Thermador Pro Harmony® Range - JustAnswer...Service Manual for the Thermador Pro Harmony Range,...

SERVICE MANUAL

Thermador

Pro Harmony® Range

Model: PRL304GH/10-17

Service Manual for the Thermador Pro Harmony Range, Model PRL304GH/10-17

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TABLE OF CONTENTS

1 General ........................................................................................ 4

1.1 Technical Documents to Read Prior to Servicing ........................... 4

1.2 Wiring Diagram ................................................................................ 4

1.3 Data Rating Plate ............................................................................ 4

1.4 Recommended Tools and Supplies ................................................ 5

1.5 Important Safety Information ........................................................... 5

1.5.1 Safety Symbols Used In This Manual ..................................... 5

1.5.2 Safety Precautions to Know Prior to Servicing ....................... 5

2 Operation ..................................................................................... 8

2.1 Control Knobs .................................................................................. 8

2.1.1 ExtraLow Feature .................................................................... 8

2.1.2 Temperature Selector Knob .................................................... 9

2.1.3 5-Position Oven Function Selector Knob ................................ 9

2.2 Automatic Re-Ignition ...................................................................... 9

2.3 Operation during a Power Outage .................................................. 9

2.4 Burner Assembly and Maintop Components ................................ 10

3 Testing, Setting, Troubleshooting - Burners and Ignition .... 10

3.1 Before Testing ............................................................................... 10

3.2 Burner Characteristics ................................................................... 11

3.2.1 Flame Characteristics ............................................................ 11

3.3 Testing Burner Ignition .................................................................. 12

3.3.1 Testing Cooktop Burner Ignition ............................................ 12

3.3.1.1 Testing the HI Setting ........................................................ 12

3.3.1.2 Testing the SIM Setting ..................................................... 12

3.3.1.3 Testing the XLO Setting .................................................... 12

3.3.2 Testing Bake Burner Ignition ................................................. 12

3.3.3 Testing Broil Burner Ignition .................................................. 12

3.4 Manually Setting Burner Valves .................................................... 12

3.4.1 Tools Needed ........................................................................ 12

3.4.2 Adjusting the Bypass Screws ................................................ 12

3.5 Burner, Flame, and Ignition Troubleshooting ................................ 13

3.5.1 Cooktop Burners – Burner and Flame Diagnostics ............... 13

3.5.1.1 Uneven Flame Distribution & Flame Noise Diagnostics ... 13

3.5.2 Ignition Diagnostics ............................................................... 14

3.5.1 Element Diagnostics .............................................................. 16

3.5.1.1 Safety Practices for Element Diagnostics ......................... 16

3.5.1.2 Element Diagnostic Tips .................................................... 16

4 Oven Light Diagnostics ........................................................... 17

5 Fault Codes .............................................................................. 18

6 Service and Repair ................................................................... 20

6.1 Preparing the Range for Servicing ................................................ 20

6.2 Accessing Components under the Maintop .................................. 20

6.2.1 Removing Knobs, Grates, and Burner Assemblies ............... 20

6.2.2 Removing the Maintop .......................................................... 22

6.2.3 Removing the Heat Shield .................................................... 23

6.2.4 Burner Support Rail Removal and Replacement .................. 23

6.3 Removal and Replacement of Top-Accessible Components........ 25

6.3.1 Jet Holder Assembly Removal and Replacement ................. 25

6.3.2 Manifold Removal and Replacement .................................... 26

6.3.3 Standard Valve Removal and Replacement ......................... 28


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6.3.4 Microswitch Removal and Replacement ............................... 29

6.3.5 Solenoid Valve Removal and Replacement .......................... 30

6.3.6 XLO Valve Removal and Replacement ................................. 31

6.3.7 Potentiometer Removal and Replacement ........................... 33

6.3.8 Temperature Selector Removal and Replacement ............... 34

6.3.9 5-Position Oven Function Selector – Removal and Replacement ......................................................................................... 35

6.3.10 Dual Valve Removal and Replacement ................................ 36

6.3.11 Regulator Removal and Replacement .................................. 37

6.3.12 Ignition Device Removal and Replacement .......................... 38

6.3.13 LED Indicator Removal and Replacement ............................ 38

6.3.14 Control Board Removal and Replacement ........................... 39

6.3.15 Simmer Control Board Removal and Replacement .............. 40

6.4 Removal and Replacement of Back-Accessible Components ...... 41

6.4.1 Backguard and Island Trim Removal and Replacement ....... 41

6.4.2 Back Panel Removal and Replacement................................ 42

6.4.3 Terminal Block Removal and Replacement .......................... 43

6.4.4 Electrical Wiring Connections at the Terminal Block ............ 43

6.4.5 Cooling Fan Removal and Replacement .............................. 43

6.4.6 Broil Burner Assembly Removal and Replacement .............. 45

6.4.7 Convection Components – Removal and Replacement ....... 47

6.5 Removal and Replacement of Front-Accessible Components ..... 50

6.5.1 Control Panel Removal and Replacement ............................ 50

6.5.2 Bake Burner Components – Removal and Replacement ..... 52

6.5.3 Oven Temperature Sensor Removal and Replacement ....... 55

6.5.4 Oven Lamp Removal and Replacement ............................... 56

6.5.5 Door Removal and Installation .............................................. 57

6.5.5.1 Removing the Door ........................................................... 57

6.5.5.2 Installing the Door ............................................................. 57

6.5.6 Door Handle Components - Removal and Replacement ...... 58

6.5.6.1 Removing Door Handle Components ............................... 58

6.5.6.2 Installing Door Handle Components ................................. 58

6.5.7 Door Gasket Removal and Replacement .............................. 59

6.5.8 Kick Panel Removal and Replacement ................................. 59

6.5.9 Bottom Plate of Front Frame – Removal and Replacement . 60

6.5.10 Door Hinge Receiver Removal and Replacement ................ 61

6.5.11 Door Hinge Removal and Replacement ................................ 62

7 Before Returning Appliance to Service ................................. 64

8 Clean-Up ................................................................................... 64

9 Additional Resources .............................................................. 64

9.1 QuickFinder ................................................................................... 64

9.2 Technical Support ......................................................................... 64


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1 GENERAL

This manual contains information that is necessary for servicing the following Thermador Pro Harmony Range:

PRL304GH/05

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.

For authorized servicers, additional assistance is available by contacting Technical Support at (800) 444-9091.

1.1 Technical Documents to Read Prior to Servicing

Before you start servicing, check QuickFinder for all other technical documents associated with this specific appliance.

1.2 Wiring Diagram

The Wiring / schematic diagram is located behind the kick panel (see Figure 1).

1.3 Data Rating Plate

The data rating plate which shows the model, serial, and FD number is located underneath the control panel, as shown in Figure 1. This information 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).

Figure 1: Data Rating Plate and Wiring Diagram Locations


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1.4 Recommended Tools and Supplies

The following tools and supplies are recommended to use when servicing this appliance:

Caution

Power Drivers

■ If using a power driver, set the clutch to the lowest setting

Driver sizes: T-10, T-20, T-25, T-30 1/4 inch nut driver or 1/4 inch socket wrench / ratchet Wrench sizes: 1/2 inch, 1/4 inch, 5/16 inch, 11/32 inch open-end Socket wrench / ratchet 11/32 inch Swivel head driver with an 11/32 inch, deep-well socket Large nut driver (1 inch min.) with a deep-well socket Long, hand-held T-20 driver Adjustable wrench Pipe wrench Precision screwdriver with a high-strength blade, 1/8 inch

(3.0 mm) wide, .020 inch (0.50 mm) thickness tip Flat blade screwdrivers: large, small Slip joint pliers Needle-Nose pliers Hook or non-straight hex key (Allen wrench) Protective gloves Gas leak test equipment Pipe sealant Small mirror Protective eye wear (such as glasses or goggles) Flashlight Amp meter Thermometer with thermocouple leads Multimeter

Air lifter / air dolly

1.5 Important Safety Information

Before starting to service an appliance, familiarize yourself with all safety information and precautions contained in this manual.

1.5.1 Safety Symbols Used In This Manual

This symbol alerts you to dangers that may result in bodily injury or death.

Caution

This symbol alerts you to actions that may result in damage to the product, or property.

1.5.2 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 by removing the fuse.

■ Turn off the gas supply to the appliance.

■ Make sure grates and burner assemblies are cool before removing them.


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Replacement Parts

Use only authorized replacement parts per catalog 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.

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.

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.

Hot Surfaces

To avoid burns and injury, do not handle components and surfaces that are hot, such as the cooktop burners, infrared broil burner, bake burner, heat deflector, and interior oven surfaces.

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.

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.

Heavy Appliance

Be careful when moving this heavy appliance. Using an air sled or oven dolly can reduce hazards or injury.


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In Case of Power Outage

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.

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.

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.

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.

Fiberglass Insulation

Wear gloves when handling fiberglass insulation.

Prior to Returning Appliance to Service

Prior to returning the appliance to service, make sure that:

■ 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

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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2 OPERATION

2.1 Control Knobs

The control knobs for each of the burners are located on the control panel, with an icon to identify the location on the range (see Figure 2). The left-front and left-rear burners have the ExtraLow (XLO) feature.

Figure 2: Burner Control Knobs

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 non-XLO burners, rotate the knob to any setting between HI and SIM. For the XLO (left front and left rear) burners, rotate the knob to any setting between HI and XLO.

NOTE: The blue LED indicator lights up when burners are lit.

2.1.1 ExtraLow Feature

When the knob is set to XLO - the very lowest setting, the flame cycles on for approximately 8 seconds and then turns off for 52 seconds of each minute.

The knob can also be set between SIM and XLO for a variable range of low heat, with the flame cycling on and off at a different frequency than the XLO setting (see Figure 3).

Figure 3: XLO Settings


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2.1.2 Temperature Selector Knob

For each oven, use the respective Temperature Selector knob (see Figure 4).

Figure 4: Temperature Selector Knob

2.1.3 5-Position Oven Function Selector Knob

Use this knob for oven bake, extended bake (Sabbath mode), convection bake, and broil (see Figure 5).

Figure 5: 5-Position Oven Function Selector Knob

2.2 Automatic Re-Ignition

Each 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.

2.3 Operation during a Power Outage

When there is a removal of electrical power, the XLO burners cannot be used. Do not attempt to light them manually.

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 5) of this manual.


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2.4 Burner Assembly and Maintop Components

Figure 6: Burner Assembly and Maintop Components

3 TESTING, SETTING, TROUBLESHOOTING - BURNERS AND IGNITION

Servicing Burners and Ignition

■ 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

Before testing the burners and ignition, do the following:

1. Reinstall any loose components that may have been removed earlier, such as burner caps and grates. Be certain that burner caps seat properly into the burner bases, burner pedestal and Venturi tube 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.

3. After gas checks are complete and before testing, connect the range to the electrical power supply.


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3.2 Burner Characteristics

If one or more burner blows out, the respective igniter electrode automatically re-ignites the flame.

At each burner port the flame should burn completely around the burner cap.

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

For LP gas, a slight “pop” sound may be heard at the burner ports a few seconds after the burner has been turned off

NOTE: If burner characteristics are not adequate, see Burner, Flame, and Ignition Troubleshooting, page 13.

3.2.1 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 8).

When the flame is properly adjusted, it should burn at each burner port, completely around the burner cap (see Figure 7).

NOTE: If flame characteristics are not adequate, see Burner, Flame, and Ignition Troubleshooting, page 13.

Figure 7: Burner Ports

Figure 8: Additional Flame Characteristics


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3.3 Testing Burner Ignition

3.3.1 Testing Cooktop Burner Ignition

Ignition Hazard

Do not touch the cooktop burners when the igniters are sparking.

For each burner, push the control knob in and then turn counter-clockwise to HI. The igniter should produce a clicking sound as the burner is sparking, and the burner should light within four seconds.

3.3.1.1 Testing the HI Setting

Set the burner knob to HI, and observe flame characteristics (see Figure 8). If any burner flame burns primarily yellow, verify if the burner cap is positioned properly on the burner base, and then re-test. If flame characteristics do not improve, call Thermador technical support at (800) 444-9091.

3.3.1.2 Testing the SIM Setting

Set the burner knob to SIM. Make sure that the flame completely surrounds the burner. There should be a flame at each burner port and there should not be an air gap between the flame and the burner. If the flame does not extend completely around any of the burners, call Thermador technical support at (800) 444-9091.

3.3.1.3 Testing the XLO Setting

The left-front and left-back burners have the XLO feature. Set the burner knob to XLO and observe if the flame cycles correctly - on for approximately 8 seconds, and then off for 52 seconds of each minute.

3.3.2 Testing Bake Burner Ignition

Set the oven to BAKE at 350° F. After 30–75 seconds the burner should ignite and stay lit until 350° F is reached. Then it should shut off. From this point forward, the burner should cycle on and off to maintain the temperature.

NOTE: The air shutter for the bake burner is factory pre-set at a fully-opened position for all conditions, and doesn’t require adjustment.

3.3.3 Testing Broil Burner Ignition

Set the mode to BROIL. After 30–75 seconds the burner should ignite. The infrared ceramic broiler does not require any adjustment.

3.4 Manually Setting Burner Valves

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 all valves.

3.4.1 Tools Needed

■ T-20 driver

■ A precision high-strength blade screwdriver, with 1/8 inch (3.0mm) wide, .020 inch (0.50mm) thickness tip should be used to reposition the bypass screws for minimum flow settings on manual valves.

3.4.2 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. Remove and retain the bezel mounting screw located to the right of the valve stem, using a T-20 driver (see Figure 9, page 13).

4. To engage the valve screw, insert the precision screwdriver with 1/8 inch blade into the same hole in the bezel that was created by the removal of the mounting screw (see Figure 10, page 13).

5. Turn the valve screw clockwise just until "bottom out" position is reached. Do not over-tighten the valve screw (see Figure 10).

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.


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Gas Leaks

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 9: Removing the Bezel Mounting Screw

Figure 10: Accessing and Setting the Bypass Screw

3.5 Burner, Flame, and Ignition Troubleshooting

3.5.1 Cooktop Burners – Burner and Flame Diagnostics

If a burner clicks (sparks) constantly, or if burner doesn’t light correctly and/or has inadequate burner/flame characteristics (per Burner Characteristics page 11 and Flame Characteristics page 11), then do the following:

Check if the manual shut-off valve is open and the unit is receiving gas (natural gas or liquid propane).

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 device and electrode, and also check grounding

Refer to the Ignition Diagnostics, page 14.

Call Thermador technical support at (800) 444-9091 for assistance if any burners fail to light, or any burners continue to burn yellow.

3.5.1.1 Uneven Flame Distribution & Flame Noise Diagnostics

If there is an uneven flame distribution around the burner ports and/or a loud noise emanating from the flame, it could be caused by bad combustion due to a misalignment of the gas jet assembly and Venturi tube. For optimal combustion, the jet needs to be centered inside of the Venturi tube. A misalignment of these two components can be caused by either the pedestal burner base and/or jet assembly not positioned correctly onto the maintop – resulting in a poor mixture of gas and air. Perform the following diagnostic steps:


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Hot Burner Components

Always use a pot holder to handle a hot burner cap, Venturi tube, or any other burner assembly component to prevent injury.

Figure 11: Problematic Burner – on High with Gaps and Uneven Flame (Left Image) and on Low (Right Image)

1. Check if the burner cap is properly installed.

2. If problem persists, switch the burner cap with one from a burner that is operating correctly. If problem is still not resolved, proceed to the next steps:

3. Remove the star burner top and then the pedestal burner base per the Removing Knobs, Grates, and Burner Assemblies procedure, page 20.

4. Make sure the jet assembly is correctly seated so that the raised part protrudes through the respective contour on the maintop (see Figure 12) and that the electrode ignition wire moves freely through the hole in the maintop (see Figure 24, page 21).

5. Reinstall the pedestal burner base (without the Venturi tube). Be careful not to over torque the screw on the pedestal burner base.

6. Insert the Venturi tube inside the pedestal burner base and make sure it can slide up and down freely without grinding or catching (see Figure 13).

7. Reinstall the rest of the burner assembly, and test the flame on low and high settings.

Figure 12: Incorrect Jet Assembly-to-Maintop Alignment (Left Image) and Proper Jet Assembly-to-Maintop Position (Right Image)

Figure 13: Pedestal Burner Base – Jet Centered Inside Venturi Tube

3.5.2 Ignition Diagnostics

The following flowchart applies in the event a burner fails to ignite.

Before performing steps in the Cooktop Burner - Ignition Diagnostics Flowchart (Figure 14, page 15), remove electrical power from appliance during disassembly and during removal and installation procedures. Restore electrical power when testing the unit if it is reassembled.


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Figure 14: Ignition Diagnostics Flowchart

STANDARD BURNERS

No ignitionBurner LED

Indicator is on?

120 VAC into

Microswitch checks

out ok?

Replace

MicroswitchYes

Sparking?Yes

120 VAC into

Ignition Device

checks out ok ?

No

Problem persists after

checking all connections

on Simmer Control Board?

Replace

Spark Module

(Ignition

Device)

Gas supply into

Regulator?

110V DC

into Solenoid

Valve?

Contact the

gas supplier

Replace

Regulator

Yes

Replace

Simmer

Control Board

Replace

Solenoid

Valve

Check burner ports for

blockage, check if burner

cap is aligned on base


checking electrical power

supply (circuit breaker/

fuse, power cord, wiring

at terminal box)?

No

Replace LED

Indicator


checking wire connection to

electrode, and checking if

electrode is free of debris?

Yes

No

Yes

Is gas present

at burner?

Yes

No (Standard burners)

No (XLO burners)

N

L1 Standard

Valve

Spark

Module

(Ignition

Device)

120V

Electrode

NDiode LED

Indicator

Burner

120V

XLO BURNERS

L1 PotentiometerSimmer

Controller

Board

Spark

Module

(Ignition

Device)

120V 5V

Solenoid

Valve

110V DCElectrode

120V

Diode LED

Indicator

Burner

N

YesCheck wiring from

Microswitch to Spark

Module (Ignition Device)

No (Standard burners)

5V from

Potentiometer to

Simmer Control

Board?

No

Problem persists

after checking all

connections on

Potentiometer?

Yes

No Yes

Yes

No

Replace

PotentiometerYes

5V from

Potentiometer to

Simmer Control

Board?

No (XLO burners) No

Yes

Yes


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3.5.1 Element Diagnostics

Use the following element circuit specification for troubleshooting:

Cavity Mode Element Watts Volts Amps Ohms

18-inch 30-inch 36-inch

Bake Bake burner HSI 420 120 3.5 34

18-inch 30-inch 36-inch

Broil Broil burner HSI 420 120 3.5 34

30-inch 36-inch

Convection Bake

Bake burner HSI 420 120 3.5 34

30-inch 36-inch

Extended Bake (active phase)

Bake burner HSI 420 120 3.5 34

Extended Bake (inactive phase)

Bake burner HSI 0 0 0 0

N/A

Griddle

NOTE: For some 36-inch & 48-inch models

Griddle element (electric)

1600 120 13.3 9.0

Figure 15: Element Circuit Specification

3.5.1.1 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 5), throughout this manual, and the Installation Manual. Ensure compliance with all applicable codes.

3.5.1.2 Element Diagnostic Tips

General The electrical wiring diagram is located behind the kick panel of

the range (see Wiring Diagram, page 4).

Bake and broil modes cannot be operated simultaneously in any single oven cavity.

Resistance Reading You can perform a resistance reading on an element with the

electrical power to the range turned off.

Amperage Reading Bake mode: The power to the bake element cycles on and off at

pre-set intervals when the bake element is preheating (preheating indicator light is on) and also during regular bake cycle (after preheating). After preheating, the broil element is on for 4 seconds out of every 60 seconds for food browning.

Broil mode: Broil element remains on until reaching the maximum temperature, and cycles off and on to maintain that temperature.

Electric griddle element and hot surface igniters (HSIs):

Check either of element wires with an amp meter and amp clamp.

NOTE: Check the HSI at one of its wire connectors, as the gas burner (attached to HSI) will ignite.

NOTE: Although the HSI may be glowing, if not enough current is running through it, the safety valve may fail.

Alternatively, you can check the electric griddle element or HSIs from the L1 and L2 terminals at the terminal block.

Alternatively, you can check the electric griddle element or HSIs from the corresponding I/O relay terminals on the main control board. Keep in mind that you will have to remove the griddle in order to access the control board.

Temperature Reading

Do not remove the thermocouple prematurely when the oven is hot.

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 to retrieve the thermocouple.

Convection Bake For convection bake, you can visually inspect if the convection fan

is working. The convection fan only works after the preheating finishes, thus it may take less time to test the convection fan on the lowest bake convection setting.


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4 OVEN LIGHT DIAGNOSTICS

Figure 16: Oven Light Diagnostics

Turn light switch OFF and

then open oven door.

Is oven light

illuminated?No

Go to Oven Light

Diagnostics 2

Go to Oven Light

Diagnostics 2

Yes

Close oven door and

turn light switch ON

Is oven light

illuminated?

No

Make sure plunger doesn’t get stuck

in closed position. Check wiring and

connections. Replace plunger switch

if necessary.

Continuity across

bulb?

Replace

bulb

No

Is there

12V DC across

socket?

Turn light

switch ON

Make sure

contacts are clean.

Replace bulb if

necessary.

Yes

Remove

light wires

at control

board

Is there

120V AC across

CB outlet?

OVEN LIGHT DIAGNOSTICS 1

OVEN LIGHT DIAGNOSTICS 2

Check transformer (120V AC

input, and 12V DC output).

Check wire continuity. Check

if wires making connections.

Yes

Replace light

wires at

control boardNo

Is there

120V AC across

light switch?Yes No

Replace

light switch

No

Trace wire for

short. Replace

control board if

necessary.

Yes

Yes

NOTE: All tests in Oven Light Diagnostics 2 must be performed with the oven door closed, or with the plunger switch pressed in.

TOOLS NEEDED: Multimeter

Turn light switch

OFF and then remove

light bulb.


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5 FAULT CODES

When a fault is detected, this appliance will display a fault code (see Figure 20, on page 19). 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 17 and Figure 18) will first blink on the left and then the right, and the vertical positioned blue LEDs (see Figure 19) will first blink on the top and then the bottom.

For example, if the first LED blinks 4 consecutive times followed immediately by the second LED blinking 3 times, that represents a fault code of 43 on the chart (see Figure 20, on page 19).

Figure 17: Two Horizontal LED Indicators

Figure 18: Three Horizontal LED Indicators (Only Blue LEDs Blink)

Figure 19: Two Vertical LED Indicators


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Figure 20: Fault Codes


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6 SERVICE AND REPAIR

6.1 Preparing the Range for Servicing

For most servicing of this appliance (for example, involving disassembly, removal or 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 by removing the fuse.

■ Make sure the range is not hot.

If testing the appliance requires the use of electrical power and/or an open gas supply, exercise extreme caution.

6.2 Accessing Components under the Maintop

This section contains the steps required to gain access to the components located under the maintop.

6.2.1 Removing Knobs, Grates, and Burner Assemblies

To access and service components located underneath the maintop (see Figure 6), remove the knobs, grates, burner assemblies, maintop, and heat shield:

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 grates.

3. Remove all Star burner caps.

4. Remove and retain the two T-30 screws from each brass Star burner base (see Figure 21).

Figure 21: Star Burner Base (Generation 5 Design Shown)

Caution

Fragile Component

The electrode is a ceramic component that can be brittle and crack easily.


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5. 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 electrode (see Figure 22 and Figure 23).

Figure 22: Igniter Wire Attached to Electrode

Figure 23: Igniter Wire Locking Tab

6. If the electrode needs replacing, remove and retain the small T-10 screw to detach it from the brass burner base. If not, leave it attached to the brass burner base.

7. Remove and retain the T-30 screw holding the cast iron pedestal burner to the maintop.

8. Remove the pedestal burner with the Venturi tube still attached to it, while gently pulling the ignition wire through (see Figure 24).

-OR-

Alternatively, you can first lift the Venturi tube out from the pedestal burner, before removing the pedestal burner from the maintop.

Figure 24: Pedestal Burner with Venturi Tube

Press tab to detach from

electrode


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6.2.2 Removing the Maintop

Caution

Fragile Component

The porcelain enamel maintop is fragile. To prevent damage such as chipping, carefully remove maintop, and do not over torque the screw holding the burner pedestal to the maintop.

1. First, remove and retain the two T-20 screws from the inner, frontward-facing left and right side corners of the range chassis (see Figure 25).

Figure 25: Screws on Inner Side of Chassis

2. Remove and retain the three T-20 screws located on the front-facing side of the backguard (see Figure 26).

3. Carefully place a tool such as a hook or a non-straight Allen wrench in a circular receptacle on the maintop (not in a receptacle for the jet holder or the ignition wire), and pry up maintop enough until you can grasp it with your hand (see Figure 27).

4. Push each ignition wire downward through its respective receptacle, as you carefully lift out the maintop, in a frontward direction.

Figure 26: Screws on Front of Backguard

Figure 27: Removing the Maintop


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6.2.3 Removing the Heat Shield

Sharp Components – Gloves Recommended

■ Sheet metal components such as the heat shield have sharp edges. Avoid injury by handling with care.

■ It is recommended to use gloves when removing or installing the heat shield.

1. Carefully lift and remove the heat shield (see Figure 28).

Figure 28: Removing the Heat Shield

6.2.4 Burner Support Rail Removal and Replacement

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 for 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 25.

Figure 29: Burner Support Rail

1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 20.

2. Using a 9/16 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 30).

Figure 30: Removing Gas Tube from Jet Holder Assembly


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3. Using a 9/16 inch wrench, unscrew the hex nut to remove the other end of the gas tubes from their respective valve as follows:

■ [Left-side XLO valves]: While using a 1/2 inch wrench to hold the bolt on the solenoid valve, unscrew the gas tube hex nut with a 9/16 inch wrench. Don’t bend the gas tube (Figure 43).

■ [Right side standard valves]: Using a 9/16 inch wrench, remove the gas tubes from the Standard valves. Be careful not to bend the gas tube.

4. Push each ignition wire downward through its respective receptacles in the burner support rail.

5. Make note of burner support rail placement on the range chassis (before removing the rails) so you can reinstall afterwards in the correct position.

NOTE: It is important to reinstall the correct burner support rails in the correct position in order to correctly match up the jet holder assemblies to the gas tubes.

Sharp Component – Gloves Recommended

The burner support rail has sharp edges. Avoid injury by using gloves when removing or installing the burner support rail.

6. 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 31). Then remove burner support rail with the two jet holder assemblies attached (see Figure 32).

Gas Leaks


Figure 31: Removing Burner Support Rail from Range Chassis

Figure 32: Burner Support Rail with Jet Holder Assemblies Attached


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6.3 Removal and Replacement of Top-Accessible Components

This section contains removal and replacement procedures for the top-accessible components, located under the maintop.

6.3.1 Jet Holder Assembly Removal and Replacement

This procedure is for removing the jet holder assembly from the burner support rail, in the event that a jet holder assembly needs replacing.

Sharp Components – Gloves Recommended

■ 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.


2. Follow all steps in Accessing Components under the Maintop, page 20.

3. Remove the wire guard clip from each jet holder assembly prior to removing the jet holder assembly from the burner support rail (see Figure 33).

NOTE: The jet holders are secured to the burner support rails with a tight fit.

4. As necessary, use a flat-bladed screwdriver to pry the jet holder assembly out until the alignment boss is disengaged from the circular receptacle on the burner support rail. Then rotate the jet holder assembly (gloves recommended) until it can be removed through the corresponding grooves in the burner support rail (see Figure 33 and Figure 34).

-OR-

Alternatively, use a slip joint pliers and gloves to disengage the alignment boss and rotate the jet holder assembly until it can be removed (see Figure 33 and Figure 34).

Figure 33: Jet Holder Assembly – Detaching Boss from Rail

Figure 34: Jet Holder Assembly – Rotating and Removal from Rail

Alignment boss

Wire guard clip


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5. Replace the jet holder assembly if needed.

NOTE: If replacing the jet holder assembly, first install the jet holder assembly onto the burner support rail before attaching the wire guard clip.

Gas Leaks


6.3.2 Manifold Removal and Replacement

Although range components can be accessed and replaced without removing the manifold, this procedure is provided if the manifold needs to be replaced due to a gas leak in the manifold, or if the threading on the manifold is bad due to removing the regulator.



3. Be sure to remove the two knobs that are connected to the respective manifold support brackets on the back side of the control panel (see Figure 35). Remove the knobs from their valve stems by slowly pulling knobs straight out, away from control panel.

4. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page 23.

Figure 35: Knobs to Remove

5. Remove the regulator from the manifold (see Regulator Removal and Replacement, page 37).

6. Remove the microswitch and standard valve attached to the right-side center knob (see Figure 35). See Microswitch Removal and Replacement page 29, and Standard Valve Removal and Replacement, page 28.

7. Remove the solenoid valve, XLO valve and potentiometer attached to the left-side center knob (see Figure 35). See Solenoid Valve Removal and Replacement page 30, XLO Valve Removal and Replacement page 31, and Potentiometer Removal and Replacement, page 33.


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8. Now remove the manifold support brackets by removing and retaining the following screws with a T-20 driver:

■ The two screws holding the manifold support bracket onto the chassis base near the regulator (see Figure 37)

■ The two screws from each bezel of the two inner knobs (see Figure 35 and Figure 36) to detach the manifold support brackets from the back of the control panel (see Figure 38)

9. After removing all brackets, gently lift the manifold out, being careful of the wires and harnesses and other components.

Gas Leaks


Figure 36: Manifold Support Bracket Screws on Bezel

Figure 37: Manifold Support Bracket on Chassis Base

Figure 38: Manifold Support Bracket on Back of Control Panel


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6.3.3 Standard Valve Removal and Replacement

The standard valves are for the right side burners only.



3. Remove knob from valve stem by slowly pulling knob straight out, away from control panel.

4. Using a 9/16 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.


6. Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the standard valve onto the manifold (see Figure 40). Be careful not to lose the rubber washer attached to the screw.

-OR-

Using a 1/4 inch nut driver, remove and retain the self-tapping screw by accessing it from under the chassis base, through the corresponding access hole (the oven door must be opened or removed) - see Figure 40. Be careful not to lose the rubber washer attached to the screw.

7. Remove the (connected) standard valve and microswitch from the manifold (see Figure 41 on page 29). 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 T-10 screw and then pulling the microswitch off the alignment pin on the standard valve (see Figure 42 on page 29).

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 39: Access Holes on Typical Range (XLO Valve Access Shown)

Figure 40: Removing the Self-Tapping Screw

Using 1/4 inch nut driver Using 1/4 inch socket wrench


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Figure 41: Standard Valve Connected to Microswitch

Figure 42: Screw Connecting Standard Valve to Microswitch

Gas Leaks


6.3.4 Microswitch Removal and Replacement

The microswitches are for the right-side burners only.




4. Using a 9/16 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.


6. Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the standard valve onto the manifold (see Figure 40). Be careful not to lose the rubber washer attached to the screw.

-OR-


7. Remove the (connected) standard valve and microswitch from the manifold (see Figure 41). Be careful not to lose the red rubber washer attached to the standard valve.


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8. First make a note of how the wires (piggyback and single) are connected to the two terminals on the microswitch, and then disconnect these wires from the terminals (see Figure 41).

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 reassembling.

HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone).

9. Detach the standard valve from the microswitch by removing and retaining the T-10 screw, and then pulling the microswitch off the alignment pin on the standard valve (see Figure 42).

10. Replace the microswitch if needed.

Gas Leaks


6.3.5 Solenoid Valve Removal and Replacement

The solenoid valves are for the left-side (XLO) burners only.




4. While using a 1/2 inch wrench to hold the nut on the solenoid valve, unscrew the gas tube hex nut with a 9/16 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 43).


6. First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals.



7. Using an adjustable wrench, 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 44, page 31).

8. Replace solenoid valve if needed.

Gas Leaks


Figure 43: Removing the Gas Tube from the Solenoid Valve


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Figure 44: Solenoid Valve with O Ring

6.3.6 XLO Valve Removal and Replacement

The XLO valves are for the left-most front and left-most rear burners only. In order to replace the XLO valve, you must remove the potentiometer together with the XLO valve.









7. Using an adjustable wrench, 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 44).

8. Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the XLO valve onto the manifold (see Figure 40). Be careful not to lose the rubber washer attached to the screw.

-OR-


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 (see Figure 45, page 32).


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Figure 45: Solenoid—XLO Valve—Potentiometer Assembly

10. Remove the white plastic side connector from the potentiometer by pressing on the connector’s tab. (see Figure 46).

Figure 46: Side Connector Tab

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 47).

Figure 47: Removing the XLO Valve from the Potentiometer

Gas Leaks


Side connector tab


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6.3.7 Potentiometer Removal and Replacement

The potentiometer (also known as the Simmer Control potentiometer or XLO potentiometer) is used to control the simmer function of the XLO burners (left front and left rear burners).

NOTE: The potentiometer should not be confused with the Temperature Selector, which is sometimes also referred to as a potentiometer.









7. Using an adjustable wrench, 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 44).

8. Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the XLO valve onto the manifold (see Figure 40). Be careful not to lose the rubber washer attached to the screw.

-OR-


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.

10. Remove the white plastic side connector from the potentiometer by pressing on the connector’s tab. (see Figure 46).

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 47).

12. Replace the potentiometer if needed.

Gas Leaks



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6.3.8 Temperature Selector Removal and Replacement

Figure 48: Temperature Selector and Knob

NOTE: For PRL304GH/05, the Temperature Selector may or may not be secured to the back of the control panel with a clamp. If a clamped Temperature Selector needs replacing, the replacement part (used without clamp) is fully compatible.




4. From the back of the control panel, first make a note of how the connector wires are connected to the Temperature Selector terminals, and then remove the wires from the terminals (see Figure 50).



5. From the front of the control panel, remove and retain the two screws on the bezel which are attached to the Temperature Selector (see Figure 49).

Figure 49: Temperature Selector Screws on Bezel

6. Remove the blade connectors from the Temperature Selector at the back side of the control panel (see Figure 50).

Figure 50: Temperature Selector


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7. Remove clamp (if there is one) by folding the left and right clamp wings up about 45 degrees (see Figure 51).

8. Pull out the Temperature Selector.

Figure 51: Removing the Clamp

6.3.9 5-Position Oven Function Selector – Removal and Replacement

Figure 52: 5-Position Oven Function Selector

NOTE: For PRL304GH/05, the 5-Position Oven Function Selector may or may not be secured to the back of the control panel with a clamp. If a clamped 5-Position Oven Function Selector needs replacing, the replacement part (used without clamp) is fully compatible.




4. From the front of the control panel, remove and retain the two screws on the bezel which are attached to the 5-Position Oven Function Selector (see Figure 53).

5. From the back of the control panel, disconnect the plastic multi-pin connector from the pins on the 5-Position Oven Function Selector (see Figure 54).

6. Remove clamp (if there is one) by folding the left and right clamp wings up about 45 degrees (see Figure 51).

7. Pull out the 5-Position Oven Function Selector.


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Caution

When installing the 5-Position Oven Function Selector, make sure to attach the connector correctly onto all of the pins.

Figure 53: Oven Function Selector Screws on Bezel

Figure 54: Multi-Pin Connector on 5-Position Oven Function Selector

6.3.10 Dual Valve Removal and Replacement

There is one dual valve on the 30-inch range.

Prior to Servicing the Dual Valve

■ Turn off the gas supply to the appliance

■ Turn off electrical power to the appliance



3. Disconnect all four blade connectors from the dual valve, and make a note of which wires are connected to each of the different terminals (see Figure 55, page 37).



4. Use a 1/4 inch wrench to unscrew the gas tube hex nut from each of the three gas tubes attached to the dual valve. Be careful not to bend the gas tubes (see Figure 55, page 37).

5. Remove and retain the two T-20 screws on the side of the support bracket that is secured to the dual valve (see Figure 56, page 37). You do not have to remove the screws securing the support bracket to the chassis.

6. Remove and replace the dual valve if necessary.


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Gas Leaks


Figure 55: Dual Valve

Figure 56: Dual Valve Support Bracket

6.3.11 Regulator Removal and Replacement

Prior to Servicing the Regulator

■ Turn off the gas supply to the appliance

■ Turn off electrical power to the appliance



3. Remove the left-side burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page 23.

4. Using two wrenches (such as pipe wrench, adjustable wrench) hold the left-side protruding receptacle of the regulator steady with one wrench, while simultaneously rotating the flared adapter with the other wrench until you can remove the flared adapter from the regulator (see Figure 57, page 38).

5. Now use a wrench to secure the connecting pipe, while you simultaneously rotate the regulator until you can remove it (see Figure 57, page 38).

6. Replace the regulator if needed.

7. When replacing the regulator or associated fittings, use pipe sealant on pipe threads only - such as the manifold 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 the flair connections or pressure fittings, such as the flair end of the flared adapter.


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8. When replacing the regulator, make sure its cap fitting is facing upward, so it can be easily accessed (see Figure 57).

Figure 57: Regulator with Fittings and Gas Flex Line

Gas Leaks


6.3.12 Ignition Device Removal and Replacement



3. Pull to detach the two plastic side connectors from the ignition device (see Figure 58).

4. Using a T-20 driver, remove and retain the two screws securing the ignition device to the range chassis.

5. Replace the ignition device if needed.

Figure 58: Ignition Devices

6.3.13 LED Indicator Removal and Replacement



3. Pull to disconnect the white plastic male and female wire connectors of the LED indicator (see Figure 59, page 39).


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4. While pushing the protruding clip at the front end of the LED indicator, push the LED indicator frontward through the hole in the control panel (see Figure 60).

5. Replace the LED indicator if needed.

Figure 59: LED Indicator Connectors

Figure 60: LED Indicator

6.3.14 Control Board Removal and Replacement



NOTE: On some models, the simmer board may be attached to the side of the control board shield.

3. Remove and retain the T-20 screw(s) holding the control board shield onto the range chassis and then remove the control board shield (see Figure 61).

Figure 61: Control Board Shield

4. Remove all multi-pin connectors and individual tab connectors from the control board (see Figure 62).

5. At the control board, detach the green ground wire from the ground screw on the range chassis.

-OR-

Alternatively, at the control board, detach the single red blade connector (for the green ground wire) from the control board (see Figure 62, page 40).

Screw

Protruding clip


58300000182999_ARA_EN_A Page 40 of 64

6. Use a needle nose pliers to carefully remove the control board from the plastic standoffs.

7. Replace the control board only if needed.

NOTE: When installing the control board, make sure the green ground wire is secured from the control board to the ground screw on the chassis.

Figure 62: Control Board

6.3.15 Simmer Control Board Removal and Replacement



3. Using a T-20 driver, unscrew and detach the ground wire connected to the range chassis. Retain the screw if you remove the screw from the chassis.

4. Gently pull to detach the two plastic multi-pin side connectors from the simmer control board (see Figure 63).

Figure 63: Simmer Control Board

Caution

Fragile Components

Be careful not to exert too much pressure on the standoffs or the simmer control board, as these are fragile components.

5. Using a needle nose pliers, disengage the simmer control board from the plastic standoffs by lightly pressing the tiny protruding clip on each plastic standoff, while simultaneously pulling the simmer control board off the standoff.

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.


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6.4 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 removing and installing the anti-tip bracket, as well as other important installation 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 weight of the range, using an air sled or oven dolly to move it may reduce the risk of injury and/or damage.

6.4.1 Backguard and Island Trim Removal and Replacement

This procedure applies for the backguards (the Lowback, and the 22-inch High Backguard), as well as for the Island Trim.

■ 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 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 70-current issue. In Canada, installation must be in accordance with the CAN 1-B149.1 and .2 – Installation Codes for Gas Burning Appliances and/or local codes.


2. Remove and retain the T-20 screws on the front-facing side of the backguard / Island Trim (see Figure 26, on page 22).

3. Remove and retain the T-20 screws on the back side of the backguard / Island Trim (see Figure 65, Figure 66).

4. Lift the backguard straight up to remove (see Figure 64).

NOTE: When reinstalling, the backguard / Island Trim must be placed inside of the two guide channels (see Figure 64).

Figure 64: Guide Channels for Backguard and Back Panels (Typical Range and Island Trim Shown)


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Figure 65: 22-Inch High Backguard (Back Side Shown)

Figure 66: Island Trim

6.4.2 Back Panel Removal and Replacement


2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 41.

3. Remove and retain the screws from the back panel, as shown in Figure 67.

Caution

Be very careful not to damage the gas flex line or terminal box (junction box) components and wiring when removing or installing the back panel.

4. Carefully remove the back panel out of the right and left side guide channels, in an upward direction (see Figure 64), and detach it from the gas flex line.

NOTE: When reinstalling the back panel, the back panel must be placed on the inside of the two guide channels (see Figure 64).

Figure 67: Back Panel Screw Locations


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6.4.3 Terminal Block Removal and Replacement

Replace the terminal block (main power connector) in the event the terminal threads are stripped, or if there is any other damage to the component.


2. Detach the wire leads from each terminal on the terminal block (see Figure 68). Retain the washers and nuts, and make a note of which wires are connected to each different terminal.



3. Remove and retain the two T-20 screws securing the terminal block onto the terminal box (junction box). See Figure 68.

4. When replacing the terminal block, refer to Electrical Wiring Connections at the Terminal Block, page 43).

Figure 68: Terminal Block

6.4.4 Electrical Wiring Connections at the Terminal Block

For electrical wiring requirements and safety precautions, refer to the Installation Manual for this appliance.

NOTE: The electrical wiring diagram is located on the back side of the kick panel (see Wiring Diagram, page 4).

6.4.5 Cooling Fan Removal and Replacement


2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 41.

3. From the back of the range, detach the three wire connectors (see Figure 69).

Figure 69: Wire Connectors (Typical Fan Shown)


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Sharp Component – Use Gloves

Use gloves as the fan has sharp edges

4. From the two access holes in the chassis (see Figure 70), use a long T-20 driver to remove the screws that secure the cooling fan onto the brackets if they cannot be removed from the back of the range (see Figure 70 and Figure 71).

5. Using gloves, remove the cooling fan.

6. Replace the cooling fan if needed.

Figure 70: Cooling Fan Access Holes in Chassis (Typical Range Chassis Shown)

Figure 71: Removing Cooling Fan Screws


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6.4.6 Broil Burner Assembly Removal and Replacement

Hot Surfaces

The oven broil burner and interior surfaces of the oven may be hot and can cause burns. Do not service the range when these components are hot.

Figure 72: Broil Burner Assembly


2. Remove both oven doors (see Door Removal and Installation, page 57).

3. Remove all trays from the oven.

4. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 41).

5. Remove the back panel (see Back Panel Removal and Replacement, page 42).

6. From the back of the range, disconnect the hot surface igniter (HSI) blade connectors (see Figure 73).

Figure 73: Hot Surface Igniter (HSI) Connectors

Figure 74: Hot Surface Igniter

Eye Protection

To protect your eyes from debris, it is recommended to wear protective eye wear when removing or installing components inside the oven cavity, such as the broil burner brackets, or the broil burner.


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7. From inside the oven cavity, remove and retain the nut and shim ring from the right and left sides of the HSI support bracket to remove the HSI-support bracket assembly from the infrared broil burner (see Figure 75).

Figure 75: Infrared Burner, Nuts and Shim Rings on HSI Bracket

8. [Only if replacing the igniter]: Turn over the HSI-support bracket- assembly and remove the 2 nuts and shim rings (see Figure 76) to detach the HSI from the bracket.

9. Gently pull the HSI (or HSI-support bracket assembly) forward (out of the oven cavity), with the HSI wires and blade connectors passing through the portal holes at the back of the range.

10. Replace the HSI if necessary.

11. From inside the oven cavity, remove the five retaining brackets by removing and retaining the respective T-20 screws (see Figure 77, page 46).

Figure 76: Screws Attaching HSI to HSI Bracket

Figure 77: Infrared Burner, Brackets, Screw Positions

12. From the back of the range, use a wrench to rotate and detach the gas line (hex nut) from the elbow connector (see Figure 78).


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Figure 78: Elbow Connector Attached to Gas Line

13. Now gently pull out the infrared broil burner from the ceiling of the cavity. Be careful not to bend the orifice holder bracket at the end of the Venturi tube (see Figure 79).

NOTE: Do not detach the elbow connector and orifice from the orifice holder bracket (see Figure 79). If the elbow connector or orifice needs replacing, replace the broil burner assembly.

Figure 79: Venturi Tube Shown with Elbow Connector and Orifice Attached to Bracket

6.4.7 Convection Components – Removal and Replacement

The convection components are accessed from both the back and the front of the range.

Figure 80: Convection Components


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4. Remove oven door (see Door Removal and Installation, page 57).

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. Remove and retain the four T-20 screws and remove the front cover (see Figure 81).

NOTE: When reinstalling front cover, it must be positioned with the cover vents facing to the right (see Figure 81).

Figure 81: Screws Securing Front Cover

7. Remove the nut, and then remove the convection fan. Retain the shim ring if it falls out when removing the fan (see Figure 80).

Fiberglass


8. From the back of the range, detach the two convection motor blade connectors (see Figure 82). Be sure to first make a note of how they are connected.



Figure 82: Convection Motor Wire Connectors

9. Remove the six T-20 screws on the rear cover shield, and pull the rear cover shield (attached to motor assembly) forward through the oven cavity to remove it (see Figure 83 and Figure 84).

10. To detach the motor assembly from the bracket, first remove and retain the shim ring (see Figure 85, page 49).


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Figure 83: Rear Cover Shield Screws

Figure 84: Rear Cover Shield / Motor Assembly (Back Side View)

11. Remove and retain the three T-20 screws from the rear cover shield (Figure 85 and Figure 86, page31), then remove the rear cover shield from the bracket and fiberglass insulation (see Figure 87, page 50).

Figure 85: Removing Shim Ring

Figure 86: Screws Attaching Rear Cover Shield to Motor Bracket

12. Wearing gloves, remove and retain the fiberglass insulation, and then remove and retain the three T-20 screws securing the bracket onto the motor (see Figure 88).


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Figure 87: Bracket (Typical Model Shown) and Insulation

Figure 88: Screws Connecting Bracket to Motor

13. Replace the convection motor, if needed.

NOTE: When installing, the front cover must be positioned with the cover vents facing to the right (see Figure 81).

6.5 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.

6.5.1 Control Panel Removal and Replacement

Figure 89: Control Panel

The following procedures for removal and replacement of the control panel are 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.

NOTE: When removing and replacing the control panel, you must first disconnect all wire and harness connections, and remove all manifold support brackets connected to the back side of the control panel.




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3. Before disconnecting the wire harness connectors, first make a note of how they are connected to all components that are housed at the back side of the control panel (solenoid valves, LED indicators, microswitches, and potentiometers).



4. Remove all valves, components and respective wiring connectors: as follows:

■ Standard valves (see Standard Valve Removal and Replacement, page 28)

■ Microswitches (see Microswitch Removal and Replacement, page 29)

■ Solenoid valves (see Solenoid Valve Removal and Replacement, page 30)

■ XLO valves (see XLO Valve Removal and Replacement, page 31)

■ Potentiometers (see Potentiometer Removal and Replacement, page 33)

■ LED indicators (see LED Indicator Removal and Replacement, page 38)

NOTE: LED indicators can stay on control panel as long as their connectors are detached.

5. At the location of the two knobs connected to the manifold brackets (see Figure 35), use a T-20 driver to remove and retain the two screws from the bezels (see Figure 36) in order to detach the manifold support brackets on the back side of the control panel (see Figure 38).

NOTE: When removing or replacing the control panel you do not have to remove the manifold support bracket on the chassis base near the regulator (see Figure 37).

6. Using a swivel head driver with a 11/32 inch deep well socket or a 11/32 inch open end wrench, remove and retain the three screws/nuts from the inner, left and right sides of the chassis (see Figure 90).

Figure 90: Screw/Nut on Inner Chassis (Upper Screw/Nut Shown)

7. Carefully lift the control panel slightly upward to detach from the lip on the range chassis (see Figure 91), and then pull away in a forward direction to remove the metal tabs from the chassis (see Figure 89 and Figure 92).

8. Replace the control panel if needed.

Gas Leaks



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Figure 91: Detaching Control Panel from Lip

Figure 92: Detaching Control Panel Tabs from Chassis

6.5.2 Bake Burner Components – Removal and Replacement

Hot Surfaces

The oven bake burner and interior surfaces of the oven may be hot and can cause burns. Do not service the range if these components are hot.


2. Remove the oven door (see Door Removal and Installation, page 57).

3. Remove all trays from the oven.

4. Remove the kick panel (see Kick Panel Removal and Replacement, page 59).

5. Detach the bottom plate of the front frame. First remove and retain the larger T-20 screws, and then remove and retain the smaller T-20 screws (see Figure 93).

Figure 93: Screws on Bottom Plate of Front Frame


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6. Remove and retain the five T-20 screws from around the rim (not the center) of the cavity base (see Figure 94).

Figure 94: Screws on Rim of Cavity Base

7. Lift the cavity base slightly up and then out (towards you). Be careful not to scratch the porcelain finish of the cavity.

8. The deflector (flame spreader) is attached to the cavity base. Only detach the deflector if it needs replacing by removing and retaining the four T-20 screws from the center of the cavity base (see Figure 95, page 53).

Caution

Set the cavity base on a flat, protected surface so that the deflector does not get bent, and so the screws don’t damage any surface.

Figure 95: Deflector Attached to Cavity Base

Figure 96: Bake Burner with Cavity Base Removed

9. Detach the orifice fitting assembly from the gas flex line by using a wrench to hold the small brass hex nut on the gas flex line, while simultaneously using another wrench to rotate the orifice holder (large aluminum 7/8 inch hex nut) until the gas flex line is released (see Figure 97 and Figure 98).


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10. Unscrew the slip nut on the orifice fitting assembly to remove it from the air shutter (see Figure 97 and Figure 98).

Figure 97: Orifice Fitting Assembly

Figure 98: Orifice Fitting Assembly Connections

NOTE: When installing an orifice fitting assembly, make sure to use pipe sealant on the orifice threads. Make sure no pipe sealant gets on the slip nut, as it must spin freely to screw into the air shutter.

11. Remove and retain the two T-20 screws from the bake burner bracket (see Figure 96).

12. Gently pull bake burner out of the slot in the oven cavity – with the hot surface igniter (HSI) attached. See Figure 99.

Figure 99: Removing Bake Burner with HSI Attached

13. Detach the HSI from the bake burner by removing and retaining the two screws that secure the HSI onto the HSI support bracket (see Figure 100 and Figure 101).

Figure 100: Hot Surface Igniter (HSI)


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Figure 101: Removing the HSI from the Bake Burner

14. Replace the bake burner if needed.

NOTE: When installing the bake burner, there is no need to adjust the air shutter, as it is pre-set in the factory to the fully-opened position.

15. [If replacing the HSI]: Detach the HSI blade connectors (see Figure 99 and Figure 100).

16. [If replacing the HSI]: Using a needle-nose pliers, squeeze the ends of the plastic tie, and pull the plastic tie out to release the HSI wires (see Figure 99).

17. Replace the HSI if needed.

6.5.3 Oven Temperature Sensor Removal and Replacement

The oven temperature sensor is located inside the oven cavity (see Figure 102).

Figure 102: Sensor and Lamp Locations inside the Oven Cavity





NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components.


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5. From the back of the range, at the left side, detach the connectors to the purple and white sensor wires (see Figure 103).

Figure 103: Sensor Wire Connectors and Portal

6. From inside the oven cavity, remove and retain the two T-20 screws (see Figure 104).

Figure 104: Sensor



7. From 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 (see Figure 103).

8. From the front of the range, gently pull the sensor connector wires through the portal.

9. Replace the sensor if necessary.

6.5.4 Oven Lamp Removal and Replacement

The oven lamp is located inside the oven cavity (see Figure 102).

NOTE: Before servicing the oven lamp, see Oven Light Diagnostics, page 17.





NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components.

5. From the back of the range, detach the lamp wire connectors (see Figure 105).

6. From inside the oven cavity, remove and retain the T-20 screw.


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7. 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 (see Figure 105).

8. From the front of the range, gently pull the lamp connector wires through the portal.

9. Replace the lamp.

Figure 105: Lamp Wire Connectors

6.5.5 Door Removal and Installation

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 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.

6.5.5.1 Removing the Door


2. Open the door fully, and then push both hinge locks downward (towards you) as far as they go, until they stop.

3. Firmly grasp the heavy door on both sides, and gently close the door until it stops against the hinge locks (at about a 45° angle).

4. Be careful not to let the door fall. While still grasping the door firmly on both sides, exert a bit more force to continue closing the door another few inches, and when the door is about 10 inches from being fully closed, it will stop.

5. Pull the door upward to lift it off the range.

6.5.5.2 Installing the Door


2. Firmly grasp the heavy door on both sides, and with the door open about 10 inches, carefully guide the hinge arms into the hinge receiver slots.

For bulb replacement, you can use any commercially available bulb with the following specification:

120 or 130 VAC, 50 W max., G8 base, Halogen maximum?), G8 base


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3. Slowly open the door a few inches until it stops against the hinge locks (at about 45°). If the door doesn’t stop and can be opened more, the hinges are not seated properly - it may be necessary to press the door inward towards the receiver slots, while using a slight rocking motion to seat the hinges.

4. Be careful not to let the door fall. While still grasping the door firmly on both sides, exert a bit more force to continue opening the door fully. Then push the hinge locks upward (away from you) as far as they go to lock the door onto the range.

5. Open and close the door to make sure the door is positioned properly and closes with a tight fit.

6.5.6 Door Handle Components - Removal and Replacement

Figure 106: Installing the Door Handle Components

6.5.6.1 Removing Door Handle Components


2. Remove the oven door (follow all warnings and steps for the Door Removal and Installation procedure, page 57).

3. From the upper, back side of the door, remove and retain the two T-20 screws and round washers attached to their respective standoffs.

4. From the bottom of the door, remove and retain the four T-20 screws and washers.

5. From the glass door panel, remove and retain the two T-20 screws and angled washers. Then use a 1/2 inch wrench to remove the two standoffs.

6. Remove door handle tube, left and right endcaps.

6.5.6.2 Installing Door Handle Components

NOTE: Prior to door reassembly, clean the door window.


2. Assemble endcaps onto door handle tube.

3. Use a 1/2 inch wrench to fasten the 2 standoffs through the glass door panel, onto the endcap standoff receptacles

4. Install the T-20 screws and angled washers through the glass door panel, onto the endcap screw receptacles.

5. Install the two T-20 washers and screws through the back side of the door, onto the standoffs. Then install the other four washers and screws onto the bottom of the door.

6. Install the oven door and test for proper positioning (follow all warnings and steps for Installing the Door, page 57).


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6.5.7 Door Gasket Removal and Replacement

Check for applicable technical documents for this appliance in QuickFinder before replacing the door gasket.



3. 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 107).

4. After replacing the gasket, check to make sure the door closes with a tight fit.

Figure 107: Removing the Gasket (Typical Oven Shown)

6.5.8 Kick Panel Removal and Replacement



3. Remove and retain the two T-20 screws from the kick plate (see Figure 108), and then lift the kick plate upward to detach from the two standoffs on the range chassis (see Figure 109).

Figure 108: Removing Kick Plate Screws

4. The wiring diagram for the range is located on the back side of the kick plate (see Figure 110).


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Figure 109: Lifting the Kick Plate off the Standoffs

Figure 110: Wiring Diagram

6.5.9 Bottom Plate of Front Frame – Removal and Replacement



3. Remove only the ends of the gasket from the respective holes in the bottom plate of the front frame (see Figure 111). You do not have to remove the entire gasket.

Figure 111: Removing the Gasket Ends

4. First remove the three T-20 screws from both the right and left sides of the bottom plate of front frame (see Figure 112).


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Figure 112: Removing Initial Screws - Bottom Plate of Front Frame

5. Then remove the T-20 screw from both the right and left sides of the bottom plate of front frame (see Figure 113).

Figure 113: Removing Next Screw - Bottom Plate of Front Frame

6. Remove the bottom plate of the front frame by pulling it out horizontally (toward you).

6.5.10 Door Hinge Receiver Removal and Replacement

Check for applicable technical documents and information in QuickFinder before replacing the door hinge receiver.

Figure 114: Door Hinge Receiver



3. Follow all steps in the Door Gasket Removal and Replacement procedure, page 59.

4. Follow all steps in the Bottom Plate of Front Frame – Removal and Replacement procedure, page 60.

5. Remove and retain the two T-20 screws that secure the hinge receiver onto the range frame (see Figure 115).




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Figure 115: Removing Hinge Receiver Screws

6. Using gloves, remove the hinge receiver (see Figure 116).

Figure 116: Removing the Hinge Receiver

6.5.11 Door Hinge Removal and Replacement

Check for applicable technical documents for this appliance in QuickFinder before replacing the Door Hinge.

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.


NOTE: You may be required to replace both hinges, as well as the oven gasket (see Door Gasket Removal and Replacement, page 59). Read the Technical Service Bulletin and all other applicable documents for this appliance listed in QuickFinder.


3. Gently place the door (porcelain side facing down) on a flat, stable surface. Then remove and retain the T-20 screws on the base of the door (see Figure 117).

Figure 117: Door (Typical Model Shown)


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4. Lift and remove the stainless steel door cover (see Figure 118).

Figure 118: Removing the Stainless Steel Door Cover

5. Turn the door over, with porcelain side facing upward.

6. For each hinge, remove and retain the three T-20 screws that hold the hinge onto the door (see Figure 119).

Figure 119: Screws Holding Hinge onto Door

Sharp Components

Wear gloves when removing the door hinge

Caution

The upper part of the porcelain door panel has two screws fastened with Loctite adhesive, which should not be removed. Therefore, when removing the hinge, open the door only as much as needed to remove the hinge, as opening the door too much may damage the door.

7. With one hand, raise the porcelain door panel upward (to separate it from the rest of the door) just enough to remove the hinge, while you simultaneously remove the hinge with the other hand.

NOTE: It may be advantageous to place a wooden block in-between the door panels when removing the hinge.

Figure 120: Hinge


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7 BEFORE RETURNING APPLIANCE TO SERVICE

After you have finished all testing and servicing, always do the following before returning the appliance to service:

■ 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.

■ Make sure all panels and components are properly and securely reassembled.

■ 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. Refer to the Installation Manual for details on anti-tip device installation.

8 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.

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.

9 ADDITIONAL RESOURCES

9.1 QuickFinder

For further information, please refer to the following documents on QuickFinder:

■ Installation Manual

■ Care and Use Manual

In addition, the following may be available on QuickFinder by visiting: http://portal.mch.bshg.com/portal

■ 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.

9.2 Technical Support

For authorized servicers, additional assistance is available by contacting Technical Support at (800) 444-9091 between the hours of 5:00 am and 5:00 pm, Monday – Friday, Pacific Standard time.

http://portal.mch.bshg.com/portal

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