical HSI Board Shield
4. Remove and retain the screws holding the HSI board shield onto the range chassis, and then remove the shield (see Figure 107). 5. Remove the multi-pin wire connector from the HSI board (see Figure 108). 6. Remove and retain the two screws that affix the HSI board onto the chassis (see Figure 108). 7. Replace the HSI board only if needed.
Figure 108: HSI Board
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4.5.17 LED Indicator Removal and Replacement Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the LED harness, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. While holding the two plastic wire connectors, rotate them and pull to detach (see Figure 109). 5. Push the protruding clip at the front end of the LED indicator while you simultaneously push the LED indicator frontward through the hole in the control panel (see Figure 110). 6. Replace the LED indicator if needed.
Figure 110: LED Indicator
4.5.18 Ignition (Spark) Module Removal and Replacement Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21.
Figure 109: LED Indicator Wire Connectors
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2. Follow all steps in Accessing Components under the Maintop, page 21. 3. If obstructing access to the ignition module, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. 4. Pull to detach the side connectors from the ignition module (see Figure 111, page 60). 5. Remove and retain the two screws securing the ignition module to the range chassis. 6. Replace the ignition module if needed.
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Figure 111: Ignition (Spark) Module – Typical Models Shown
4.5.19 Door Latch Removal and Replacement Removing and replacing the door latch requires access from both the top and front of the range. Depending on the model and index number of the range, a replacement door latch may or may not require an adapter harness to be installed. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
4. If obstructing access to the door latch access panel, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. NOTE: Depending on the model range, if the door latch and/or plunger switch is located under the griddle/grill you need you may need to remove the griddle/grill first in order to gain access. See Griddle Removal and Replacement, page 26 and Grill Components – Removal and Replacement, page 32. 5. Remove and retain the single screw that holds the access panel to the range chassis (see Figure 113). 6. Lift the access panel up, and detach its two tabs from the chassis (see Figure 113, page 60). 7. Remove and retain the two T-20 screws under the front control panel (see Figure 114). 8. Gently lift the latch out of the cavity (see Figure 115).
Figure 112: Door Latch – Typical Models Shown
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. Remove the corresponding oven door (see Oven Door Removal, Installation, page 77).
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Figure 113: Door Latch Access Panel (Small Oven Access Panel Shown)
1 2
Tabs (2) Screw
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Figure 114: Door Latch, Screws, and Plunger Switch
1 2 3
T-20 screws (2) Door latch Plunger switch
Figure 115: Removing the Door Latch
1
Plunger switch
9. Detach the spade wire connectors from the latch and the white plastic piggyback wire connector on the door latch’s microswitch (see Figure 116, page 62). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone).
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Figure 117: Typical Plunger Switch
1
Figure 116: Door Latch (Shown Removed from Cavity)
1 2 3
Spade connectors (2) Piggyback wire connector Door latch
10. Replace the door latch if needed. NOTE: If replacing the plunger switch, it must be done before the door latch is re-installed (see Plunger Switch Removal and Replacement, page 62). 4.5.20 Plunger Switch Removal and Replacement Removing and replacing the plunger switch requires access from both the top and front of the range. These instructions are for the plunger switch shown in Figure 117. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
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Tabs (2) – press both to release plunger switch
1. First follow steps 1 through 8 of the Door Latch Removal and Replacement procedure, starting on page 60. 2. [For small oven plunger switch only] Detach the two wire connectors from the two wider blade terminals of the plunger switch (there are four blade terminals on the plunger switch). See Figure 118, page 63. 3. [For large oven plunger switch only] Detach the four wire connectors from the four terminals on the plunger switch. See Figure 115, page 61. NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone). 4. In order to remove the plunger switch, from inside the cavity press the two metal tabs on the sides of the plunger switch (see Figure 117) as you pull the plunger switch outward from the front of the range. You may need to pry the bezel of the plunger switch out with a flat-blade screwdriver in order to pull it out (see Figure 119, page 63). 5. Replace the plunger switch if needed.
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4.5.21 Griddle and Grill Thermostat Removal and Replacement Both the griddle and grill require a thermostat. For models with both griddle and grill, there are two thermostats. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 118: Plunger Switch in Cavity (Small Oven of 48-Inch Model Shown)
Figure 120: Typical Griddle/Grill Thermostat
m Caution
When installing the thermostat, extend the capillary tube to the needed length, however be careful not to twist or bend it, or it may impede the component’s ability to operate properly.
Figure 119: Prying out Plunger Switch Bezel
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1. Follow all safety precautions and steps in the Preparing the Range for Servicing, page 21. 2. First make a note how the wires are connected to the thermostat on the back side of the control panel, and then disconnect the wire harnesses and connectors. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone).
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3. Remove and retain the two screws on the bezel of the griddle/grill thermostat (see Figure 97, page 52). 4. [For griddle]: Remove thermostat bulb from the retaining bracket, and then gently pull it through the receptacle (see Griddle Removal and Replacement on page 26, and Figure 121). 5. [For grill]: Remove the thermostat bulb from the grill burner box (see Grill Thermostat Removal and Replacement, page 36). 6. Remove the thermostat from the back of the control panel, and replace it if needed.
4.5.22 Control Panel and Bullnose Removal and Replacement
Figure 122: Bullnose and Control Panel (Shown with Knobs Removed)
Access to the control panel and bullnose is from the top and front of the range. This procedure is provided primarily in the event the control panel is damaged and needs replacing. Most components can be accessed and serviced without the need to remove the control panel. Be sure to check QuickFinder for relevant information, documentation, and correct part numbers when replacing any of these components. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Follow all steps in Accessing Components under the Maintop, page 21. 3. From the back of the control panel, first make a note of how the wires are connected, and then detach only the wire connectors for all the LED indicators, as well as the wire connector for the temperature gauge. You do not have to detach the wire connectors for other knob components.
Figure 121: Removing the Thermostat Bulb from Retaining Bracket (Griddle)
1 2
Retaining bracket Thermostat bulb
NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). NOTE: LED indicators can stay on control panel as long as their connectors are detached. 4. Remove all knobs from the control panel.
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Figure 124: Three Nuts / Lockwashers (Right Side of Range Shown)
9. Remove and retain the screw at the right and left side panels (see Figure 125). Figure 123: Locations to Remove Knobs and Manifold Support Bracket Screws
1 2
Location attached to manifold support bracket Location attached to manifold support bracket
5. Unscrew and remove the bezels for the oven lamp switches. 6. At the bezels on the control panel, remove and retain the screws that connect to the two manifold support brackets (see Figure 123). 7. At the bezels on the control panel, remove the bezel screws and bezels that connect to the following components: five-position oven function selector, three-position oven function selector, griddle/grill control(s), oven temperature select switch(es). 8. Use a swivel head driver or an open end wrench to remove and retain the three nuts with lockwashers from both sides of the range (see Figure 124).
Figure 125: Removing Screws at Sides
1
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Screws (1 per side) to remove at right and left sides
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10. While holding the control panel to support it from falling, remove and retain the screws from under the control panel (see Figure 126).
Figure 127: Tabs and Bracket Studs Shown on Control Panel
1 2 Figure 126: Removing Screws Under the Control Panel
1
Screws to remove from under the control panel
11. Carefully pull away the control panel from the range in a forward direction to detach the two metal tabs from the chassis (see Figure 127) and remove the control panel with bullnose attached (see Figure 128, page 67).
Tab Studs (3) on bracket (left side shown)
12. After the control panel with bullnose attached has been removed (see Figure 128, page 67), before replacing it remove the temperature gauge (see Oven Temperature Gauge Removal and Replacement, page 53) and the LED indicators (see LED Indicator Removal and Replacement, page 59). 13. Use a flat blade screwdriver to pry out the two brackets (right and left sides of control panel). The bracket is pliable and may be fastened with double-sided tape, so it should come out without using any force (see Figure 129, page 67 and Figure 130, page 67). NOTE: The studs are affixed onto the brackets and are not to be removed. NOTE: Depending on the range model, the brackets will have either two or three studs.
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Figure 130: Bracket (Shown Removed) Figure 128: Control Panel Removed (Attached to Bullnose)
1 2
Control Panel (shown with some knobs removed) Bullnose
14. At the back side of the control panel and bullnose, remove and retain the screws that secure the bullnose onto the control panel. 15. Pull the bullnose off of the control panel, and replace either or both of these parts if needed. 16. When installing, it may be easier to affix the brackets to the bullnose and control panel by placing a piece of double-sided tape on the bracket. This enables you to have the brackets affixed so they don’t fall out when positioning the control panel / bullnose on the range (see Figure 131).
Figure 131: Bracket (Shown with Tape Attached) Figure 129: Removing a Bracket
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4.6 Removal and Replacement of Back-Accessible Components This section contains removal and replacement procedures for the components that can be accessed from the back of the range. NOTE: Before and after servicing the range from the back side, refer to the Installation Manual for instructions on moving the appliance, installing the anti-tip bracket, and other important installation and safety information.
Moving the Range For servicing that requires access from the back of the range, it may be necessary to move the range. Due to the immense weight of the range, using an air sled or dolly to move it may reduce the risk of injury and/or damage. For 48-inch ranges, it is recommended to have an air sled and more than one person to move the appliance. 4.6.1
the CAN 1-B149.1 and .2 – Installation Codes for Gas Burning Appliances and/or local codes. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove and retain the screws on the front-facing side of the backguard / Island Trim (see Figure 132). 3. Remove and retain the screws on the on the back side of the backguard / Island Trim (see Figure 133, page 69), and then remove the backguard. 4. Lift the backguard / Island Trim straight up to remove (see Figure 134, page 69). NOTE: When re-installing, the back-facing side of the backguard / Island Trim needs to be placed inside of the two guide channels (see Figure 134, page 69).
Backguard and Island Trim Removal and Replacement
This procedure applies for all backguards (Lowback, High Backguard models (with and without shelf), as well as for the Island Trim. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
■
■
If replacing with a different backguard or Island Trim model, the installation must be performed with adherence to all procedures and warnings/cautions in the Installation Instructions manual. Always check local building codes for the proper method of installation. Local codes vary. Installation, electrical connections and grounding must comply with all applicable codes. In the absence of local codes the appliance should be installed in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54 current issue and National Electrical Code ANSI/NFPA 70current issue. In Canada, installation must be in accordance with
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Figure 132: High Backguard on Typical Range Showing Frontal Screw Locations
1
Screw locations (varies per backguard size) on front of backguard
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4.6.2
Back Panel Removal and Replacement
Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 133: Backguard, Back Panel, Crossmember Cover
1 2 3
Backguard Back panel Crossmember cover
Figure 135: Typical Back Panel
1
Screw locations (number varies per panel model)
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 68.
m Caution
Be careful not to damage any components at the back of the range when removing or installing the back panels. 3. Remove and retain the screws from the back panels, and remove the panel (see Figure 133 on page 69 and Figure 135). Figure 134: Backguard Installed Inside Guide Channels
1 2
4. Replace the back panel if needed.
Backguard (or Island Trim) Guide channels (2)
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4.6.3
Crossmember Cover Removal and Replacement
You will need to remove the crossmember cover if you are removing a wire connector to the bake burner HSI or bake burner electrode. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
4.6.4
Terminal Block Removal and Replacement
At the terminal box (junction box), replace the terminal block in the event the terminal threads are stripped, or if there is any other damage to the component. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21.
Figure 136: Typical Crossmember Cover
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove and retain the screws from the crossmember cover (see Figure 136 and Figure 133, page 69). 3. [If removing the crossmember cover]: Push the power cord through the receptacle on the crossmember cover, so that you can remove it without having to detach the power cord wiring at the terminal block. 4. [If replacing the crossmember cover]: You will need to detach the power cord from the terminal block first before replacing the crossmember cover (see Electrical Wiring Connections at the Terminal Block, page 71).
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Figure 137: Typical Terminal Block Positioned In the Terminal Box
2. Detach the wire leads from each terminal on the terminal block (see Figure 137). Retain the washers and nuts (see Figure 138), and make a note of how all the wires are connected to the different terminals.
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4.6.6
Cooling Fan Removal and Replacement
Some models use a cooling fan with a Hall Effect sensor attached, which is a part of the cooling fan assembly. Other models use a cooling fan with an air interlock switch installed (see Air Interlock Switch Removal and Replacement, page 72). Figure 138: Securing Power Supply Wire to Terminal
1 2 3 4
Flat washer Supply wire Cupped wire Upper nut
NOTE: It is always recommended to label and tag all wires and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone).
Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Sharp Component – Use Gloves Use gloves when handling the cooling fan, as it has sharp edges
3. Remove and retain the two screws that secure the terminal block onto the terminal box. 4. When replacing the terminal block, refer to Electrical Wiring Connections at the Terminal Block, page 71). 4.6.5
Electrical Wiring Connections at the Terminal Block
The range must be connected to the power supply utilizing either a three-wire connection, four-wire connection, or a permanent connection (hard wiring). For electrical wiring requirements and safety precautions, refer to the Installation Instructions manual for this appliance. NOTE: The electrical wiring diagram is located on the back side of the kick panel (see Wiring Diagram, page 5).
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Figure 139: Cooling Fan Showing Mounting Plate and Screw Locations
1
Screw locations (4) securing fan mounting plate onto range
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 68. 3. Remove back panel, per Back Panel Removal and Replacement procedure, page 69.
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4. At the back of the range, detach the wire connectors, and make a note of which wires are connected to each of the two different terminals (see Figure 140, page 72). NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone).
4.6.6.1 Air Interlock Switch Removal and Replacement The air interlock switch can be removed and replaced independently of the cooling fan. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
5. Remove and retain the screws that secure the cooling fan mounting plate onto the range chassis (see Figure 139). 6. Using gloves, remove the cooling fan. 7. Replace the cooling fan if needed. Figure 141: Air Interlock Switch
Figure 142: Bracket
Figure 140: Typical Cooling Fan
1
Wire connectors (2)
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 68. 3. Remove back panel, per Back Panel Removal and Replacement procedure, page 69. 4. At the cooling fan, remove and retain the nuts securing the air interlock switch onto its bracket (see Figure 141, Figure 142, and Figure 143, page 73). 5. Replace the air interlock switch if needed.
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4.6.7
Thermal Fuse Removal and Replacement
When the range temperature reaches the maximum temperature threshold, the thermal fuse breaks the electrical circuit in order to protect the electronics from abnormally high heat conditions. Some model ranges have thermal fuses installed, while other models do not, as they are protected from adverse heat conditions by cavity venting. Thermal fuses are installed at the back of the range. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
Figure 143: Air Interlock Switch on Cooling Fan
1 2
Bracket Air interlock switch
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Figure 144: Typical Thermal Fuses
1. Follow all safety precautions and steps in the Preparing the Range for Servicing, page 21. 2. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 68). 3. Remove the back panels (see Back Panel Removal and Replacement, page 69). 4. Depending on the model range, you may have to remove the crossmember cover (see Crossmember Cover Removal and Replacement, page 70). 5. Detach the wire connectors from the terminals and make a note of how the wires are connected (label and tag, or photograph). 6. Remove and retain the screw(s) securing the thermal fuse to the range chassis. 7. Replace the thermal fuse if needed.
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4.7 Removal and Replacement of Front-Accessible Components This section contains removal and replacement procedures for the components that can be accessed from the front of the range. 4.7.1
Oven Temperature Sensor Removal and Replacement
8. At the back of the range, while wearing gloves, clear a path in the fiber glass insulation so the sensor wire connectors can be pulled through the sensor portal. 9. At the front of the range, gently pull the sensor connector wires through the portal. 10. Replace the sensor if necessary.
The oven temperature sensor is located inside each oven cavity (see Figure 145). Access is needed from both the front and back of the range in order to replace the sensor bulb. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 68). 3. Remove the back panels (see Back Panel Removal and Replacement, page 69). 4. Remove oven door (see Oven Door Removal, Installation, page 77). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components. 5. Remove oven trays. 6. From inside the oven cavity, remove and retain the two screws (see Figure 145, page 74). 7. At the back of the range, detach the sensor wire connectors.
Figure 145: Sensor and Lamp Locations Inside Oven Cavity
1 2 3 4
Lamp Lamp screw Oven temperature sensor screws (2) Oven temperature sensor
Fiberglass Wear gloves when handling fiberglass insulation.
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4.7.2
Oven Lamp and Bulb Removal, Replacement, and Diagnostics
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 68). 3. Remove the back panels (see Back Panel Removal and Replacement, page 69). 4. Remove oven door (see Oven Door Removal, Installation, page 77).
5. 6. 7. 8. 9.
Figure 146: Typical Oven Lamp Assembly
1 2 3
Wire connectors Bulb Lens (shown removed)
The oven lamp is located inside each oven cavity (see Figure 145). Access is needed from both the front and back of the range in order to replace the oven lamp, however replacing just the bulb only requires access from the front of the range. NOTE: The bulb can be replaced without replacing the lamp assembly. Refer to the Use and Care manual for the bulb type. Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component.
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NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components. Remove the oven trays. From the back of the range, detach the lamp wire connectors. From inside the oven cavity, remove and retain the screw that holds the lamp onto the oven cavity (see Figure 145, page 74). Remove the fixing clip and lens of the oven lamp assembly. Replace the bulb if needed.
Fiberglass Insulation Wear gloves when handling fiberglass insulation. 10. From the back of the range, while wearing gloves, clear a path in the fiber glass insulation so the lamp wire connectors can be pulled through the sensor portal. 11. From the front of the range, gently pull the lamp connector wires through the sensor portal. 12. Replace the lamp if needed. 4.7.2.1 Oven Light Diagnostics To diagnose problems with the oven light, see Oven Light Diagnostics (Figure 147, page 76). Also see Oven Lamp Transformer Removal and Replacement, page 50).
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Figure 147: Oven Light Diagnostics
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4.7.3
Oven Door Removal, Installation, and Alignment
Failure to comply with these warnings can result in injury and/or damage: ■ Before removing the oven door, make sure the gas supply and electrical power to the range are turned off, and that the door and oven are not hot. ■ Be careful when removing the oven door as it is very heavy. Use both hands to remove or replace the oven door, and firmly grasp both sides of the door when handling it. ■ When the door is removed from the range, never release locking levers or try to close the hinges. Without the weight of the door, the powerful springs will snap the hinges shut with great force. 4.7.3.1 Removing the Door 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Open the door fully and use a flat blade screwdriver to pry the locking levers downward (towards you) as far as it goes (see Figure 148, page 77).
Figure 148: Prying Locking Lever Downward with Screwdriver
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3. Close the door until it stops against the locking levers while firmly grasping the door with both hands. The open locking levers will hold the door open at a slight angle. 4. Grasp the door firmly on the ends of the door handle, and lift the door up (there will be some spring resistance to overcome). When the door is lifted sufficiently to clear the hinge hooks, pull the door straight out (see Figure 149), and place it in a safe location.
Figure 149: Hinge Shown Removed
4.7.3.2 Installing the Door 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. While firmly grasping the door on both sides, position the door at a slight angle and insert both hinges into their respective slots. The hinges will be securely hooked into the slots when properly installed. NOTE: Do not let the door fall. Do not force or bend the door. TIP: Rest the door on your foot while using your leg for stability. 3. Open the door fully and then use a flat blade screwdriver to push the locking levers upward all the way (away from you) into the hinge slots. Careful not to scratch the range during this process. 4. Open and close the door to make sure the door is positioned properly and closes with a tight fit. Do not force the door to open or close. If the door is properly installed, it should move smoothly
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and rest straight on the front of the range when closed. If the door does not operate correctly, verify that the hinges are properly seated into the hinge slots, and that the locking levers are fully engaged into the slots. If the door is not aligned correctly, see Aligning the Door. 4.7.3.3 Aligning the Door On models that have an alignment mechanism as a part of the hinge receiver, you can adjust the door alignment by using the alignment screw that is located below each hinge / hinge receiver slot. 1. Make sure the door is installed correctly so it will not pose any danger by falling while adjusting the screw (see Installing the Door, page 77). 2. Locate the alignment screw below the door hinge (see Figure 150 and Figure 151). 3. Use a T-27 driver to turn the alignment screw until the door is properly aligned.
Figure 151: Alignment Screw (Shown with Door Removed for Clarity)
1 2 3
Slot for hinge Hinge receiver screw (do not rotate this screw as it is not for door alignment) Door alignment screw
Figure 150: Alignment Screw (View at Small Door of 48-Inch Range)
1
Alignment screw
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4.7.4
Convection Components – Removal and Replacement
Although most convection components are accessed from the front of the range, you may also need access from the back of the range (such as for the convection motor wire connectors). Be sure to check QuickFinder for relevant information, documentation, and correct part numbers when replacing any of these components.
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 68). 3. Remove the back panels (see Back Panel Removal and Replacement, page 69). 4. Remove oven doors (see Oven Door Removal, Installation, page 77). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door / latch components. 5. Remove all the oven racks. 6. From the back of the range, using needle nose pliers, gently pull to detach the convection element wire connectors (see Figure 154, page 80). NOTE: It is always recommended to label and tag all wires and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Remove and retain the four screws and remove the front cover (see Figure 153, page 80).
Figure 152: Convection Components
1 2 3 4 5 6 7 8 9 10
Motor for convection fan Bracket Insulation Rear cover shield Reflector cover shield Shim ring Fan Nut Convection element Front cover
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NOTE: When re-installing front cover, it must be positioned with the cover “arrow-shaped” vents facing to the right, as shown in Figure 153, page 80.
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Figure 154: Convection Element
Figure 153: Front Cover
1
1 2 3
Wire connector terminals (2) Screw locations (2) Screw location (1)
Screw locations (4) securing front cover
8. Remove and retain the three screws securing the convection element onto the reflector cover shield, and then remove the convection element (see Figure 154). 9. Wearing gloves, remove the nut, and then remove the convection fan. Retain the shim ring if it falls out when removing the fan (see Figure 155).
Figure 155: Fan, Nut, Shim Ring and Washer
1 2 3
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Shim ring and washer Fan Nut
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10. Remove the reflector cover shield (see Figure 156).
Figure 156: Reflector Cover Shield
Figure 157: Convection Motor Wire Connectors
12. Remove the six screws on the rear cover shield (see Figure 158), and then pull the rear cover shield (attached to motor assembly) forward through the oven cavity to remove it. Fiberglass Wear gloves when handling fiberglass insulation. 11. From the back of the range, detach the two convection motor wire connectors. Be sure to first make a note of how they are connected (see Figure 157). NOTE: It is always recommended to label and tag all wires and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone).
Figure 158: Screws on Rear Cover Shield
1
Screw locations (6)
13. To detach the motor assembly from the bracket, first remove and retain the shim ring and washer (see Figure 159, page 82). 14. Remove and retain the four screws from the rear cover shield that are attached to the bracket (see Figure 160, page 82).
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15. Remove the bracket (with fiberglass insulation) attached to motor (see Figure 161).
Figure 159: Removing the Washer and Shim Ring
1 2
Washer Shim ring
Figure 161: Bracket and Insulation
1 2
Screw locations (4) that attach to rear cover shield Fiberglass insulation
16. Wearing gloves, remove and retain the fiberglass insulation. 17. Remove and retain the three screws securing the bracket onto the motor (see Figure 162 and Figure 163, page 83), and then remove the motor.
Figure 160: Removing Bracket Screws on Rear Cover Shield
1
Screws (4) securing rear cover shield to bracket
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Figure 162: Three Screws Connecting Bracket to Motor
1
Screws (3) securing the bracket to the motor
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Eye Protection To protect your eyes from debris, it is recommended to wear protective eye wear at all times when removing or installing components inside the oven cavity.
Fiberglass Wear gloves when handling fiberglass insulation. Figure 163: Rear Cover Shield, Bracket, and Motor (Back-of-Range View)
1 2
Screws securing bracket to rear cover shield (4) Screws securing motor to bracket (3)
18. Replace the convection motor, if needed. 4.7.5
Broil Burner Removal and Replacement
This procedure requires access from both the front and the back of the range. On 48-inch models, the broil burner removal and replacement procedure is the same for both small and large ovens. Be sure to check QuickFinder for relevant information, documentation, and correct part numbers when replacing any of these components.
Figure 164: Broil Reflector Plate
Figure 165: Broil Element
Hot Surfaces The oven broil burner components and interior surfaces of the oven may be hot and can cause burns. Do not service the range when these components are hot. Figure 166: Bracket
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1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove all trays from the oven. 3. Remove oven doors (see Oven Door Removal, Installation, page 77). 4. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 68). 5. Remove the back panel (see Back Panel Removal and Replacement, page 69). 6. From the back of the range at the portals for the broil element wires, use needle nose pliers to detach the broil element wire connectors. 7. From inside the oven cavity, remove and retain the two screws securing the broil element to the oven cavity (see Figure 167).
8. Remove and retain the four screws securing the front-facing element bracket onto the reflector plate (see Figure 168).
Figure 168: Front Element Bracket Secured to Reflector Plate
1
Screws (4) securing front element bracket to reflector plate
Figure 167: Element Secured to Oven Cavity
1
Screws (2) securing element to oven cavity
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9. Hold the element-bracket assembly in place (so as not to bend the element) while you remove and retain the four screws securing the rear element bracket on the reflector plate (see Figure 169).
Figure 169: Rear Element Bracket Secured to Reflector Plate
1
Screws (4) securing rear element bracket to reflector plate
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10. While continuing to hold the element-bracket assembly, lower it slightly while you remove the reflector (see Figure 170).
Figure 170: Removing the Reflector Plate
1
Reflector plate
11. Slowly pull the element-bracket assembly out (towards you), while guiding the element wires through the element portal.
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4.7.6
Bake Element Components – Removal & Replacement (Large Oven)
This procedure is for the large oven of 48-inch ranges, as well as for the oven of 30-inch and 36-inch ranges. Bake element components are accessible from the front of the range. Be sure to check QuickFinder for relevant information, documentation, and correct part numbers when replacing any of these components.
4. Remove the kick panel (see Figure 171 and Kick Panel Removal and Replacement, page 94. 5. Using a flashlight, and wearing gloves, reach through the gap under the oven, and detach the two wire connectors behind the bake element tray (see Figure 171 and Figure 172). NOTE: The wire connectors may be a bit tight to remove.
Sharp Components Wear gloves when handling bake element components, as they may have sharp edges 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove oven doors (see Oven Door Removal, Installation, page 77). 3. Remove all the oven racks.
Figure 172: Accessing the Element Wire Connectors
1 2
Bake element tray (view from under the range) Location of element wire connectors (2) – located behind the element tray.
Figure 171: Kick Panel Removed
1
Gap under oven
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6. Remove and retain the four screws on the bottom cover that secure it to the brackets on the bake element tray, and then remove the bottom cover (see Figure 173 and Figure 176).
7. Remove and retain the screws holding the ends of the element onto the bake element tray (see Figure 176).
Figure 173: Bottom Cover
1
Screw locations (4) on bottom cover Figure 176: Bake Element Tray with Element Installed
1 2 3
Figure 174: Bake Element Tray
Brackets (4) Element Ends of element with screws attached to bake element tray
8. Pull out the element from the bake element tray. 9. Replace the element if needed.
Figure 175: Element
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4.7.7
Bake Element Components – Removal & Replacement (Small Oven)
This procedure is for the small oven of 48-inch ranges. Bake element components are accessible from the front of the range. Be sure to check QuickFinder for relevant information, documentation, and correct part numbers when replacing any of these components.
6. Remove and retain the two screws on the bottom cover that secure it to the bake element tray, and then remove the bottom cover (see Figure 177.and Figure 178).
Sharp Components Wear gloves when handling bake element components, as they may have sharp edges 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove oven doors (see Oven Door Removal, Installation, page 77). 3. Remove all the oven racks. 4. Remove the kick panel (see Figure 171 and Kick Panel Removal and Replacement, page 94). 5. Using a flashlight, and wearing gloves, reach through the gap under the oven, and detach the two wire connectors behind the bake element tray (see Figure 171 and Figure 172, page 86). NOTE: The wire connectors may be a bit tight to remove.
Figure 178: Screw Locations on the Bake Element Tray
1
Screw locations (2) on the bake element tray
7. Remove and retain the two screws securing the element onto the bake element tray, and then remove the element (see Figure 179).
Figure 179: Element Figure 177: Bottom Cover
1
Screw locations (2) on bottom cover
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1
Screw locations (2) securing element to element tray
8. Replace the element if needed.
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4.7.8
Door Handle Components – Removal and Replacement
Be sure to check QuickFinder for relevant information, documentation, and correct part numbers when replacing any of these components.
Figure 181: Screws at Top of Door
1
Location of screws (3) at top of door
Figure 180: Typical Door Handle Components
1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove the oven door (see Oven Door Removal, Installation, page 77). 3. Remove the oven trays. 4. Gently place the door on a flat, stable, and non-abrasive surface. 5. Remove and retain the three screws at the top of the door (see Figure 181).
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6. Remove and retain the three screws at the bottom of the door (see Figure 182).
Figure 183: Hex Head Cap Screws and Washers Figure 182: Screws at Bottom of Door
1
1
Location of screws (3) at bottom of door
7. Gently lift front door panel off the door. 8. At the back side of the front door panel, at both the left and right sides, remove and retain the two hex head cap screws and washers (see Figure 183). This will detach the endcaps from the door assembly. 9. After removing the right and left endcaps, pull the door handle tube out from the endcaps.
4.7.9
Hex head cap screws and washers (4 of each) – left side shown Door Hinge Removal and Replacement
Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. When the door is removed from the range, never release locking levers or try to close the hinges. Without the weight of the door, the powerful springs will snap the hinges shut with great force.
10. Replace the door handle components if needed. 11. After replacing door handle components, install the oven door and test for proper positioning - follow all warnings and steps for Installing the Door, page 77.
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Sharp Components Wear gloves when removing the door hinge
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1. Follow steps 1 through 7 of the Door Handle Components – Removal and Replacement procedure, page 89. 2. Place the back door panel on a flat, stable, and non-abrasive surface, with the porcelain side facing upward (see Figure 184). The hinge and locking lever are in a specific position that occurs after the oven door has been removed (as shown in Figure 184). In this position, do not move the hinge with your hands.
5. With the deep-well socket or similar tool still pressing on the hinge thumb, slowly release it, bringing the hinge and locking lever all the way forward to the “safe” position for hinge removal. The locking lever will have dropped into the slot (see Figure 186).
Figure 185: Removing the Hinge (Shown Moving Hinge Downward)
Figure 184: Door Hinge (Shown in the Position after Door Removal)
1 2
Hinge locking lever Hinge “thumb”
3. Use a large deep-well socket or similar tool to securely place over the hinge “thumb” and then press the tool downward just a little bit (towards the base of the door - see Figure 185) and hold it there. 4. While still holding the hinge in the downward position, use a tool (not your fingers) like a flat-blade screwdriver to press the hinge locking lever downward (towards the hinge) as far as it goes. See Figure 184.
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Figure 186: Hinge (Shown in “Safe” Position for Hinge Removal)
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6. Remove and retain the screws as shown in Figure 187 and Figure 188.
Figure 188: Screws for Hinge Removal Figure 187: Screws for Hinge Removal
1
1
Screws (2)
Screws (2)
7. Repeat steps 3 through 6 for the hinge at the other side of the door. 8. Turn the door upside-down, so that the porcelain surface is facing down. 9. Remove the four screws from the inner panel (see Figure 190, page 93). 10. Lift the inner panel off of the door, and then remove the hinge (see Figure 191, page 93). 11. Replace hinges if needed.
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Figure 189: Typical Hinge
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4.7.10 Door Gasket Removal and Replacement Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove oven door (see Oven Door Removal, Installation, page 77). 3. Remove and retain the screws on the bracket, and then remove the bracket (see Figure 192, and Figure 193 on page 94).
Figure 190: Inner Panel and Screws
1 2
Screws (4) Inner panel Figure 192: Bracket
4. Starting from one end of the gasket while carefully working your way to the other end, gently pull the gasket clips out of the receptacles on the oven frame. See Figure 194, page 94. 5. After replacing the gasket, check to make sure the door is positioned correctly, and closes with a tight fit. 6. Re-install the bracket.
Figure 191: Removing the Hinge
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4.7.11 Kick Panel Removal and Replacement Be sure to check QuickFinder for relevant information, documentation, and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 21. 2. Remove both oven doors (see Oven Door Removal, Installation, page 77). 3. Remove and retain the screws from the kick panel (see Figure 195), and then lift the kick panel off the range chassis.
Figure 193: Screws on Bracket Figure 195: Typical Kick Panel
1
Location of screws (2)
NOTE: The wiring diagram for the range is located on the back side of the kick panel (see Wiring Diagram, page 5).
5
BEFORE RETURNING APPLIANCE TO SERVICE
After you have finished all testing and servicing, always do the following before returning the appliance to service:
Figure 194: Oven Gasket and Bracket
1 2
Gasket Bracket
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■
Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test.
■
Make sure all electrical connections are correct and secure.
■
Make sure all safety grounds (internal and external) are correctly and securely connected.
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■
Make sure all panels and components are properly and securely reassembled.
7
■
Make sure the range is level and adjust accordingly.
■
If the range was pulled away from the wall for servicing, cleaning, or any other reason, make sure that the range is properly secured onto the anti-tip device when the range is pushed back against the wall (not needed for 48-Inch ranges). See the Installation Instructions manual for details on anti-tip device installation.
7.1 QuickFinder
6
CLEAN-UP
After you have finished servicing an appliance, clean up grease, fingerprints, and other residue that is present as the result of servicing the appliance. Refer to the Care and Use manual for clean-up information.
Clean-up Hazards ■ Don’t allow any cleaning or polishing solutions/compounds, disinfectants or bleaches to remain in contact with the stainless steel surfaces for long periods, or after clean-up. These may contain chemicals or materials which could release harmful inhalants or may damage the appliance. After cleaning or polishing, always rinse the cleaning/polishing materials with clear water and wipe dry with a clean, soft, non-abrasive cloth. ■
Clean the range with caution. Do not use flammable cleaners to clean the range. Avoid steam burns; do not use a wet sponge or cloth to clean the range while it is hot. Do not use any type of aerosol cleaner on or around the rangetop when hot. Some cleaners produce noxious fumes if applied to a hot surface. Follow directions provided by the cleaner manufacturer.
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ADDITIONAL RESOURCES
For further information, please refer to the following documents on QuickFinder: ■
Installation Instructions
■
Care and Use Manual
In addition, the following may be available on QuickFinder at http://portal.mch.bshg.com/portal : ■
Product Information screen (includes technical specification for the appliance)
■
Gas Information (Repair Instruction)
■
Wiring Diagram
■
Accessories List
■
Spare Parts Notes/Information (Technical Service Bulletins, and Technical Information Bulletins)
■
Exploded View Drawing
■
Parts List NOTE: Not all service parts are shown on the QuickFinder exploded views; review the Parts List for additional information.
7.2 Technical Support For Thermador technical support, call (800) 444-9091 between 5:00 am and 5:00 pm, Monday – Friday, Pacific Standard time.
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