Thermador PRL304EG Service Manual Download

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Service Manual for Thermador Pro Grand LP Gas Ranges, Models: PRL304EG, PRL364EDG, PRL364ELG, PRL366EG, PRL484ECG, PRL486EDG, PRL486EDPG, PRL484ELG

58300000156573_ARA_EN_B

Page 98 of 119

Sharp Components

Wear gloves and be careful when handling sharp bake burner
components

7. Remove the reflector from the burner box (see Figure 194).

Figure 194: Reflector

Figure 195: Reflector

Figure 196: Inside Bake Burner Box (Shown with Reflector Removed)

Brackets that attach to reflector

Bake burner bracket and two screws

Hot Surface Igniter (HSI)

Electrode (flame sensor)

5 Bake

burner

8. Remove and retain the two screws to remove the straight bracket

(see Figure 197, page 99).

Summary of Contents for PRL304EG

Page 1: ...on 12 3 1 Before Testing 12 3 2 Rangetop Burner Characteristics 12 3 3 Rangetop Flame Characteristics 13 3 4 Testing Rangetop Burner Ignition 14 3 4 1 Testing Rangetop Burner Ignition 14 3 4 1 1 Testing the HI Medium and Low Settings 14 3 4 1 2 Testing the XLO Setting 14 3 4 2 Testing Broil Burner Ignition 14 3 4 3 Testing Bake Burner Ignition 14 3 5 Adjusting Bake Burner Flame with the Air Shutte...

Page 2: ...56 4 5 16 Bake Burner Solenoid Removal and Replacement Under Maintop 58 4 5 17 Control Board Removal and Replacement 59 4 5 17 1 Control Board Removal and Replacement Main Oven 59 4 5 17 2 Control Board Removal and Replacement Small Oven 60 4 5 18 Simmer Control Board Removal and Replacement 61 4 5 19 Hot Surface Igniter Board Removal and Replacement 62 4 5 20 DSI Module Removal and Replacement 63...

Page 3: ...7 6 3 Replacing the Bake Burner Electrode Large Oven 102 4 7 6 4 Replacing the Bake Burner Orifice Assembly Large Oven 104 4 7 7 Bake Burner Components Small Oven Removal Replacement 105 4 7 7 1 Replacing the Bake Burner Small Oven 105 4 7 7 2 Replacing the Bake Burner Hot Surface Igniter Small Oven 109 4 7 7 3 Replacing the Bake Burner Electrode Small Oven 110 4 7 7 4 Replacing the Bake Burner Or...

Page 4: ...cal condition may arise BSH Home Appliances Corporation is not liable for damages caused by improper repairs performed by unauthorized parties Local codes and standards apply and must be observed Contact Technical Support for further assistance 1 2 Data Rating Plate The data rating plate which shows the model serial and FD number is located at the bottom of the range behind the kick panel as shown...

Page 5: ...pment Pipe sealant Small mirror Air sled or dolly Protective eye wear such as glasses goggles Flashlight Amp meter Thermometer with thermocouple leads Multimeter 1 6 Important Safety Information Before starting to service an appliance familiarize yourself with all safety information and precautions contained in this manual 1 6 1 Safety Symbols Used In This Manual Warnings alert you to dangers that...

Page 6: ...ting with electrical power on 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 th...

Page 7: ...round the rangetop when hot Some cleaners produce noxious fumes if applied to a hot surface Follow directions provided by the cleaner manufacturer Fiberglass Insulation Wear gloves when handling fiberglass insulation 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 ex...

Page 8: ...r the standard burners rotate the knob to any setting between HI and SIM NOTE The blue LED indicator lights up when burners are lit Figure 2 Standard Burner Control Knob 2 1 2 ExtraLow Burners When in XLO mode the very lowest flame setting the flame cycles on for approximately 8 seconds and then turns off for 52 seconds of each minute 3 Press a control knob in and turn counter clockwise to HI sett...

Page 9: ...perature Selector Knob Use this knob for setting the oven temperature broil and speed clean mode The small oven does not have the speed clean feature See Figure 6 Figure 6 Temperature Knobs Large Oven Left Small Oven Right 2 1 6 Five Position Oven Function Selector Knob On the large oven for 48 inch ranges and for all 30 inch and 36 inch ranges use this knob for bake convection bake broil and spee...

Page 10: ...ter electrode automatically re ignites the flame 2 4 Operation During a Power Outage When there is a removal of electrical power the XLO burners griddle and grill cannot be used Do not attempt to light them manually during a power outage m Caution Power Outage Precautions Ventilate well by opening a door or window and wait at least five minutes until all the gas dissipates If you smell gas comply ...

Page 11: ...orrectly 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 3 2 Rangetop Burner Cha...

Page 12: ...or fluttering Orange colored streaks in the flame are produced from burning airborne debris which is normal at startup and should dissipate in a few minutes see Figure 14 When the flame is properly adjusted it should burn completely around the burner cap at each burner port see Figure 12 Figure 13 Correct Flame Color and Characteristics 1 Dark blue 2 Secondary cone 3 Light blue 4 Primary cone Figu...

Page 13: ... minute 3 4 2 Testing Broil Burner Ignition Set the mode to BROIL After 15 50 seconds depending on the model the burner should ignite The broiler burners do not have an air shutter and no adjustment is necessary 3 4 3 Testing Bake Burner Ignition Set the oven to BAKE at 350 F After 15 50 seconds depending on the model the burner should ignite and stay lit until 350 F is reached Then it should shut...

Page 14: ...position 2 Remove knobs from valve stems by slowly pulling knobs straight out away from control panel 3 For newer models Remove and retain the two bezel mounting screws and remove the bezel 4 For older models Valve screws can be accessed directly through the control panel without removing the bezel mounting screws 5 To engage the valve screw insert the precision screwdriver with 1 8 inch blade int...

Page 15: ...perly 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 wirin...

Page 16: ...or Thermador Pro Grand LP Gas Ranges Models PRL304EG PRL364EDG PRL364ELG PRL366EG PRL484ECG PRL486EDG PRL486EDPG PRL484ELG 58300000156573_ARA_EN_B Page 17 of 119 Figure 19 Rangetop Burner Ignition Diagnostic Flowchart ...

Page 17: ...ower 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 temp...

Page 18: ...lue LEDs that blink are located either horizontally or vertically on the control panel The horizontal positioned blue LEDs see Figure 21 and Figure 22 will first blink on the left and then the right and the vertical positioned blue LEDs see Figure 23 will first blink on the top and then the bottom For example if the first LED blinks 4 times followed immediately by the second LED blinking 3 times t...

Page 19: ...Service Manual for Thermador Pro Grand LP Gas Ranges Models PRL304EG PRL364EDG PRL364ELG PRL366EG PRL484ECG PRL486EDG PRL486EDPG PRL484ELG 58300000156573_ARA_EN_B Page 20 of 119 Figure 24 Fault Codes ...

Page 20: ...use of electrical power and or an open gas supply exercise extreme caution 4 2 Accessing Components under the Maintop This section contains the steps required to gain access to the components located under the maintop s 4 2 1 Removing Knobs Grates and Burner Assemblies To access and service components located underneath the maintops see Figure 11 first remove the knobs grates and burner assemblies...

Page 21: ...e Figure 27 and Figure 28 Figure 27 Igniter Wire Locking Tab 1 Tab press it to detach wire from electrode 8 Only if the ignition plug needs replacing Remove and retain the spring from the ignition plug by rotating the ignition plug clockwise while simultaneously holding the spring with a flat blade screwdriver to prevent its rotation so that the spring is unscrewed from the plug You may need to pu...

Page 22: ...ve receptacle as you carefully lift out each spill tray see Figure 30 and Figure 31 Figure 30 Typical Spill Tray Figure 31 Removing the Spill Trays Ignition Wire Shown 4 2 3 Removing Heat Shields Figure 32 Typical Heat Shields Sharp Components Gloves Recommended Use gloves when removing or installing a heat shield as the edges may be sharp 1 Remove and retain the screws that secure the heat shield...

Page 23: ...port Rail 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 Using a 9 16th inch wrench unscrew the hex nuts to remove the gas tubes from the jet holder assemblies Be careful not to bend the gas tubes see Figure 35 4 Using a 9 16th inch wrench unscrew the hex nut to remove the other end of th...

Page 24: ...void injury by using gloves when removing or installing the burner support rail Gas Leaks With electrical power off carefully check for gas leaks at each gas component that was removed replaced or otherwise serviced using a gas leak detector or bubble test 7 Using a large flat blade screwdriver push one side of the burner support rail to the other side of the chassis until the 2 prongs come out fr...

Page 25: ...n documentation and the correct part number when replacing this component 4 3 1 Griddle with Removable Brackets Removal and Replacement Fiberglass Wear gloves when handling fiberglass insulation Figure 38 Element Support Brackets and Screws 1 Screws 2 2 Element support brackets 1 of 2 shown Griddle Hazard The griddle plate must always be correctly in place when it is on 1 Follow all safety precaut...

Page 26: ...ket onto the back frame see Figure 42 6 Remove right and left brackets by lifting the pins out of the slots on the element tray see Figure 40 NOTE Depending on the model and FD number some ranges will not use the bracket shown in Figure 40 page 27 Figure 40 Bracket 1 Screw location attaches to back frame 2 Screw location attaches to element flange 3 Pins 2 Figure 41 Removing Element Flange from Br...

Page 27: ...bracket do not push the bulb through the receptacle in the element tray yet Figure 43 Removing the Thermostat Bulb from Retaining Bracket 1 Retaining bracket 2 Thermostat bulb 8 Disconnect the 1 4 inch spade connectors of both right and left element wires You may have to pull the element wires out a bit to access the connectors while doing this be careful not to damage the element wires 9 Remove t...

Page 28: ...the element tray slightly carefully push the bulb through the circular receptacle in the element tray see Figure 46 Figure 46 Receptacle for Removing Thermostat Bulb 11 While removing the insulation see Figure 47 be careful not to pull on the thermostat bulb Figure 47 Removing the Insulation 12 Remove the insulation support bracket by pulling its two prongs out of the slots in the retaining plate ...

Page 29: ... Burner Assemblies page 21 3 Remove the griddle plate and grease tray see Figure 39 4 Carefully remove the bulb from the fixed retaining bracket see Figure 49 NOTE After removing the thermostat bulb from retaining bracket don t push the bulb through the receptacle in the element tray yet 5 Disconnect the 1 4 inch spade connectors of both right and left element wires You may have to pull the elemen...

Page 30: ...re 50 7 Remove the two screws from the element tray see Figure 51 Figure 50 Fixed Element Brackets Figure 51 Locations of Screws on Element Tray 8 Detach the insulation support bracket from under the element tray see Figure 52 Figure 52 Detaching Insulation Support Bracket 9 While lifting up the element tray slightly carefully push the bulb through the circular receptacle in the element tray see F...

Page 31: ...problems with the grill also see Hot Surface Igniter Board Removal and Replacement page 62 For adjustment of the grill burner flame see Adjusting Bake Burner Flame with the Air Shutter page 14 Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing any of these components Grill Hazards The grill plate must be correctly in place whenever the gr...

Page 32: ...rner Box View of from Underneath 1 Solenoid valve for grill attached to gas flex line 2 Burner box mounting brackets 2 3 Electrode terminal connecting wire not shown 4 HSI wire connector 5 Grill burner only Venturi tube section is visible 6 Air shutter shown with orifice visible inside 7 Elbow connector attached to orifice 4 4 1 Grill Flame Spreader Removal and Replacement 6 Remove and retain the ...

Page 33: ...Burner Removal and Replacement 7 Lift the grill burner out of the burner box slightly upward in the direction towards the open end of the burner box so that the tab end is disengaged from the slot in the burner box See Figure 59 NOTE For adjustment of the grill burner flame see Adjusting Bake Burner Flame with the Air Shutter page 14 Figure 59 Removing the Grill Burner 1 Tab at end of grill burner...

Page 34: ...ode 1 Electrode screw shown securing electrode onto electrode bracket 2 HSI screw shown securing HSI onto burner box 4 4 4 Grill Electrode Removal and Replacement On the grill the electrode functions as a flame sensor that is if the electrode does not heat up enough in a short time frame the electrode will close the solenoid valve to avoid gas build up in the grill burner See Figure 63 Figure 63 E...

Page 35: ...nel of Grill Burner Box Shown Attached 1 Screw securing side panel onto burner box 2 Left side panel of burner box 13 Gently remove the sensor bulb by sliding it out of the bracket the bracket does not have to be removed See Figure 65 Figure 65 Thermostat Sensor Bulb Shown with Left Side Panel of Burner Box Removed 1 Bracket 2 Sensor bulb 3 Capillary tube 4 Portal for sensor bulb m Caution You can...

Page 36: ... of the burner box see Figure 66 and Figure 67 and then remove the burner support see Figure 68 Figure 66 Screws for Connecting Piece 1 Screw locations 2 securing the burner support onto the burner box Figure 67 Burner Support 1 Portal for orifice 2 Screw holes 2 Figure 68 Burner Support Removed with Orifice and Elbow Connector Attached 1 Elbow connector shown attached to gas flex line 2 Burner su...

Page 37: ... using a gas leak detector or bubble test 4 5 Removal and Replacement of Top Accessible Components This section contains removal and replacement procedures for the top accessible components located under the maintop 4 5 1 Jet Holder Assembly Removal and Replacement This procedure is for removing and replacing the jet holder assembly from the burner support rail The assembly includes the jet holder...

Page 38: ...nch to remove the nut see Figure 73 Figure 73 Removing the Nut on the Burner Support Rail 6 Replace the jet holder assembly if needed Be sure to retain and re use the wire guard clip if you are ordering a replacement jet holder assembly 7 When installing the jet holder do the following NOTE Before attaching the wire guard clip first install the jet holder onto the burner support rail and tighten t...

Page 39: ... jet holder assembly Be careful not to bend the gas tube 5 If a burner support rail obstructs access to the standard valve then remove the burner support rail with jet holder assemblies attached by following the steps in Removing the Burner Support Rail page 24 6 Using a 1 4 inch nut driver or a 1 4 inch socket wrench ratchet remove and retain the valve screw that secures the standard valve onto t...

Page 40: ...rners only Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component Figure 79 Microswitch 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 If a burner support rail obstructs access to the microswitch then remove the burner...

Page 41: ...ing the microswitch off the alignment pin on the standard valve see Figure 78 page 41 10 Replace the microswitch if needed Gas Leaks With electrical power off carefully check for gas leaks at each gas component removed replaced or otherwise serviced using gas leak detector or bubble test 4 5 4 Solenoid Valve for XLO Burner Removal and Replacement This procedure is for the solenoid valves which are...

Page 42: ...oid Valve 4 5 5 Solenoid Valve for Grill Removal and Replacement Access for the solenoid valve for the grill is under the maintop Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component For the procedure to remove and replace the solenoid valve for the XLO burners see Solenoid Valve for XLO Burner Removal and Replacement page 42...

Page 43: ...snap the potentiometer off the XLO valve Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component Figure 83 Typical XLO Valve 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 Remove knob from valve stem by slowly pulling k...

Page 44: ...t to lose the plastic O ring positioned inside the large hex nut of the solenoid valve as it may fall out easily see Figure 80 8 Use a 1 4 inch nut driver or a 1 4 inch socket wrench ratchet to remove and retain the valve screw that secures the XLO valve onto the manifold by accessing it from under the chassis base through the corresponding access hole The oven door must be opened or removed see F...

Page 45: ...wdriver to gently remove the XLO valve from the potentiometer standoffs Then slide the potentiometer off the valve stem see Figure 87 Gas Leaks With electrical power off carefully check for gas leaks at each gas component that was removed replaced or otherwise serviced using a gas leak detector or bubble test For XLO valves you may need the electrical power to be on when testing for gas leaks Use ...

Page 46: ...ve knob from valve stem by slowly pulling knob straight out away from control panel 4 If obstructing access to the potentiometer XLO valve solenoid assembly remove the burner support rail with jet holder assemblies attached by following the steps in Removing the Burner Support Rail page 24 5 Use a 1 2 inch wrench to hold the nut on the solenoid valve while unscrewing the gas tube hex nut with a 9 ...

Page 47: ... for rangetop burners is sold as an assembly which comes with XLO and standard valves pre installed Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 Remove burner su...

Page 48: ...u can photograph the wire connections prior to disconnecting for example with your mobile phone 14 Remove gas tubes from standard valves Use a 9 16th inch wrench to remove the gas tubes by unscrewing the hex nuts connected to the standard valves and to the jet holder assemblies Be careful not to bend the gas tubes 15 Remove gas tubes from solenoid valves Use a 1 2 inch wrench to hold the nut on a ...

Page 49: ... Lamp Transformer 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 If obstructing access to the oven lamp transformer remove the burner support rail with jet holder assemblies attached by following the steps in the Removing the Burner Support Rail procedure page 24 4 First make a note how t...

Page 50: ...ber when replacing this component Figure 93 Small Oven Temperature Selector Typical Models Shown Figure 94 Front and Back of Small Oven Temperature Selector Typical Model Shown with Retaining Bracket 1 Retaining bracket Figure 95 Large Oven Temperature Selector Typical Models Shown Figure 96 Front and Back of Large Oven Temperature Selector Typical Model Shown with Retaining Bracket 1 Retaining br...

Page 51: ...ch to the oven temperature selector see Figure 97 and then remove the bezel 7 At the back of the control panel remove the oven temperature selector and replace it if necessary Figure 97 Screw Locations on Bezel 1 Location of screws 2 4 5 11 Five Position Oven Function Selector Removal and Replacement The Five Position Oven Function Selector switch is for the large oven on 48 inch ranges only Depen...

Page 52: ...panel remove and retain the two T 20 screws on the bezel which are attached to the Five Position Oven Function Selector see Figure 100 and then remove the bezel Figure 100 Screws on Bezel of Oven Function Selector 7 At the back of the control panel remove the five position oven function selector and replace it if necessary 4 5 12 Three Position Oven Function Selector Removal and Replacement The Th...

Page 53: ...nel remove the Three Position Oven Function Selector and replace it if necessary NOTE When installing the Three Position Oven Function Selector make sure to attach the connector correctly onto all pins 4 5 13 Oven Temperature Gauge Removal and Replacement For 48 inch model ranges the temperature gauge is for the large oven only Be sure to check QuickFinder for relevant information documentation an...

Page 54: ...2 2 Temperature gauge 3 Mounting bracket 4 Four pin wire connector 4 5 14 Regulator Removal and Replacement Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component Figure 105 Regulator in Typical Range with Fittings and Gas Flex Line 1 Gas flex line 2 Hex nut on gas flex line 3 Flared adapter 4 Large nut on regulator 5 Regulator...

Page 55: ...in Figure 105 Gas Leaks With electrical power off carefully check for gas leaks at each gas component that was removed replaced or otherwise serviced using a gas leak detector or bubble test 4 5 15 Bi Metal Gas Valve Removal and Replacement Under Maintop There is an individual bi metal gas valve for each broil burner For 30 inch and 36 inch ranges the bi metal gas valves are located under the main...

Page 56: ... tubes at the inlet and outlet Be careful not to bend the gas tubes see Figure 107 6 Remove and retain the screws that secure to the single valve onto the range chassis see Figure 107 7 Remove and replace the bi metal valve if necessary Gas Leaks With electrical power off carefully check for gas leaks at each gas component that was removed replaced or otherwise serviced using a gas leak detector o...

Page 57: ...steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 If obstructing access to the solenoid remove the burner support rail with jet holder assemblies attached by following the steps in the Removing the Burner Support Rail procedure page 24 4 At the solenoid valve outlet use a wrench to remove and retain the 9 16th inch compression...

Page 58: ...l boards of 48 inch ranges For replacing the small oven control board of 48 inch ranges see Control Board Removal and Replacement Small Oven page 60 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 If obstructing access to the large oven control board remove the burner support rail with jet...

Page 59: ...e sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 If obstructing access to the small oven control board remove the burner support rail with jet holder assemblies attac...

Page 60: ...llowing the steps in Removing the Burner Support Rail page 24 4 Remove and retain the screw to detach the ground wire from the chassis see Figure 113 m 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 control board from all the plastic standoffs by lightly pre...

Page 61: ...ct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 If obstructing access to the HSI board remove the burner support rail with jet holder assemblies attached by following the steps in Removing the Burner Support Rail page 24 4 Remove and retain the ...

Page 62: ...emblies attached by following the steps in Removing the Burner Support Rail page 24 5 Remove the wire connector 6 Remove and retain the two screws securing the DSI module onto the chassis floor 7 Remove and then replace the DSI module if needed 4 5 21 LED Indicator Removal and Replacement Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing...

Page 63: ...Pull to detach the side connectors from the ignition module see Figure 119 page 64 5 Remove and retain the two screws securing the ignition module to the range chassis 6 Replace the ignition module if needed Figure 119 Ignition Spark Module Typical Models Shown 4 5 23 Door Latch Removal and Replacement Removing and replacing the door latch requires access from both the top and front of the range D...

Page 64: ...need you may need to remove the griddle grill first in order to gain access See Griddle Removal and Replacement page 26 and Grill Components Removal and Replacement page 32 5 Remove and retain the single screw that holds the access panel to the range chassis see Figure 121 6 Lift the access panel up and detach its two tabs from the chassis see Figure 121 page 65 7 Remove and retain the two T 20 sc...

Page 65: ...page 66 NOTE It is always recommended to label and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly identify their connections locations when re assembling Alternatively you can photograph prior to disconnecting for example with your mobile phone Figure 124 Door Latch Shown Removed from Cavity 1 Spade connectors 2 2 Piggyback wire connector 3 Door latch 10...

Page 66: ... blade terminals of the plunger switch there are four blade terminals on the plunger switch See Figure 126 page 67 3 For large oven plunger switch only Detach the four wire connectors from the four terminals on the plunger switch See Figure 123 page 66 NOTE It is always recommended to label and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly identify thei...

Page 67: ...steps in the Preparing the Range for Servicing page 21 2 First make a note how the wires are connected to the thermostat on the back side of the control panel and then disconnect the wire harnesses and connectors NOTE It is always recommended to label and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly identify their connections locations when re assembli...

Page 68: ...r for relevant information documentation and the correct part number when replacing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Follow all steps in Accessing Components under the Maintop page 21 3 From the back of the control panel first make a note of how the wires are connected and then detach only the wire connectors for all the LED in...

Page 69: ...onnect to the two manifold support brackets see Figure 132 7 At the bezels on the control panel remove the bezel screws and bezels that connect to the following components five position oven function selector three position oven function selector griddle grill control s oven temperature select switch es 8 Use a swivel head driver or an open end wrench to remove and retain the three nuts with lockw...

Page 70: ... see Figure 137 page 72 Figure 136 Tabs and Bracket Studs Shown on Control Panel 1 Tab 2 Studs 3 on bracket left side shown 12 After the control panel with bullnose attached has been removed see Figure 137 page 72 before replacing it remove the temperature gauge see Oven Temperature Gauge Removal and Replacement page 54 and the LED indicators see LED Indicator Removal and Replacement page 63 13 Us...

Page 71: ...the back side of the control panel and bullnose remove and retain the screws that secure the bullnose onto the control panel 15 Pull the bullnose off of the control panel and replace either or both of these parts if needed 16 When installing it may be easier to affix the brackets to the bullnose and control panel by placing a piece of double sided tape on the bracket This enables you to have the b...

Page 72: ... model the installation must be performed with adherence to all procedures and warnings cautions in the Installation Instructions manual Always check local building codes for the proper method of installation Local codes vary Installation electrical connections and grounding must comply with all applicable codes In the absence of local codes the appliance should be installed in accordance with the...

Page 73: ...uickFinder for relevant information documentation and the correct part number when replacing this component Figure 144 Typical Back Panel 1 Screw locations number varies per panel model 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove the backguard per Backguard and Island Trim Removal and Replacement procedure page 73 m Caution Be careful not to dama...

Page 74: ...ver see Figure 146 and Figure 142 page 74 3 If removing the crossmember cover Push the power cord through the receptacle on the crossmember cover so that you can remove it without having to detach the power cord wiring at the terminal block 4 If replacing the crossmember cover You will need to detach the power cord from the terminal block first see Electrical Wiring Connections at the Terminal Blo...

Page 75: ...n the single screw from the left side and the two screws from the right side see Figure 148 and Figure 149 4 Remove the dilution flue and replace if necessary Figure 148 Dilution Flue Shown Attached 1 Screw on left side of dilution flue 2 Screws 2 on right side of dilution flue Figure 149 Dilution Flue Removed 1 Location of screw at left side bracket 2 Location of screws 2 at right side bracket ...

Page 76: ...e Figure 150 Retain the washers and nuts see Figure 151 and make a note of how all the wires are connected to the different terminals Figure 151 Securing Power Supply Wire to Terminal 1 Flat washer 2 Supply wire 3 Cupped wire 4 Upper nut NOTE It is always recommended to label and tag all wires and harnesses prior to disconnecting them so as to correctly identify their connections locations when re...

Page 77: ...nto fan housing 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove the backguard per Backguard and Island Trim Removal and Replacement procedure page 73 3 Remove back panel per Back Panel Removal and Replacement procedure page 74 4 At the back of the range detach the wire connectors from the fan s Hall Effect sensor and make a note of which wires are co...

Page 78: ...mber when replacing this component Figure 154 Air Interlock Switch Figure 155 Bracket 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove the backguard per Backguard and Island Trim Removal and Replacement procedure page 73 3 Remove back panel per Back Panel Removal and Replacement procedure page 74 4 At the cooling fan remove and retain the nuts securin...

Page 79: ...ove the crossmember cover see Crossmember Cover Removal and Replacement page 75 5 Detach the wire connectors from the terminals and make a note of how the wires are connected NOTE It is always recommended to label and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly identify their connections locations when re assembling Alternatively you can photograph th...

Page 80: ... the gas tubes from the manifold arm Be careful not to bend the gas tubes see Figure 159 6 Remove the two solenoid valves from the manifold see Bake Burner Solenoid Removal and Replacement Back of Range page 82 NOTE Use pipe sealant on pipe threads only for example on the threaded end of the flared adapter and the threaded outlets on the manifold arm Never use pipe sealant on the flair connections...

Page 81: ...llow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove the backguard see Backguard and Island Trim Removal and Replacement page 73 3 Remove the back panels see Back Panel Removal and Replacement page 74 4 Remove solenoid valves from manifold arm see Figure 160 NOTE When removing a solenoid valve from the manifold arm see Figure 160 since it is secured with pipe...

Page 82: ...est 4 6 11 Bi Metal Gas Valve Removal and Replacement Back of Range There is a dedicated bi metal gas valve for each individual broil burner For 48 inch ranges the bi metal gas valves are located and accessible at the back of the range For 30 inch and 36 inch ranges the bi metal gas valves are located under the maintop see Bi Metal Gas Valve Removal and Replacement Under Maintop page 56 Be sure to...

Page 83: ... connections locations when re assembling Alternatively you can photograph the wire connections prior to disconnecting for example with your mobile phone 5 Use an adjustable wrench to remove the compression nuts and then detach the gas tubes at the inlet and outlet Be careful not to bend the gas tubes see Figure 164 6 Remove and retain the two screws that secure to the bi metal gas valve onto the ...

Page 84: ...g page 21 2 Remove the backguard see Backguard and Island Trim Removal and Replacement page 73 3 Remove the back panels see Back Panel Removal and Replacement page 74 4 Remove oven door see Oven Door Removal Installation page 88 NOTE It is recommended to remove the door to prevent weight or force applied from damaging the door and latch components 5 Remove oven trays 6 From inside the oven cavity ...

Page 85: ... Removal and Replacement page 73 3 Remove the back panels see Back Panel Removal and Replacement page 74 4 Remove oven door see Oven Door Removal Installation page 88 NOTE It is recommended to remove the door to prevent weight or force applied from damaging the door and latch components 5 Remove the oven trays 6 From the back of the range detach the lamp wire connectors 7 From inside the oven cavi...

Page 86: ...ce Manual for Thermador Pro Grand LP Gas Ranges Models PRL304EG PRL364EDG PRL364ELG PRL366EG PRL484ECG PRL486EDG PRL486EDPG PRL484ELG 58300000156573_ARA_EN_B Page 87 of 119 Figure 167 Oven Light Diagnostics ...

Page 87: ...page 88 Figure 168 Prying Locking Lever Downward with Screwdriver 3 Close the door until it stops against the locking levers while firmly grasping the door with both hands The open locking levers will hold the door open at a slight angle 4 Grasp the door firmly on the ends of the door handle and lift the door up there will be some spring resistance to overcome When the door is lifted sufficiently ...

Page 88: ...sm as a part of the hinge receiver you can adjust the door alignment by using the alignment screw that is located below each hinge hinge receiver slot 1 Make sure the door is installed correctly so it will not pose any danger by falling while adjusting the screw see Installing the Door page 88 2 Locate the alignment screw below the door hinge see Figure 170 and Figure 171 3 Use a T 27 driver to tu...

Page 89: ... Insulation 4 Plate 5 Shim ring 6 Fan 7 Nut 8 Cover 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove the backguard see Backguard and Island Trim Removal and Replacement page 73 3 Remove the back panels see Back Panel Removal and Replacement page 74 4 Remove oven doors see Oven Door Removal Installation page 88 NOTE It is recommended to remove the door...

Page 90: ...is always recommended to label and tag all wires and harnesses prior to disconnecting them so as to correctly identify their connections locations when re assembling Alternatively you can photograph the wire connections prior to disconnecting for example with your mobile phone Figure 175 Convection Motor Wire Connectors 9 Remove the six screws on the rear cover shield and pull the rear cover shiel...

Page 91: ...uring rear cover shield to bracket 12 Remove the bracket with fiberglass insulation attached to motor see Figure 179 Figure 179 Bracket and Insulation 1 Screw locations 4 that attach to rear cover shield 2 Fiberglass insulation 13 Wearing gloves remove and retain the fiberglass insulation 14 Remove and retain the three screws securing the bracket onto the motor see Figure 180 and Figure 181 and th...

Page 92: ...SI control board see Hot Surface Igniter Board Removal and Replacement page 62 Be sure to check QuickFinder for relevant information documentation and correct part numbers when replacing any of these components 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 Fiberglass Wear gloves when handli...

Page 93: ...ire spade connectors see Figure 183 and Figure 184 and make a note of which wires are connected to each of the two different terminals NOTE It is always recommended to label and tag all wires wire connectors and harnesses prior to disconnecting them so as to correctly identify their connections locations when re assembling Alternatively you can photograph the wire connections prior to disconnectin...

Page 94: ...the back of the range 4 Replace the HSI if necessary 4 7 5 2 Broil Burner Removal and Replacement Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component Figure 186 Broil Burner Assembly 1 Broil Burner 2 Venturi tube 3 Orifice holder bracket 4 Elbow connector with orifice attached 1 Follow all steps in Broil Burner Components Re...

Page 95: ...cle Figure 189 Bracket at Broil Burner Receptacle 4 From inside of the range use a 9 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 see Figure 185 on page 95 and Figure 190 and then remove the HSI retaining bracket NOTE If you have not removed the HSI you ll now remove the HSI retaining bracket with the HSI a...

Page 96: ...ket If either the elbow connector or the orifice needs replacing replace the broil burner assembly Figure 192 Broil Burner Assembly Shown Removed 4 7 6 Bake Burner Components Large Oven Removal Replacement Both the large and small oven have bake burners whose components require access from both the front and back of the range 4 7 6 1 Replacing the Bake Burner Large Oven Be sure to check QuickFinde...

Page 97: ... handling sharp bake burner components 7 Remove the reflector from the burner box see Figure 194 Figure 194 Reflector Figure 195 Reflector Figure 196 Inside Bake Burner Box Shown with Reflector Removed 1 Brackets that attach to reflector 2 Bake burner bracket and two screws 3 Hot Surface Igniter HSI 4 Electrode flame sensor 5 Bake burner 8 Remove and retain the two screws to remove the straight br...

Page 98: ...9 NOTE Although the air shutter is optimally set in the factory it may be adjusted by unscrewing the adjustment screw and rotating the air shutter so that its opening is more open or closed see Figure 199 and Adjusting Bake Burner Flame on page 14 11 NOTE When installing the bake burner make sure that it snaps correctly into place so that the air shutter Figure 199 is aligned with the orifice asse...

Page 99: ...eat up enough in a short time frame the electrode will close the solenoid valve to avoid gas build up in the burner Be sure to check QuickFinder for relevant information documentation and the correct part number when replacing this component 1 Perform all steps in Replacing the Bake Burner Large Oven page 97 2 From the back of the range remove the crossmember panel see Crossmember Cover Removal an...

Page 100: ...r box 7 Replace the HSI if needed NOTE When installing the HSI onto the burner box make sure the small bracket is secured onto the HSI as shown in Figure 204 The screw goes through the holes on both the HSI and the small bracket fastening them both onto the burner box Figure 204 Small Bracket Shown Removed from HSI Left and Position when Attached to HSI Right NOTE When installing the HSI feed the ...

Page 101: ... the electrode also functions as a flame sensor that is if the electrode does not heat up enough in a short time frame the electrode will close the solenoid valve to avoid gas build up in the burner The direct spark ignition DSI module is used whenever the electrode is the igniter for the bake burner whether or not the broil burner uses the HSI or electrode as the igniter See DSI Module Removal an...

Page 102: ...he two screws that secure the bracket to the burner box chassis see Figure 209 Then remove the electrode and bracket 4 Replace the electrode if needed Figure 208 Electrode 1 Electrode terminal 2 Location of screw that secures electrode onto bracket Figure 209 Electrode Bracket 1 Location of screw that secures electrode onto bracket 2 Location of screws 2 that secure bracket to burner box Gas Leak ...

Page 103: ...mounted onto the front of the burner box 2 Portal for aligning orifice assembly and bake burner 3 Bracket underneath burner box 4 Receptacle on bracket for green electrode wire 1 Perform all steps in Replacing the Bake Burner Large Oven page 97 2 From the back of the range remove the crossmember panel see Crossmember Cover Removal and Replacement page 75 3 From inside the burner box remove and ret...

Page 104: ...erviced using a gas leak detector or bubble test 4 7 7 Bake Burner Components Small Oven Removal Replacement On the 48 inch ranges both the large and small oven have bake burners whose components require access from both the front and back of the range 4 7 7 1 Replacing the Bake Burner Small Oven Be sure to check QuickFinder for relevant information documentation and the correct part number when r...

Page 105: ... see Figure 215 and Figure 216 Figure 215 Baffle Figure 216 Burner Box with Baffle Removed 9 From inside the burner box remove and retain the four screws on the cover plate and then slide the cover plate out of the burner box see Figure 217 and Figure 218 on page 107 10 At the back of the range detach the HSI wire connector see Figure 219 on page 107 11 At the back of the range use gloves to reach...

Page 106: ...ode Wire Portal Shown from Back of Range 1 Burner box 2 HSI wire connector 3 Portal for green electrode wire wire shown 12 From inside the burner box remove and retain the two screws that secure the bracket onto the front of the burner box see Figure 220 on page 108 This bracket holds one end of the bake burner and also holds the orifice elbow connector assembly NOTE In order to remove the bake bu...

Page 107: ... Assembly Burner Box Shown Removed for Reasons of Clarity 1 Screws holding bracket for the bake burner and orifice elbow connector assembly Figure 221 Bake Burner 1 Tab inserts into slot in burner box 2 Receptacle that receives bracket pin 3 Air shutter adjusting screw 4 Air shutter opening Figure 222 Bracket 1 Pin holds end of bake burner 2 Screws 2 that attach to front of burner box 3 Receptacle...

Page 108: ...t it is secured in its correct installed position while you install the pin of the bracket with elbow connector and orifice securely attached onto the burner receptacle c From inside the burner box re attach the two screws through the burner box chassis onto the respective bracket holes see Figure 222 on page 108 and Figure 223 Both sets of holes must be aligned Be careful so that the bracket s pi...

Page 109: ...cket is secured onto the HSI as shown in Figure 204 page 101 The screw goes through the holes on both the HSI and the small bracket fastening them both onto the burner box NOTE When installing the HSI feed the harness with wire connector through the portal at the back of the range as shown in Figure 219 page 107 Gas Leak Testing With electrical power off carefully check for gas leaks at each gas c...

Page 110: ...rminal see Figure 219 page 107 9 Remove and retain the single screw that secures the electrode to the bracket see Figure 208 page 103 as well as the two screws that secure the bracket to the burner box chassis see Figure 209 page 103 Then remove the electrode and bracket 10 Replace the electrode if needed Gas Leak Testing With electrical power off carefully check for gas leaks at each gas componen...

Page 111: ...ould be able to access and remove the bake burner bracket and orifice assembly without removing the bake burner box If you need to lift the burner box out of the cavity for another reason do the following 1 Per respective procedures make sure the burner has been removed wire connections for the HSI and electrode have been detached and that the orifice assembly is not in the way 2 Wearing gloves pu...

Page 112: ... check QuickFinder for relevant information documentation and correct part numbers when replacing any of these components Figure 228 Door Handle Components 4 7 8 1 Removing Door Handle Components 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove the oven door follow all warnings and steps for the Oven Door Removal Installation procedure page 88 3 Remov...

Page 113: ...the right and left endcaps pull the door handle tube out from the endcaps 10 Replace the door handle components if needed 11 After replacing door handle components install the oven door and test for proper positioning follow all warnings and steps for Installing the Door page 88 Figure 231 Hex Head Cap Screws and Washers 1 Hex head cap screws and washers 4 of each left side shown 4 7 9 Door Hinge ...

Page 114: ...fter Door Removal 1 Hinge locking lever 2 Hinge thumb 3 Use a large deep well socket or similar tool to securely place over the hinge thumb and then press the tool downward just a little bit towards the base of the door see Figure 233 and hold it there 4 While still holding the hinge in the downward position use a tool not your fingers like a flat blade screwdriver to press the hinge locking lever...

Page 115: ...Figure 235 Screws for Hinge Removal 1 Screws 2 7 Repeat steps 3 through 6 for the hinge at the other side of the door 8 Turn the door upside down so that the porcelain surface is facing down 9 Remove the four screws from the inner panel see Figure 238 page 117 10 Lift the inner panel off of the door and then remove the hinge see Figure 239 page 117 11 Replace hinges if needed Figure 236 Screws for...

Page 116: ...acing this component 1 Follow all safety precautions and steps in Preparing the Range for Servicing page 21 2 Remove oven door see Oven Door Removal Installation page 88 3 Remove and retain the screws on the bracket and then remove the bracket see Figure 240 and Figure 241 page 118 Figure 240 Bracket 4 Starting from one end of the gasket while carefully working your way to the other end gently pul...

Page 117: ...r Removal Installation page 88 3 Remove and retain the screws from the kick panel see Figure 243 and then lift the kick panel off the range chassis Figure 243 Typical Kick Panel 1 Location of screws 2 NOTE The wiring diagram for the range is located on the back side of the kick panel see Wiring Diagram page 5 5 BEFORE RETURNING APPLIANCE TO SERVICE After you have finished all testing and servicing...

Page 118: ...nce After cleaning or polishing always rinse the cleaning polishing materials with clear water and wipe dry with a clean soft non abrasive cloth Clean the range with caution Do not use flammable cleaners to clean the range Avoid steam burns do not use a wet sponge or cloth to clean the range while it is hot Do not use any type of aerosol cleaner on or around the rangetop when hot Some cleaners pro...

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Thermador PRL304EG, Service Manual

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