Thermador CJ302B Service Manual Download Page 1

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SERVICE MANUAL

for

THERMADOR

BUILT-IN OVENS

MODELS:

CJ302B / CJ302W / CJ302S

Lit No. 94-30-007A

October 2001

Summary of Contents for CJ302B

Page 1: ...SERVICE MANUAL for THERMADOR BUILT IN OVENS MODELS CJ302B CJ302W CJ302S Lit No 94 30 007A October 2001 2001 BSH Home Appliances Corp...

Page 2: ...oltage Diode 46 High Voltage Capacitor High Voltage Transformer 47 Magnetron Magnetron Thermal Cutout TCO 48 Magnetron Fan Motor Crossflow Blower Motor 49 Door Latch Assembly Monitor Secondary Switche...

Page 3: ...SERVICING THE THERMADOR BUILT IN OVEN MODELS CJ302B CJ302W CJ302S THIS MANUAL IS DESIGNED TO BE USED ONLY BY QUALIFIED SERVICE PER SONNEL THERMADOR RECOMMENDS THAT CUSTOMERS DO NOT SERVICE THEIR OWN...

Page 4: ...AIRS MADE ON OUR PRODUCTS BY ANYONE OTHER THAN AUTHORIZED THERMADOR SERVICE TECHNICIANS This symbol alerts you to check for micro wave radiation leakage and to record the readingontheservicerepairtick...

Page 5: ...defective or misadjusted components in the interlock monitor door seal and micro wave generating and transmission systems shall be repaired replaced or adjusted by procedures described in this manual...

Page 6: ...eginning repair work 2 Discharge the electric charge in the high voltage capacitor For about 30 seconds after the oven stops an electric charge remains in the high voltage capacitor When replacing or...

Page 7: ...007A Page 5 WARNING To Avoid Electrical Shock Disconnect the power to the appliance before servicing For those checks requiring the use of elec trical power exercise extreme care Do not attempt high...

Page 8: ...ion Leakage monitor should initially be set to the highest scale To prevent false readings hold the test probe by the grip portion of the handle only and move it along the shaded area shown in the fol...

Page 9: ...etron 5 Measuring A Fully Assembled Oven After all components including the top panel are fully assembled measure for radiation leakage around the door periphery and the door viewing window 6 Record k...

Page 10: ...800 735 4328 Length of Warranty FULL ONE YEAR For one year from date of instal lation or date of occupancy for a new previously unoccupied dwelling Save all dated receipts or other evidence of date o...

Page 11: ...wish to service COMPONENT LOCATIONS TOP PLENUM COMPONENTS FRONT COMPONENTS Control Panel Door Switch Monitor Secondary Switch Assembly Door Latch Assembly High Temp Cutout Magnetron Fan Assembly Elec...

Page 12: ...e careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 4 To remove the top front plenum cover a Remove the seven 7 screws b Pull th...

Page 13: ...om the oven see Page 10 4 Remove the four screws from the control panel mounting bracket pull the catches out of the ball studs at each end of the bracket see the small inset and remove the bracket fr...

Page 14: ...t of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers from the oven see Page 10 4 Remove the control panel mounting bracket see Step 4 o...

Page 15: ...oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers from the oven see Page 10 4 To remove the light transforme...

Page 16: ...rrer Bushing Screws 28 Bracket Screws 1 Stirrer Screw 1 Stirrer Screw Washer Stirrer Motor Stirrer Motor Bracket Stirrer Motor Insulation Mounting Bracket Stirrer Motor Stirrer Bushing Stirrer Shaft S...

Page 17: ...rim and top plenum covers from the oven 4 Disconnect the stirrer motor wires from the terminal block and the in line connec tor 5 Remove the fische paper over the stirrer motor cover 2 screws 6 Remove...

Page 18: ...rself if you are not careful 1 Turn off the electrical power going to the oven 2 Pull the oven out of its mounting location so that you can access the trim and plenum covers 3 Remove the trim and top...

Page 19: ...e not careful 1 Turn off the electrical power going to the oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers...

Page 20: ...or from the transformer side shield 1 Turn off the electrical power going to the oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim...

Page 21: ...ng to the oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers from the oven see Page 10 4 CAUTION DISCHARGE THE...

Page 22: ...see Page 10 4 CAUTION DISCHARGE THE HIGH VOLTAGE MICROWAVE CAPACITOR WITH A 20 000 OHM 1 OR 2 WATT RESISTOR TO CHASSIS GROUND SEE PAGE 17 BEFORE WORKING ON ANY OF THE HIGH VOLTAGE COM PONENTS BE VERY...

Page 23: ...transformer from the oven 9 Remove the heat sink plate from the top of the high voltage microwave trans former 10 Apply a liberal amount of heat sink paste over the top of the new transformer then pl...

Page 24: ...VOLTAGE MICROWAVE CAPACITOR WITH A 20 000 OHM 1 OR 2 WATT RESISTOR TO CHASSIS GROUND SEE PAGE 17 BEFORE WORKING ON ANY OF THE HIGH VOLTAGE COM PONENTS BE VERY CAREFUL NOT TO TOUCH THE BARE RESISTOR LE...

Page 25: ...loosely installed d Alternately tighten Nuts 1 through 4 until they are snug The base of the magnetron should be perfectly paral lel with the waveguide to operate prop erly 8 To reinstall the magnetr...

Page 26: ...and lift the plate off the control panel b Pull the top of the control panel for ward and unhook the two ball studs at the top right and left corners from the catches c Disconnect the five cables from...

Page 27: ...t careful 1 Turn off the electrical power going to the oven 2 Open the microwave oven door 3 Remove the four outer black screws from the bottom of the control panel assembly see Step 3a Page 23 4 Remo...

Page 28: ...h assembly must each be replaced as an assembly Individual parts are not available 8 To remove the door latch assembly a Use an angled 1 4 socket and remove the two hex head screws from the front of t...

Page 29: ...res from the termi nals 10 To remove the monitor and secondary switch assembly Note We have placed 2 access holes on the relay board partition to remove the 2 left side latch screws a Remove the four...

Page 30: ...hen you remove the halogen lens holder and lens in the next step be care ful that the lens does not fall out and break 5 Remove the four screws from the halogen lens holder and remove the holder and l...

Page 31: ...side of the liner 2 Install the bulb in the socket 3 When you reinstall the metal screen do not install screws at the four corners see Step 6 on the previous page 4 When you reinstall the rack support...

Page 32: ...the two front screws from the jet plate top b Carefully lower the jet plate down c To remove bottom jet plate lift jet plate up from front tabs and pull forward Jet plate can be removed without re mov...

Page 33: ...are sharp edges present and you can cut yourself if you are not careful WAVE GUIDE Stirrer screw Stirrer washer Stirrer Assembly JetPlate Top Clip Light Assembly JetPlate Top Wave Guide The wave guide...

Page 34: ...6 socket and re move the hex nut 5 Remove the screw from the meat probe jack access panel on the right side of the oven 6 Remove the piece of insulation that is cov ering the meat probe jack 7 Pull th...

Page 35: ...base of the CJ Upper Oven Module To replace this part you will need to pull the oven out of the wall and remove the element from the right side of the oven This element is used in cooking and self cle...

Page 36: ...are not careful 1 Turn off the electrical power going to the oven 2 Open the microwave oven door 3 Remove the two screws from the oven thermal sensor 6 Using the instructions in the Thermal Sensor Ki...

Page 37: ...e hole in the door liner 3 Unclip the gasket from the door liner and remove it Tech Tip Use a small screwdriver to insert the ends of the gasket into the liner hole Fully insert one end at a time Uppe...

Page 38: ...CAUTION Be careful handling the oven door when removing it as it is very heavy Never lift the door by the handle 1 Pull the oven out of its mounting location so that you can access the left and right...

Page 39: ...top and carefully close it until the hook in the hinge contacts the hinge support approximately 3 4 of the way You will feel some spring resistance while you do this which is normal 7 Gently lean aga...

Page 40: ...nstall the two hinge locking screws Rotate U Clip Forward To Unlock After reinstalling the oven door check around the door for microwave radiation leakage Service Alert Make sure that the door seal is...

Page 41: ...the unit see Page 37 and lay it on a padded surface with the glass side down and the bottom edge facing you 2 Remove the two bottom edge screws and the two top screws from the liner This will separat...

Page 42: ...padded work surface NOTE Set the oven door glass assembly out of the way so it does not get damaged 4 To remove an oven door hinge a Remove the mounting screw at the bot tom edge of the door b Slide...

Page 43: ...inner glass is not heat treated like the center glass Be sure to install the untreated glass in the in ner glass position 7 To remove the RF screen and the inner glass a Remove the bottom insulation...

Page 44: ...ill indicate a short 0 If the meter does not indicate a read ing infinity the glass is untreated After reinstalling the oven door check around the door for microwave radiation leakage Service Alert Te...

Page 45: ...steps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to the R x 1 scale 3 Touch the test leads to the metal end caps of the fuse If the fuse is good the meter should indicate a short c...

Page 46: ...d indi cate less than 1 at each location a Terminals 8 and 6 b Terminals 8 10 c Terminals 6 and 10 LIGHT TRANSFORMER Refer to Page 13 to access the double line break relay To test the double line brea...

Page 47: ...ps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to the R x 1 scale 3 Disconnect the wires from the diode IMPORTANT Use the above photo for the proper terminal polarity connections Di...

Page 48: ...tage transformer To test the high voltage trans former perform the following steps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to the R x 1 scale Testing The Primary Winding 3 Disco...

Page 49: ...AGNETRON THERMAL CUTOUT TCO Refer to Page 22 to access the magnetron ther mal cutout TCO To test the TCO perform the following steps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to t...

Page 50: ...the mag netron fan motor terminals 4 Touch the test leads to the motor termi nals The meter should indicate less than 1 CROSSFLOW BLOWER MOTOR RefertoPage16toaccessthecrossflowblower To test the moto...

Page 51: ...Terminals Door Unlock Switch N O Terminals Latch Interlock Switch N O Terminals Refer to Page 25 26 to access the monitor and secondary switches To test the switches per form the following steps 1 Tur...

Page 52: ...cate an open circuit infinite resistance 5 Press the switch button to close the con tacts The meter should indicate a short circuit 0 OVEN THERMAL SENSOR Refer to Page 35 to access the oven thermal se...

Page 53: ...the con vection motor 4 Touch the test leads to the convection motor terminals The meter should indi cate between 10 and 20 Terminals Terminals LOWER OVEN BROIL ELEMENT Refer to Page 79 to access the...

Page 54: ...lement 4 Touch the test leads to the convection elementterminals Themetershouldindi cate 25 9 Refer to Page 9 to access the mullion element terminals To test the element perform the fol lowing steps 1...

Page 55: ...he jack perform the following steps 1 Set the ohmmeter to the R x 1 scale 2 Disconnect one of the wires from the meat probe jack 3 Touch the test leads to the meat probe jack terminals The meter shoul...

Page 56: ...18 volts DC activates the relay coil and the 6 volts DC activates the triac on the Microwave PCB Control Terminal P2 1 Inputs 120 volts AC from the latch interlock switches Terminal P2 2 Outputs 120 v...

Page 57: ...Oven Service Manual Lit No 94 30 007A Page 56 MICROWAVE COMPONENTS DESCRIPTION 4 1 2 3 6 5 1 Fuse 2 Diode 3 Capacitor High Voltage 4 Transformer 5 High Temp Cutout mag tube 6 Magnetron Tube 1 2 3 6 4...

Page 58: ...activated switches 1 Upper oven door switch 2 Lower oven door switch 3 Monitor switch 4 Secondary switch Door latch assembly switches 1 Latch interlock switch primary 2 Latch lock switch 3 Latch unlo...

Page 59: ...itch contacts and breaks the circuit The broken circuit signals the board to turn the oven light on and to turn the convection motor off in any convection mode Terminals N O Door Switch 5 4 3 2 1 DAC...

Page 60: ...9 Door Hook Switches Switches Activated by Hook Monitor switch secondary switch These switches are activated by a spring action hook on the microwave oven door When the door is opened and closed these...

Page 61: ...time The right side door interlock switch secondary is mounted on the right side of the oven bracket It is normally open The switch is closed by side ways motion of the hook when the oven door is clo...

Page 62: ...ck switch primary the n o lock switch and the n o unlock switch These switches are positioned as follows in the idle state unlatched Normally Open Latch Interlock Switch Open Normally Open Latch Unloc...

Page 63: ...atched When microwave mode is selected the latch motor runs The cam on the latch assembly closes the N O latch interlock switch and completes the circuit to the microwave board see illustration below...

Page 64: ...tage circuit to the board Latch Lock Unlock Switch Circuit In Microwave When microwave is selected the latch motor runs The cam on the latch assembly opens the unlock switch and closes the lock switch...

Page 65: ...motors Air movement from the cooling motors closes the air switches and completes the circuit The completed circuit signals the board that the cooling motors are working and the board allows the oven...

Page 66: ...and an explanation of the fuse protection system The safety switches are the monitor switch and the latch interlock switch primary switch and the right side door interlock switch secondary switch The...

Page 67: ...tely 1 second before the high voltage circuit is energized MAGNETRON TUBE The magnetron tube is a vacuum tube in which the flow of electrons from the heated cathode to the anode is controlled by a mag...

Page 68: ...wo Pin Headers P1 and P3 and two 1 4 terminals P2 1 and P2 2 K1 Relay This relay transfers 120 Volts AC to the high voltage transformer to activate the micro wave circuit The K1 Relay Coil is activate...

Page 69: ...CJ Oven Service Manual Lit No 94 30 007A Page 68 CJ CONTROLS...

Page 70: ...en Cooling Motor K5 Lower Oven Cooling Motor K6 Upper Oven Halogen Lamp K7 Lower Oven Halogen Lamp K8 Upper Oven Both Jet Blowers K9 Upper Oven Convection Elements K10 Upper Oven Jet Plate Mullion Ele...

Page 71: ...K15A transfers 120 V A C from L2 Relay K4 transfers 120 V A C from L2 Relay K5 transfers 120 V A C from L2 Upper Oven convection element top Upper Oven convection element lower Upper Oven jet plate e...

Page 72: ...P5 outputs signal voltage Pin P6 outputs 24 V D C Lower Oven Latch Motor Microwave Board Rectifies AC to DC 12 V A C to Upper Oven Latch Motor Upper Oven Halogen Lights Lower Oven Halogen Lights Uppe...

Page 73: ...oven can proceed into self clean or microwave mode The air switches must also physically close by air movement from the cooling blowers before the oven proceeds into a bake or broil mode If the coolin...

Page 74: ...ontrol that the cooling motor is working and it is ready to go into the selected mode DAC control relays output pins The DAC control has 14 relays K0 K15 and 7 output pin CONNECTORS P2 P3 P5 P6 P9 P14...

Page 75: ...vection elements The following parts require 120 volts A C to function Dac control step down transformer 120 volts to 24 volts A C and D C High voltage transformer steps down 120 V A C volts to 3 2 V...

Page 76: ...cooling motors K6 Transfers current to complete 12 v a c Upper oven halogen light circuit K7 Transfers current to complete 12 v a c Lower oven halogen light circuit K8 Transfers 120 volts from L2 to...

Page 77: ...harness so it cannot be miswired P5 Sends current to the lower oven latch switches It is a 5 pin header Only 1 2 3 and 5 are used 4 is missing on the pin header and is plugged on the harness to preven...

Page 78: ...oor latch P0 3 Blank P0 4 Sends 120VAC to lower oven latch motor P0 5 Blank P0 6 Sends 120 VAC to microwave stirrer motor P0 7 Not used P0 8 Blank P1 large pin header has 8 pins and are identified as...

Page 79: ...upper oven convection motor P8 large pin header has 4 pins and are identified as follows P8 1 Current from L2 to K15 relay P8 2 Current to lower oven convection motor P8 3 Blank P8 4 Blank P18 large p...

Page 80: ...Harness The wire harness slide onto the pin headers of the relay board display head and touch control boards The illustration above shows the pin headers on the relay board The wire harness is shown...

Page 81: ...The 2 hole on the connector housing is plugged there is no wire This harness sends commands between the left tcb and the right tcb 8 Wire Yellow Display Harness This 8 wire yellow harness connects fro...

Page 82: ...t all modes except self clean When set in self clean DOR will flash and self clean will erase P9 Upper oven door latch Will accept all modes except self clean When set in self clean dor will flash and...

Page 83: ...s will close but the lights and motors will not work P8 Lower oven convection motor No fail code The lower oven convection motor will not work The relay will snap closed P7 Upper oven convection motor...

Page 84: ...y Head MICROWAVE PROBE JETDIRECT BAKE UPPER CONVECTION LOWER COOKSMART SELF CLEAN BROIL ROAST UPPER 1 2 3 4 OFF PAUSE PROOF STOP COOK LOWER RESUME DEHYDRATE TIME TIME OFF LIGHT PANEL LOCK CLOCK TIMER...

Page 85: ...in antistatic bags When removing the boards from their bags handle them as follows Touch Control Board Handle the Touch Control Board only by the edges of the glass and the plastic frame DO NOTTOUCHt...

Page 86: ...me size The difference between a 27 inch oven and a 30 inch oven is deter mined by the control panel Mounting brackets There are 6 mounting brackets that hold the glass against the control panel snug...

Page 87: ...has 8 pins only 7 are used 2 is missing and connects to the small right side touch control board P3 pin header on the large left side touch control board is not used Right side touch control board Th...

Page 88: ...ader has 2 pins and connects to the L O meat probe P4 pin header has 2 pins and connects to the lower oven air switch P6 pin header has 2 pins and connects to the upper oven air switch P8 pin header h...

Page 89: ...per oven air switch F 34 will appear if upper oven air switch does not close If air switch does not close the mode is cancelled after about 45 seconds P4 Lower oven air switch F64 will appear if lower...

Page 90: ...30 007A Page 89 Hidden Bake Element Under Oven Liner White Wires Bracket Screws BACK OF LINER Broil Element 2 Top Front Mounting Screws Broil Element Brackets Access Panel Cover Hex Nut Meat Probe Jac...

Page 91: ...t so you can access the flange at the bottom of the oven 6 Remove the six screws from the flange 7 Remove the two wires from the bake ele ment 8 Refer to Figure C Page 86 and bend the bottom flange do...

Page 92: ...ws Flange Flange Remove 6 Screws Remove 3 Screws Support Bracket Bake Element Wires Wire Tie Figure B FigureA Bend Flange Down Bend Flange Down Flange Figure C Hidden Element Cover Hidden Bake Element...

Page 93: ...edges present and you can cut yourself if you are not careful CAUTION 4 Remove the screws from the bracket and pull the oven temperature sensor forward until the wire connectors are through the openi...

Page 94: ...crews from the convection bake element bracket and the screw from the bottom support and pull the element forward then disconnect the wires from the terminals 7 Install the new convection bake element...

Page 95: ...he electrical power circuit to the oven at the main junction box before ser vicing this unit When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and...

Page 96: ...94 30 007A Page 95 Oven Liner Fan Motor White Wire 44 Fan Motor Screws Pan E Ring Flat Washer Hex Nut Left Rotating Thread Bracket with Insulation Convection Blade Brown Wire 45 Top Screw Top Screw Bo...

Page 97: ...you pry the lamp holder out of the cutout 6 Cut the plug off the new lamp holder 7 Connect the cut wires to the new lamp holder with two red inline splices After you connect the wires pull on them to...

Page 98: ...ndary Winding 10 6 1 5 WARNING Turn off the electrical power circuit to the oven at the main junction box before ser vicing this unit When you work on the oven be careful when handling the sheet metal...

Page 99: ...the latch assembly to the right so that the flange on the left side clears the bracket and then pull it forward as far as the wires will allow c Remove the wires from the switch con nectors and the m...

Page 100: ...Oven Motor 07 08 Com Com N O N O Unlock Switch Latch Interlock Switch SCREWS OVEN DOOR LATCH SCREWS UPPER AIR VENT GRILLE AIR VENT GRILLE AIR VENT GRILLE SCREWS Hex Head Screw Hex Head Screw Bracket S...

Page 101: ...steps 1 Turn off the electrical power to the oven 2 Pull the oven out of its mounting location so that you can access the back cover and both air switches 3 UpperAir Switch Remove the two screws from...

Page 102: ...CJ Oven Service Manual Lit No 94 30 007A Page 101 REMOVING THE AIR SWITCHES Figure 3 Air switch through the diverter Figure 2 Lower air switch Air switch 2 wires 2 screws Switch Bracket...

Page 103: ...assembly to the plenum 4 To remove the lower blower see Figure B Page 5 93 a Remove the oven from the wall b Remove the rear panel from the oven c Remove the four bracket screws 1 2 6 7 from the back...

Page 104: ...White 24 Lt Blue 97 Dk Blue 23 Upper Blower Mounting Bracket Screw Screw Screw BACK OF PLENUM Blower Wire 24 To Upper Blower Motor Blower Bracket Blower Wire 23 To Upper Blower Motor 1 2 3 4 5 6 7 Upp...

Page 105: ...on each of the hinges Position Up To Remove Door Position Down To Close Door 3 To remove the door a Grasp the door by the sides toward the back and raise the front of the door sev eral inches there w...

Page 106: ...t it is locked into place 6 Using the eraser end of a pencil push the ends of the gasket fully into the holes in the oven door 7 Check the entire gasket to make sure that all of the clips are properly...

Page 107: ...elow as you remove the door components The illustration shows the order of removal When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cu...

Page 108: ...ts from the oven shown in illustration below Refer to the sections in this manual for the procedures on removing the components 5 With all of the oven components removed remove the six screws three on...

Page 109: ...switch in its normal position and continuity when it is activated 5 If the readings are not correct remove and replace the switch WARNING Motor Terminals BLOWER ASSEMBLY TO AVOID ELECTRICAL SHOCK DISC...

Page 110: ...ads to the secondary terminals The meter should indicate 2 5 If the readings are not correct remove and replace the lamp transformer Primary Winding Secondary Winding 10 6 1 5 THE CONVECTION FAN MOTOR...

Page 111: ...ch terminal The meter should indicate no continuity with the switch in its normal position and continuity when it is activated OVEN DOOR LATCH Motor Terminals Com Com N O N O Lock Switch Unlock Switch...

Page 112: ...ele mentterminals Themetershouldindicate15 4 If the reading is not correct remove and replace the broil element THE HIDDEN BAKE ELEMENT Refer to Pages 80 and 81 to access the bake ele ment 1 With no...

Page 113: ...r leads to the terminals The meter should indicate continuity 4 If the reading is not correct remove and re place the hi temp cutout Terminals Hi Temp Cutout Reset Button THE CONVECTION BAKE ELEMENT R...

Page 114: ...32 Upper oven over temperature while cleaning F33 Upper oven over temperature while cooking F34 Upper oven cooling fan not operating F40 Upper meat probe shorted F50 Upper door signal shorted low F51...

Page 115: ...CJ Oven Service Manual Lit No 94 30 007A Page 114 CJ302 ELECTRONIC OVEN CONTROL WIRING...

Page 116: ...CJ Oven Service Manual Lit No 94 30 007A See 11 x 17 Page CJ302 Wiring Diagram Page 115...

Page 117: ......

Page 118: ...CJ Oven Service Manual Lit No 94 30 007A See 11 x 17 Page CJ302 Schematic Drawing Page 116...

Page 119: ......

Page 120: ...CJ Oven Service Manual Lit No 94 30 007A Notes Page 117...

Page 121: ...5551 McFadden Avenue Huntington Beach CA 92649 800 735 4328 RO8577CJ 94 30 007A 2001 BSH Home Appliances Corp Litho U S A 10 01...

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