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Thermador PRG486JDG/01, Service Manual, Page: 48 / 91

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Thermador PRG486JDG/01 Service Manual Download Page 48

Service Manual for the Thermador Pro Grand Next Generation 48-Inch Natural Gas and LP Gas Ranges, Models: 

PRG486JDG/01, PRL486JDG/01

 

 

 

 

 

 

 

 

 

 

58300000159722_ARA_EN_D

 

 

 

 

 

 

 

      Page 49 of 92

 

6.7.13 

Oven Temperature Gauge Removal and Replacement 

 The temperature gauge is for the large oven only. Assess is from 

the top and front of the range. 

The gauge shows the temperature setting the user has selected, not 
the current oven temperature. 

Be sure to check QuickFinder for relevant information, documentation, 
and the correct part number when replacing this component. 

  

 

Figure 65: Oven Temperature Gauge (Front, and Back Views) 

1.  Follow all safety precautions and steps in 

Preparing the Range for 

Servicing

, page 

22

. 

2.  Follow all steps in 

Accessing Components under the Maintop,

 

page 

22.

 

3.  At the back of the control panel, remove and retain the two nuts 

with lockwashers from their respective studs on the bracket (see 
Figure 66). 

4.  Carefully pull out the bracket (see Figure 67). 

 

Figure 66: Removing a Nut with Lockwasher on the Temperature Gauge 
Bracket 

1 

Nuts with lockwashers (2) 

 

Figure 67: Removing the Temperature Gauge Bracket 

Summary of Contents for PRG486JDG/01

Page 1: ...etop Flame Characteristics 13 3 4 Testing Ignition for Burners 14 3 4 1 Time to Ignite 14 3 4 2 Testing Ignition for Standard Burner Settings HI MEDIUM SIM 14 3 4 3 Testing Ignition for XLO Burner Set...

Page 2: ...6 7 18 Ignition Spark Module Removal and Replacement 54 6 7 19 Door Latch Removal and Replacement 55 6 7 20 Plunger Switch Removal and Replacement 57 6 7 21 Griddle Grill Thermostat Removal and Replac...

Page 3: ...6 9 8 1 Bake Burner HSI for Small Oven Removal and Replacement 84 6 9 8 2 Bake Burner for Small Oven Removal and Replacement 86 6 9 8 3 Bake Burner Orifice and Elbow Connector for Small Oven Removal a...

Page 4: ...odes and standards apply and must be observed For authorized servicers additional assistance is available by contacting our Technical Support Team at 800 444 9091 1 1 Technical Documents to Read Prior...

Page 5: ...ers large small Precision flat blade screwdriver with a high strength blade 1 8 inch 3 0 mm wide 020 inch 0 50 mm thickness tip Drivers T 10 T 20 T 27 T 30 2 foot long rachet extension Rachet with 6 i...

Page 6: ...zed replacement parts for this appliance Use of substitutions may defeat compliance with safety standards set for home appliances will void the warranty and may create safety hazards resulting in bodi...

Page 7: ...ment shall be in accordance with the National Electric Code Hot Surfaces To avoid burns and injury do not handle components and surfaces that are hot such as the rangetop burner assemblies maintop gri...

Page 8: ...sive spillage Do not clean rub damage move or remove the door gasket as it is essential for providing a tight seal during oven operation If the gasket becomes worn or excessively soiled with food part...

Page 9: ...ignition Burner should ignite within 4 seconds 2 1 3 Griddle Grill Control Knob The griddle grill knob controls the temperature to the griddle or grill from 150 F to 500 F Press and turn the knob cloc...

Page 10: ...urned on If one or more burner blows out the respective igniter electrode automatically re ignites the flame 2 4 Operation during a Power Outage In Case of Power Outage When there is a removal of elec...

Page 11: ...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...

Page 12: ...light 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 produ...

Page 13: ...and SIM settings If flame characteristics do not improve call Thermador technical support at 800 444 9091 3 4 3 Testing Ignition for XLO Burner Settings Set the burner knob to XLO and observe if the...

Page 14: ...to a more closed position If the flame is too yellow rotate the shutter counter clockwise to set the opening to a more open position 3 Tighten the adjustment screw 4 Reinstall the burner 5 Test to eva...

Page 15: ...n when performing gas leak testing on XLO valves 3 7 Troubleshooting Burners Flame and Ignition 3 7 1 Burner and Flame Diagnostics for Rangetop Burners If a rangetop burner clicks sparks constantly or...

Page 16: ...l for the Thermador Pro Grand Next Generation 48 Inch Natural Gas and LP Gas Ranges Models PRG486JDG 01 PRL486JDG 01 58300000159722_ARA_EN_D Page 17 of 92 Figure 9 Diagnostic Flowchart for Rangetop Bu...

Page 17: ...to maintain that temperature Bake mode The power to the bake burner cycles on and off at pre set intervals when the bake burner is preheating preheating indicator light is on and also during regular b...

Page 18: ...ty 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...

Page 19: ...e reading and simultaneous temperature reading to check the oven temperature sensor The resistance fluctuates according to ambient room temperature To avoid injury it is recommended to wait until the...

Page 20: ...Service Manual for the Thermador Pro Grand Next Generation 48 Inch Natural Gas and LP Gas Ranges Models PRG486JDG 01 PRL486JDG 01 58300000159722_ARA_EN_D Page 21 of 92 5 FAULT MESSAGES...

Page 21: ...electrical power and or an open gas supply exercise extreme caution 6 2 Component Removal Videos 6 3 Accessing Components under the Maintop This section contains the steps required to gain access to...

Page 22: ...burner base onto the pedestal see Figure 12 Figure 12 Burner Base 1 T 30 screws 2 5 Slowly lift the burner base off of the pedestal see Figure 13 6 Press the locking tab on the igniter wire terminal...

Page 23: ...the Venturi tube still attached while gently pushing the ignition wire through see Figure 15 OR Alternatively you can first lift the Venturi tube out from the pedestal burner before removing the pede...

Page 24: ...the burner support rail or needs to be replaced see Jet Holder Assembly Removal and Replacement page 34 Be sure to check QuickFinder for relevant information documentation and the correct part number...

Page 25: ...injury by using gloves when removing or installing burner support rails Gas Leaks With electrical power off carefully check for gas leaks at each gas component that was removed replaced or otherwise...

Page 26: ...precautions and steps in Preparing the Range for Servicing page 22 2 Complete steps for Accessing Components under the Maintop page 22 3 Remove the grill griddle plate and grease tray see Figure 22 Fi...

Page 27: ...1 Screws 2 holding insulation support bracket 2 Fixed brackets 5 3 Screws 2 holding element ends onto range 11 Detach and remove the insulation support bracket from under the element tray see Figure...

Page 28: ...Figure 27 Figure 27 Removing the Insulation Tray 6 5 Side Panel Removal and Replacement This procedure is for both the right and left side panels Figure 28 Side Panel Locations of Screws and Nuts 1 Sc...

Page 29: ...el see Figure 28 on page 29 and Figure 29 5 Use a rachet with 6 inch long minimum swivel head extension fitted with a 5 16 inch deep well socket to remove and retain the nut with lockwasher on the upp...

Page 30: ...58300000159722_ARA_EN_D Page 31 of 92 Figure 30 Nuts with Lockwashers 1 Upper nut with lockwasher 1 on screw 2 Lower nut with lockwasher 1 on screw 3 Access hole to remove lower nut with lockwasher Fi...

Page 31: ...control panel remove and retain the screws that connect to the two manifold support brackets These are located at the second from left and second from right bezels see Figure 33 Figure 33 Locations o...

Page 32: ...e to use as a cushion if placing the control panel there see Figure 38 page 34 For this you may need to detach some of the wire connectors if they are not long enough Sharp Components Use Gloves Wear...

Page 33: ...replacing the jet holder assembly from the burner support rail The assembly includes the jet holder as well as the orifice jet which is an integral part of the assembly and is not available separatel...

Page 34: ...oved through the corresponding grooves in the burner support rail You may need a crescent wrench to assist in rotating the jet assembly see Figure 40 and Figure 41 6 Replace the jet holder assembly if...

Page 35: ...rd valve and to the jet holder assembly and then remove the tube 5 From under the manifold use a 1 4 inch wrench to remove and retain the valve screw that secures the standard valve onto the manifold...

Page 36: ...the microswitch see Figure 43 page 36 and then pull the microswitch off the alignment pin on the standard valve 6 Replace the microswitch if needed 6 7 4 Solenoid Valve Removal and Replacement The so...

Page 37: ...ire connections prior to disconnecting for example with your mobile phone Figure 46 Removing Gas Tube from the Solenoid Valve 7 Rotate the solenoid valve counter clockwise until the large hex nut on t...

Page 38: ...age 40 5 Use an adjustable wrench to unscrew the large hex nut on the solenoid and remove the XLO valve from the solenoid valve Be careful not to lose the plastic O ring positioned inside the large he...

Page 39: ...til you can slide the potentiometer off of the valve shaft see Figure 50 6 Replace the potentiometer if needed Figure 50 Potentiometer 1 XLO valve shaft 2 Side connector on potentiometer Gas Leaks Wit...

Page 40: ...and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly identify their connections locations when reassembling Alternatively you can photograph the wire connect...

Page 41: ...the standard valves Be careful not to bend the gas tubes Solenoid valves Use a 1 2 inch wrench to hold the nut on a solenoid valve while unscrewing the attached gas tube hex nut with a 9 16 inch wrenc...

Page 42: ...the backguard see Backguard Removal and Replacement page 61 Figure 55 Large Flue Cover 1 Screws 2 securing large flue cover to the range 4 Remove the back panel s See Back Panel for Small Oven Remova...

Page 43: ...57 Figure 57 Bake and Broil Manifold with Fittings 1 Flared adapter shown attached to gas flex line 2 Elbow connecting piece 3 Manifold for bake and broil burners 4 Screws 2 on each manifold bracket...

Page 44: ...page 22 3 If obstructing access to the regulator remove the burner support rail with jet holder assemblies attached by following the steps in Removing the Burner Support Rail page 25 4 Use two wrench...

Page 45: ...bi metal gas valve and make a note of which wires are connected to each of the two different terminals see Figure 61 page 47 NOTE It is always recommended to label and tag all wires wire connectors a...

Page 46: ...TE Before replacing the oven lamp transformer see Figure 10 page 19 to diagnose problems with the oven lamp Be sure to check QuickFinder for relevant information documentation and the correct part num...

Page 47: ...d Replacement This procedure is for both ovens and covers the removal and replacement of the dual function selector switch for the oven function and oven temperature Be sure to check QuickFinder for r...

Page 48: ...or relevant information documentation and the correct part number when replacing this component Figure 65 Oven Temperature Gauge Front and Back Views 1 Follow all safety precautions and steps in Prepa...

Page 49: ...en replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 22 2 Follow all steps in Accessing Components under the Maintop page 22 3 Remove the gri...

Page 50: ...he left Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range f...

Page 51: ...o check QuickFinder for relevant information documentation and the correct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page...

Page 52: ...Finder for relevant information documentation and the correct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 22 2 Follow...

Page 53: ...nder for relevant information documentation and the correct part number when replacing this component Figure 76 Ignition Spark Module 1 Screws 2 2 Wire connectors 2 1 Follow all safety precautions and...

Page 54: ...steps in Preparing the Range for Servicing page 22 2 Follow all steps in Accessing Components under the Maintop page 22 3 Remove the corresponding oven door see Oven Door Removal Installation and Ali...

Page 55: ...the white plastic piggyback wire connector on the door latch s microswitch see Figure 79 and Figure 80 page 57 NOTE It is always recommended to label and tag all wires wire connectors and harnesses pr...

Page 56: ...ire connectors are attached to each terminal on the plunger switch NOTE It is always recommended to label and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly...

Page 57: ...lary tube to the needed length however be careful not to twist or bend it or it may impede the component s ability to operate properly 1 Follow all safety precautions and steps in Preparing the Range...

Page 58: ...nd or display module access is from the top of the range Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component Figure 86 Oven Di...

Page 59: ...ol panel detach the wire connector from the display module 8 Remove the display module by pulling it over the manifold 9 Replace the display module if needed Figure 88 Removing Oven Light Switch from...

Page 60: ...n 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 I...

Page 61: ...Panel for Small Oven Removal and Replacement Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component Figure 92 Typical Back Panels...

Page 62: ...Power Cord Removal and Replacement At the terminal box junction box replace the terminal block in the event the terminal threads are stripped or if there is any other damage to the component The power...

Page 63: ...other Typical Cooling Fan View from Under the Mounting Bracket 1 Screw locations 4 securing bracket onto the range 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 2...

Page 64: ...mall Ovens Removal and Replacement For the oven temperature sensors access is required from the front and side of the range Before replacing the temperature see Oven Temperature Sensor Diagnostics pag...

Page 65: ...mponents Figure 98 Meat Probe Receptacle Components 1 Nut 2 Lockwasher 3 Cover 4 Oven cavity shown for reference 5 Receptacle for probe probe not shown 1 Follow all safety precautions and steps in Pre...

Page 66: ...Figure 100 Detaching the Meat Probe Wire Connector Figure 101 Removing the Meat Probe Receptacle 6 9 3 Rack Support Removal and Replacement Figure 102 Rack Support Shown with Screw and Washer 1 Follo...

Page 67: ...rom the front of the range NOTE Before servicing the oven lamp see Oven Light Diagnostics page 18 Be sure to check QuickFinder for relevant information documentation and the correct part number when r...

Page 68: ...emove the bulb by carefully pulling it straight out to ensure its two prongs do not break off inside the lamp holder socket 6 When installing a Halogen bulb to prevent premature burn out of the bulb n...

Page 69: ...the oven door as it is very heavy Use both hands to remove or replace the oven door and firmly grasp both sides of the door when handling it When the door is removed from the range never release locki...

Page 70: ...when properly installed It may be necessary to press firmly inward on the lower portion of the door using a rocking motion to fully seat the door s hinges NOTE Do not let the door fall Do not force o...

Page 71: ...alignment screw until the door is properly aligned Figure 109 Alignment Screw Shown with Door Removed 1 Slot for hinge 2 Hinge receiver screw NOTE Do not rotate the hinge receiver screw It is not use...

Page 72: ...tor assembly attached forward through the oven cavity See Figure 113 page 73 Figure 112 Rear Cover Shield 1 Screw locations 6 7 Label and then detach the two spade connectors on the motor terminals se...

Page 73: ...DG 01 PRL486JDG 01 58300000159722_ARA_EN_D Page 74 of 92 Figure 114 Removing Four Bracket Screws on Rear Cover Shield Figure 115 Bracket and Insulation 1 Screw locations 4 that attach to rear cover sh...

Page 74: ...is recommended to wear protective eye wear at all times when removing or installing components inside the oven cavity such as the broil burner HSI or HSI retaining bracket Gas Leak Testing With electr...

Page 75: ...ons when reassembling Alternatively you can photograph the wire connections prior to disconnecting for example with your mobile phone 7 From inside of the range use a 9 mm open end wrench to remove an...

Page 76: ...mm open end wrench to remove and retain the two nuts with lock washers that secure the HSI retaining bracket onto the broil burner studs and then detach the HSI retaining bracket see Figure 120 page 7...

Page 77: ...racket 4 Elbow connector with orifice attached 6 9 7 Bake Burner Components Large Oven Removal and Replacement Bake burner components require access from both the front and back of the range Be sure t...

Page 78: ...to burner box 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 22 2 Remove the backguard see Backguard Removal and Replacement page 61 3 Remove the back panel see B...

Page 79: ...two screws holding the two ends of the burner onto the burner box chassis see Figure 124 page 79 Figure 128 Bake Burner Brackets 1 U shaped bracket remains fixed on burner box 2 Straight bracket with...

Page 80: ...serviced using a gas leak detector electronic leak detectors are highly recommended or bubble test 6 9 7 2 Bake Burner for Large Oven Removal and Replacement For replacing the bake burner access is fr...

Page 81: ...d replaced or otherwise serviced using a gas leak detector electronic leak detectors are highly recommended or bubble test 6 9 7 3 Bake Burner Orifice and Elbow Connector for Large Oven Removal and Re...

Page 82: ...to remove the large hex nut and then remove the elbow connector from the retaining bracket see Figure 133 7 Use an adjustable wrench to remove the orifice from the elbow connector 8 Replace the orifi...

Page 83: ...debris it is recommended to wear protective eye wear at all times when removing or installing components inside the oven cavity Gas Leak Testing With electrical power off carefully check for gas leak...

Page 84: ...t to the oven cavity and reflector and then remove the cover see Figure 135 Figure 135 Bottom Cover of Small Cavity 1 Screws 2 on bottom cover of oven cavity Sharp Components Wear gloves and be carefu...

Page 85: ...bracket the HSI bracket is built in on the bake burner see Figure 139 and then remove the HSI 13 See HSI and Element Diagnostics on page 18 and replace the HSI if needed Gas Leak Testing With electri...

Page 86: ...air shutter is aligned with the orifice elbow connector assembly Figure 141 Removing the Bake Burner Gas Leak Testing With electrical power off carefully check for gas leaks at each gas component that...

Page 87: ...and Elbow Connector 1 Gas Tube 2 Compression nut 3 Bracket 10 When installing the bake burner make sure that it fits correctly into place so that the air shutter is aligned with the orifice elbow conn...

Page 88: ...the entire surface See Figure 144 6 9 10 Oven Door Components Removal and Replacement Be sure to check QuickFinder for relevant information documentation and correct part numbers when replacing any of...

Page 89: ...remove 1 on each side of door 2 Screw to remove 1 on each side of door 3 Upper bracket 1 4 Inner glass panel 5 Lower retaining brackets 1 on each side of door 6 9 11 Door Gasket Removal and Replaceme...

Page 90: ...t the kick panel upward to detach the right and left side grooves from respective screws see Figure 148 page 91 7 BEFORE RETURNING APPLIANCE TO SERVICE After you have finished all testing and servicin...

Page 91: ...m burns do not use a wet sponge or cloth to clean the range while it is hot Do not use any type of aerosol cleaner on or around the rangetop when hot Some cleaners produce noxious fumes if applied to...

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