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Whirlpool 4322452, Service Manual

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INTRODUCTION

This program is designed to teach the servicer basic skills in handling common
service procedures for gas ranges. This program does not cover the diagnosis and
repair of all range problems and components, (oven liner, wiring harness, etc.).

PROGRAM OBJECTIVE

Upon completion of this program, the participants will be able to identify the location
of major range components, as well as diagnose problems, and remove and repair
the components causing the problem.

INSTRUCTIONS

This program has the following sections:

•

Fundamental Properties of Gas

•

Pressure Regulators

•

The Cooktop Burner System

•

The Oven Burner System

•

Natural And L.P. Gas Conversion

•

Testing The Components

Phillips Screwdriver

Long-Nosed Pliers

Adjustable Wrench

Pipe Sealer

Special Tools:

•

Volt-Ohmmeter

TOOLS YOU WILL NEED

Summary of Contents for 4322452

Page 1: ...GAS RANGES 4322452 ...

Page 2: ...er probes 4 Touch the component terminals or wires with the meter probe tips only 5 Touch the meter probe tips only on the terminals being checked Touching other components could damage good parts PARTS QUALITY An important step in the appliance repair procedure is the selection of FSP FACTORY SPECIFICATION PARTS as replacements Use of fits all or look alike parts could result in early parts failu...

Page 3: ...nturi 3 9 Burner Head 3 10 Flame Characteristics 3 11 Improper Flame Diagnostics 3 15 Cleaning The Burners 3 16 Standing Pilot Ignition System 3 17 Operation 3 17 Relighting A Standing Pilot 3 18 Adjusting The Pilot Flame Height 3 19 Cleaning The Pilot 3 20 Electronic Ignition System 3 21 Operation 3 21 Conventional Burner 3 23 Sealed Burner 3 24 Electronic Ignition Diagnostics 3 25 Performance Ch...

Page 4: ... Check 5 5 Testing The Components 6 1 Warning Labels 6 1 General Information 6 2 Testing An Oven Glo Bar Ignitor 6 3 Testing An Ignitor Switch 6 4 Testing An Oven Light Switch 6 5 Testing An Oven Temperature Sensor 6 6 Testing An Oven Door Latch 6 7 Testing A Gas Safety Valve 6 9 Testing The Gas Control Valves 6 10 Testing The Gas Pressure Regulator 6 11 Troubleshooting Chart 6 12 Schematic Diagra...

Page 5: ...gram the participants will be able to identify the location of major range components as well as diagnose problems and remove and repair the components causing the problem INSTRUCTIONS This program has the following sections Fundamental Properties of Gas Pressure Regulators The Cooktop Burner System The Oven Burner System Natural And L P Gas Conversion Testing The Components Phillips Screwdriver L...

Page 6: ...vi NOTES ...

Page 7: ...U is equal to the amount of heat needed to raise one pound of water one degree Fahrenheit see Figure 1 1 1 B T U the heat necessary to raise 1 lb of water 1 F A wooden kitchen match will produce approximately 1 B T U of heat energy F 120 110 100 90 80 70 60 50 40 30 20 10 0 F 120 110 100 90 80 70 60 50 40 30 20 10 0 90 F 91 F HEAT ENERGY PRODUCED BY BURNING GAS ONE POUND OF WATER Figure 1 1 ...

Page 8: ...d has a heat value of between 700 and 900 B T U per cubic foot 3 MANUFACTURED GAS Manufactured Gas is made from coal and petroleum It is lighter than air and has a heat value of between 500 and 700 B T U per cubic foot 4 LIQUEFIED PETROLEUM L P GAS Liquefied Petroleum L P Gas consists of the heavy hydrocarbons propane or butane Both of these gases are converted from a gaseous to a liquid state by ...

Page 9: ... Has A Heat Valve Of 700 to 900 B T U Per Cubic Foot Specific Gravity Is 0 5 Category 3 Manufactured Gas Made From Coal Petroleum It Has A Heat Valve Of 500 to 700 B T U Per Cubic Foot Specific Gravity Is 0 38 To 0 40 Category 4 Liquefied Petroleum L P Gas Made Of Propane Or Butane Is Converted To A Liquid State Under Moderate Pressure For Easy Transportation In Pressurized Tanks Propane Has A Hea...

Page 10: ...2 44 100 200 300 Zero Butane Propane L P Natural Mixed Manufactured Fahrenheit Degrees BOILING POINT OF GAS F U E L O X Y G E N HEAT THE COMBUSTION PROPERTIES Figure 1 2 Figure 1 3 Gases will ignite at temperatures between 900 F and 1200 F A proper mixture or ratio of gas and air is needed to produce a flame If the air to gas ratio is not correct incomplete combustion or an improper flame will res...

Page 11: ...side the buildings see Figure 1 6 Gas Meter Service Regulator Gas Main 25 60 Pounds In House Gas Supply Line Water Heater Range Furnace Dryer Appliance Regulator 4 7 WCP 1 4 Pound 25 To 60 Pounds Pressure Main 7 WCP 1 4 Pound Pressure DISTRIBUTION REGULATOR SERVICE REGULATOR SERVICE REGULATOR A gas piping system is able to supply gas to all of the appliances in a building at one time Ranges genera...

Page 12: ...een 10 and 12 inches water column pressure Each appliance usually has its own pressure regulator to more accurately meet the designed requirements see Figure 1 8 Service Regulator L P Gas Main 28 WCP 1 lb 10 12 WCP In House Gas Supply Line Water Heater Range Furnace Dryer L P Gas Tank Appliance Regulator 10 Figure 1 8 ...

Page 13: ...as pressure to the desired level for the particular application see Figure 2 1 This is the final stage of gas regulation It controls gas at a lower pressure and flow rate Appliance Pressure Regulator Figure 2 1 Manual Gas Shutoff Valve Fitting Flexible Gas Line Fitting Pressure Regulator It is recommended that the pressure regulator be connected to a manual gas shutoff valve via a flexible line de...

Page 14: ...ooktop Burners Gas Outlet To Oven Burners Manual Gas Shutoff Valve To Oven Burner As the gas pressure against the diaphragm drops the tension from the spring pushes the diaphragm downward moving the tapered plug away from the valve seat allowing more gas pressure to flow to the burners see Figure 2 4 Additional gas may then flow into the regulator pushing the diaphragm back up thus restricting the...

Page 15: ... shutoff on some pressure regulators will allow the gas to be turned off to the oven burners during service to allow gas flow to the cooktop to remain on The gas to the oven burners is turned off by moving the manual shutoff lever in the direction shown in Figure 2 6 Cap L P Position Tension Spring OPEN POSITION Diaphragm Gas Inlet Gas Outlet To Cooktop Burners Gas Outlet To Oven Burners Manual Sh...

Page 16: ...gm with the eraser end of a pencil Usually the appliance regulator is replaced rather than serviced since it has few replaceable or serviceable parts and is a relatively inexpensive device VENTING Pressure regulators contain an air vent in the upper chamber to allow a free flow of air in and out of the chamber during operation see Figure 2 7 The vent s secondary purpose is to safely control the fl...

Page 17: ...BEEW E SERIAL TGENG006 120V 60 HZ 10A BTU RATINGS RF LF RR LR BAKE BROILER 9500 9500 6500 7500 16500 10000 8500 8500 5500 6500 15500 9000 4 WC NAT 10 WC LP When it becomes necessary to measure these pressures there are two instruments available that you can use a manometer and a magnehelic gauge A manometer is basically a U shaped tube with a scale marked in inches of water column To prepare and u...

Page 18: ...ter To use the gauge l Check the appliance model serial plate and note the gas pressure rating see Figure 2 8 on the previous page 2 Turn off the gas pressure to the range 3 Remove a burner from the appliance and place the free end of the tubing over the burner orifice 4 Turn on the gas supply to the range 5 Read the gas pressure directly from the scale of thegauge Itshouldmeasurewithinthepressure...

Page 19: ... to the individual burners The valves on all Whirlpool ranges are push to turn types to keep them from being turned on accidentally When the valve is turned on gas flows through the valve and out an orifice ORIFICE The orifice is a special fitting at the outlet of the valve that controls the amount of gas released through the valve The orifice controls the gas flow and directs it into the venturi ...

Page 20: ...mpletelyopenbymanuallyrotatingthevalvestemfrom0 to90 Thesecond type of valve has a stem rotation of 220 The 220 gas valve has a low flame adjustment screw that is located inside the shaft of the valve stem see Figure 3 4 To adjust the control use a small screwdriver and turn the control until the desired flame is produced Mounting Screw Rubber Washer Rubber Washer Gas Openings Gas Manifold Pipe Or...

Page 21: ...threaded seat a chamber and a metered hole The threaded seat allows the orifice to be securely fastened to the burner valve The chamber is used as a passageway to allow gas to flow through the orifice opening The orifice is used to control or limit the amount of gas going to the burner This type of orifice is not adjustable Orifice Natural Gas Orifice Drill Size No Stamped On Top L P Gas Orifice D...

Page 22: ...gas is higher than natural gas it takes less cubic feet of L P gas to produce the same amount of heat An L P orifice will always be smaller than a natural gas orifice with an equivalent B T U rating see the following Orifice Specifications Chart It is also important to remember that much more air is needed with the L P gas system 24 cu ft than with the natural gas system 10 cu ft The identificatio...

Page 23: ...anging orifices by using a univer sal orifice The universal orifice consists of an L P gas insert that is threaded into a cap orifice This insert is actually an orifice itself When natural gas is used the cap is in the position shown in Figure 3 7 Gas enters through both the cap and the insert The amount of gas leaving the orifice is controlled by the size of the cap orifice Figure 3 7 Figure 3 8 ...

Page 24: ...he orifice may not be secured because of the cross threading causing a small gas leak The mixture will again be too lean and inefficient burning will occur c Theorificesizemaybeincorrect IfaconversionismadefromnaturaltoL P gas theorifice mustbechangedtomaintainthedesiredheatoutput Theorificesizemayalsobetoosmall due to a high consumption rate so that the burner cannot meet its maximum B T U output...

Page 25: ...Page 3 7 PERFORMANCE CHECK 1 Remove the gas valves 2 Remove the orifices ...

Page 26: ...ed with the correct amount of air referred to as the air gas ratio A correct air gas ratio will result in a flame that is stable without yellow tips The ratio depends upon the fuel gas type being used Ten cubic feet of air are needed to completely burn one cubic foot of natural gas 10 to 1 ratio and twenty four cubic feet of air are needed to completely burn one cubic foot of L P gas 24 to 1 ratio...

Page 27: ... flow to the burner from the orifice Air enters the burner through the venturi tube and is used as a pathway for gas as well as an area for gas and air to be mixed together for combustion 3 A Burner Head to provide an exit for gas so it can be ignited The exits are normally holes or slots called burner ports Figure 3 11 Venturi Burner Head Air Shutter AIR SHUTTER VENTURI An inlet for primary air i...

Page 28: ...urner head disperses the gas air mixture for ignition In addition to the burner ports at the top of the burner head there are also ports along the side of theburner calledchargeportsandclimberports Thechargeportsinjectgasdowntheflashtube to be ignited by the pilot flame The climber ports allow the flame to climb the side of the burner head and ignite the gas at the top ports Figure 3 13 Flash Tube...

Page 29: ...ter cone Too Much Primary Air As the primary air is increased the gas air mixture burns at a faster speed like fanning a flame The additional primary air results in a greater volume of air gas flow through the burner ports With increased delivery pressure and a faster burning flame the result is a flame that blows straight out of the burner and burns with a sound similar to a blow torch The flames...

Page 30: ...that would be consumed in the inner cone pass into the outer cone Thesizeoftheouterconeisalsoreducedbythelackofprimaryair Theouterconecannotconsume the volume of by products flowing from the inner cone A percentage of these by products flow into the outer envelope where the carbon content of the by product is burned causing the flame to have yellow tips see Figure 3 16 Figure 3 16 Outer Envelope Y...

Page 31: ...fadjustmenteasilybyputtingexcessiveweightonthem forexample by leaning on them The distance from the highest point of the burner to the top of the grate should be approximately 3 4 see Figure 3 19 Figure 3 19 The over fueled burner has more of a normal flame structure and less of a blowing noise than a burner with too much primary air The easiest way to determine whether the burner is over fueled i...

Page 32: ...n quenching occurs see Figure 3 20 the customer may complain of a chemical odor This odor results from the Aldehydes being released from the flame as one of the by products of incomplete combustion Some customers may associate this odor with a gas smell but the two odors are quite different By examining the flame length between the burners and other components and by looking for an out of place co...

Page 33: ...d adjust the gas pressure Flame is yellow 1 Insufficient primary air 2 Blocked primary air shutter 3 Oversized burner orifice 1 Adjust primary air shutter 2 Clean primary air shutter adjust for proper air gas mixture 3 Replace burner orifice Flame is noisy rumbles or gurgles 1 Excessive primary air 2 Excessive gas pressure 1 Clean primary air shutter adjust for proper air gas mixture 2 Use a manom...

Page 34: ...nter a main burner Whether or not the burner is operating dust can still be drawn into the burner through the air shutter The debris can clog the venturi orifice or burner ports Again this type of clogging can reduce if not stop the flow of gas through the burner In addition the primary air shutter itself can become blocked restricting the flow of primary air into the burner In any event cleaning ...

Page 35: ...r Pilot assemblies consist of a gas supply tube and an adjustment screw that controls the amount of gas flow to the pilot To produce a pilot flame gas is supplied through the gas supply tube see Figure 3 23 and directed toward the pilot opening or port As the gas is available it is manually lit The pilot flame is usually set to a height of approximately 1 4 This is accomplished by turning the pilo...

Page 36: ...pilot flame The burning gas from the pilot also helps to draw gas through the tube for combustion Flash Tube Pilot Flame Inside Shield Pilot Flame Charge Ports Climber Ports Top Burner Ports Flash Tube Figure 3 25 RELIGHTING A STANDING PILOT Caution If the pilot has been out for some time and you detect a strong odor of gas ventilate the room before trying to relight the pilot Turn off all range c...

Page 37: ...urn off the controls and prop open the cooktop 2 Using a screwdriver turn the needle valve screw slowly in the direction necessary to set the size of the pilot flame as shown in Figure 3 27 The flame should have a sharp blue cone that is approximately 1 4 high as shown in the inset 3 Lower the cooktop Pilot Gas Line Adjustment Screw Figure 3 27 1 4 Flame Bracket Proper Flame Size Inset ...

Page 38: ...eed to be cleaned To clean the pilot insert a straight pin into the pilot opening as shown in Figure 3 28 and move it up and down gently being careful not to enlarge or deform the opening If there is a protective metal shield over the pilot that prevents you from reaching the opening remove it by pressing in on the tabs on either side and unhooking it Straight Pin Shield Pilot Opening Figure 3 28 ...

Page 39: ...odule by opening and closing the circuit Theignitorswitchesaremountedonthestemofeachburnercontrolvalve andarerotary actuated There are two types of switches used on Whirlpool ranges One is for a 90 valve shown in Figure 3 29 and the other is for a 220 valve Each gas valve has its own ignitor switch The ignitor switches are wired in parallel IGNITOR SWITCH TO IGNITOR SPARK MODULE Burner Off Switch ...

Page 40: ...ustments that can be made to the module and it is serviced only as an assembly The system operates at very low amperage 4 milliamps so that the high voltage pulses or sparks present no severe shock hazard A Surface Burner Ignitor is a metal rod with a ceramic insulating body that is wired directly to the ignitor spark module Pulses from the ignitor module cause the ignitor to arc to the ground str...

Page 41: ...tors x The pulses cause a spark y to occur between the spark ignitor electrode and the ground strap bracket z The gas and air mixture at the burner head flows through the three climber ports in the side of the head and into the flash tube As gas flows through the flash tube it is ignited by the spark The combusted gas flashes back through the tube and ignites the burner Refer to Figure 3 32 for th...

Page 42: ...manifold t through the open valve As gas passes through the valve and its orifice it is directed into the venturi u where it mixes with primary air to create the proper mixture necessary for combustion At the same time line voltage is applied through the ignitor switch v to the ignitor spark mod ule w which produces high voltage pulses to all of the spark ignitors x The pulses cause a spark y to o...

Page 43: ...switch pull the leads from the switch touch the bare lead ends together and see if the ignitor sparks CAUTION When testing these switches do not forget that they operate on 110 volts so do not touch the lead ends or you will receive an electrical shock Use a pair of insulated needle nose pliers to pull the leads off the switch Iftheignitorswillnotstopsparking usuallyoneoftheignitorswitcheshasshort...

Page 44: ...Page 3 26 PERFORMANCE CHECK 1 Remove the burners 2 Remove the ignition system ignitor spark module ignitor switches and surface burner ignitors ...

Page 45: ...see Figure 4 1 is controlled by two very important mechanical components The first is a thermostat that is mounted on the manifold pipe and accessible to the customer and the other is an oven safety valve that controls the gas flow into the oven burner If either of these components is not working properly the system will not function The burner air shutter and venturi are also critical components ...

Page 46: ...perates based on the temperature it senses in the oven cavity O F F N A T L P Oven Thermostat Main Gas Line Pilot Gas Line Sensing Bulb Capillary Tube Manifold Gas In Figure 4 2 Orifice Hood Heater Sensing Bulb Capillary Tube Gas Inlet From Thermostat Cold Sensor Valve Closed No Gas Flow Safety Valve The Oven Safety Valve is also a hydraulic valve that has a gas inlet line and a gas port that is m...

Page 47: ...ot Flame Standing Pilot Assembly When the thermostat is turned ON to any temperature its primary function is to increase the flow of gas to the oven pilot assembly so that the standing pilot flame enlarges to create a larger standing pilot or a heater pilot flame This larger flame is deflected by a flame spreader see Figure 4 5 to heat the sensing bulb from the safety valve and hydraulically open ...

Page 48: ...ts Sensor Valve Opens Gas Flows To Oven Burner Pressure Forces Contact Against Switch Opens Valve Safety Valve Gas Safety Valve Open Figure 4 6 Gas Safety Valve Closed When the oven reaches the selected temperature the sensing bulb for the thermostat closes the thermostat gas lines and reduces the heater pilot flame back to a smaller standing pilot flame With no heater pilot flame the sensing bulb...

Page 49: ... Figure 4 8 Inset LIGHTING THE OVEN PILOT To light the pilot perform the following steps see Figure 4 9 1 Turn off all the range controls 2 If your range is equipped with a broiler drawer open it and wait five minutes for any gas inside the range to dissipate 3 Remove the baffle and oven bottom 4 Hold a lighted match near the tip of the pilot on the burner assembly until a flame appears 5 Replace ...

Page 50: ...n create a very efficient system that is safe and dependable Unlike the mechanical system that works with a sensor and capillary tubetooperatethesafetyvalve thissystemoperatesentirelyonanelectricalsystemrequiring120 volts AC alternating current Oven Thermostat Oven Burner Sensing Bulb Capillary Tube Main Gas Inlet Glo Bar Ignitor Safety Valve Manual Gas Shutoff Valve Pressure Regulator 120 Volt Su...

Page 51: ...ure monitored in the oven cavity When the thermostat is turned to the ON position contacts within the thermostat close to complete an electrical circuit see Figure 4 11B As the oven heats up to a selected temperature the internal pressure within the sensing bulb increases until the thermostat contacts are forced open see Figure 4 11C As the oven cools the pressure from the sensor actuator decrease...

Page 52: ...istance of the ignitor should be between 50 and 1100 Ω At room temperature the ignitor can not provide enough amperage to properly operate the safety valve see Figure 4 14 Amperage voltage divided by resistance cold ignitor Amperage 120 volts 500 ohms Amperage 24 Figure 4 14 As the ignitor heats toward 2000 F its resistance drops to approximately 40 to 45 Ω and can then operate the safety valve se...

Page 53: ...es a Single Safety Valve that is bimetal operated see Figure 4 16 It has one gas inlet and one gas outlet for the combination Bake and Broil burner The safety valve uses an electrically operated device at the gas outlet to control the gas flow to the oven burner The device consists of an electric heater coil wrapped around a bimetal strip One end of the bimetal is riveted to the plate of the valve...

Page 54: ...120 Volt Supply Terminal Safety Valve When current flows through the ignitor heat is applied to the bimetal strip The amount of heat necessary to warp the bimetal enough to open the valve requires 3 0 amps of current flow in the circuit see Figure 4 18 The reason the valve is designed not to open below 3 0 amps is to insure that the temperature of the oven ignitor is above 1800 F before the valve ...

Page 55: ... the air shutter The debris can clog the venturi orifice mixing tube or burner ports Again this type of clogging can reduce if not stop the flow of gas through the burner In addition the primary air shutter itself can become blocked restricting the flow of primary air into the burner In any event cleaning the burner normally eliminates most of the dirt buildup Also it is a good practice to keep th...

Page 56: ...igure 4 22 SELF CLEANING SYSTEM All Whirlpool Self Cleaning Gas ranges use two burners in the oven to provide even heating during the Bake and Broil functions and higher temperature during the Self Clean cycle see Figure 4 22 To provide each of these features the system incorporates a bake burner that operates just like the Glo Bar Ignition System already discussed plus an additional broil burner ...

Page 57: ...operated devices one for each outlet to control thc gas flow The devices consist of an electric heater coil wrapped around a bimetal strip One end of the bimetal is riveted to the plate of the valve The other end has a rubber seat attached to it that covers a gas outlet At room temperature the spring force of the bimetal presses the rubber seat against the gas outlet When current flows through the...

Page 58: ...and closing the relays operate the various customer selected cycles Figure 4 26 OVEN CONTROL TRANSFORMER P5 P4 P3 1 P2 1 P3 4 P3 2 P2 4 P2 2 LATCH SOLENOID RELAY BROIL RELAY BAKE RELAY OVEN CONTROL TRANSFORMER P5 P4 P3 1 P2 1 P3 4 P3 2 P2 4 P2 2 LATCH SOLENOID RELAY BROIL RELAY BAKE RELAY OVEN CONTROL Oven Off Bake Cycle Broil Cycle TRANSFORMER P5 P4 P3 1 P2 1 P3 4 P3 2 P2 4 P2 2 LATCH SOLENOID RE...

Page 59: ...y closed position of the opposite relay is needed to complete the circuit N L1 W W BU N C N C N C N C BU R R P3 1 P2 1 P3 4 P3 2 P2 4 P2 2 BROIL RELAY BAKE RELAY BAKE VALVE BROIL VALVE BAKE IGNITOR BROIL IGNITOR N L1 W W BU BU R R P3 1 P2 1 P3 4 P3 2 P2 4 P2 2 BROIL RELAY BAKE RELAY BAKE VALVE BROIL VALVE BAKE IGNITOR BROIL IGNITOR Figure 4 27 Figure 4 28 BAKE BROIL ...

Page 60: ... for welded relays if OK then replace temperature sensor E0 Sensor open E1 Sensor shorted E2 Non self clean over temperature usually 550 F E3 Self clean over temperature usually 900 F F5 Latch Subsystem Failure Check for proper latch movement check for proper switch actuation check for proper clearance between latch and door E0 Latch switch does not agree with door switch i e Iatch in locked posit...

Page 61: ...Page 4 17 PERFORMANCE CHECK 1 Remove the oven s operating system burners safety valves and ignitors ...

Page 62: ...atch NOTE The oven sensor is also a critical component of the system because it monitors temperatures needed to control the system The Self Clean System begins at the control board see Figure 4 29 As the CLEAN function is programmed into the control and the START pad is pushed the latch relay on the microcomputer board closes for less then a second This allows just enough time to provide a 110 vol...

Page 63: ...en the oven light circuit so that the light cannot be operated during the Clean function b Provide a logic circuit for the electronic board to indicate that the door is locked and that the Clean cycle can continue L1 N BK W OVEN CONTROL LATCH SOLENOID RELAY LATCH SOLENOID P4 P1 3 P1 5 BU GY Y Y W W W BK R DOOR LATCH SWITCH DOOR LATCH SWITCH DOOR LIGHT SW OVEN LIGHT MANUAL OVEN LIGHT SWITCH N O N O...

Page 64: ...1 1 1 SEC PULSE When the oven temperature reaches 600 the oven door cannot be opened until the oven cools down to below 550 At that point the latch solenoid relay will close for just a second and provide a 120 VAC pulse to the latch solenoid see Figure 4 31 This unlocks the door and toggles the door latch switches to their normal state Solenoid Plunger Retracted Actuator Rod DOOR UNLOCKED Door Lat...

Page 65: ...e In other words the range uses less fuel and more air with L P gas to create the same amount of heat with natural gas L P gas is also distributed and used at higher pressure 11 WCP than natural gas 4 WCP This is why the pressure regulator must be converted when changing from natural gas to L P operation refer to the following chart CHARACTERISTICS NATURAL PROPANE BUTANE Colorless Odorless Non Tox...

Page 66: ...A or the regulator cap see Figure 5 1B CONVERTING COOKTOP BURNERS The cooktop burners can be converted from natural to L P gas operation by changing the orifice spuds on the gas valves The L P orifice spuds are packed in the literature package that is shipped with the range Always make sure that the correct spud is installed in the valves at the proper location see Figure 5 2 The spuds are color c...

Page 67: ...e oven burners use universal orifice hoods To convert the oven burners use a 1 2 combination wrench and turn the orifice hood 2 to 2 1 2 turns so it is just against the L P orifice inlet DO NOT OVERTIGHTEN the hood or you will damage the inlet The burner flame cannot be properly adjusted if this conversion is not made In self cleaning ovens both burners must be converted using the same procedure s...

Page 68: ...ue flame The oven burner flame should be approximately 3 4 high and have a distinct blue flame If the flame is noisy or blowing off the burner it is getting too much air If the flame is soft and lazy it is not getting enough air Air adjustments can be made by adjusting the air shutter at each burner see Figures 5 5A B C NOTE There is no air adjustment for sealed burner cooktops Air Shutter Figure ...

Page 69: ...Page 5 5 PERFORMANCE CHECK 1 Convert the pressure regulator cooktop and oven burners for use with L P gas ...

Page 70: ...Page 5 6 NOTES ...

Page 71: ...BELS This manual is intended for factory service technicians only We recommend that customers DO NOT service their own units because of the complexity and risk of high voltage electrical shock The following information should be read carefully ...

Page 72: ...ontopburners andsiliconcarbide glow bar oven igniters with combination bake and broil burners 5 The following pages provide a general procedure for troubleshooting each of the major components in the range The component locations are shown in Figure 6 1 CONSOLE CONVENTIONAL BURNER DOOR LATCH GAS VALVE SPARK IGNITOR SWITCH MANUAL OVEN LIGHT SWITCH GAS SAFETY VALVE AUTOMATIC OVEN LIGHT SWITCH OVEN L...

Page 73: ... OVEN GLO BAR IGNITER If the glo bar ignitor see Figure 6 2 does not glow perform the following steps to test it 1 Turn off the gas and electrical power to the range 2 Disconnect the oven igniter quick disconnect plug from the main harness connector 3 Connect an ohmmeter across the wire ends or terminals of the glo bar If the meter reads over 1100 Ω replace the igniter Carborundum Ignitor Figure 6...

Page 74: ... 6 3A is located on the gas control valve stem and closes when the knob is turned to the LITE position see Figure 6 3B to provide power to the ignitor spark module To test a switch 1 Turn off the gas and electrical power to the range 2 Disconnect the wires from the ignitor switch terminals 3 Set the ohmmeter to the R x 1 position 4 With the control knob in the OFF position touch the meter leads to...

Page 75: ...w NOTE It may be necessary to pull the range out of its location To test a switch 1 Turn off the gas and electrical power to the range 2 Set the ohmmeter to the R x 1 position 3 Touch the meter leads to the rocker or pushbutton switch terminals and operate the switch The meter should switch between continuity and no continuity as the switch is operated see the following illustrations If the meter ...

Page 76: ...heRTDisnonadjustable but it may be checked with an ohmmeter at various temperatures To test a switch 1 Turn off the gas and electrical power to the range 2 Unplug the connector from the oven temperature sensor 3 Set the ohmmeter to the R x 10 position 4 Touch the meter leads to the plug pins The meter should indicate approximately 1100 Ω at 75 F For resistances at other temperatures refer to the c...

Page 77: ...You should obtain a reading of between 40 Ω and 70 Ω If the reading is not within the range shown the solenoid may be considered defective and should be replaced SOLENOID TERMINALS TESTING AN OVEN DOOR LATCH Gas ranges that have a self clean feature incorporate an oven door latching system see Figure 6 6 which locks the oven door during the self clean cycle The door latch assembly consists of a so...

Page 78: ...ohmmeter to the R x 1 position 4 Connect one of the ohmmeter leads to the common COM terminal 5 Touch the other ohmmeter lead to the normally open N O switch terminal The ohmmeter should indicate infinity or an open circuit 6 Close the switch and the ohmmeter should now indicate continuity 0 Ω If the above results are not obtained the switch is defective and should be replaced ...

Page 79: ... in Figures 6 9 through 6 11 To test a gas safety valve 1 Turn off the gas and electrical power to the range 2 Set the ohmmeter to the R x 1 position 3 Disconnect the wires from the bake and broil terminals 4 Touch the meter leads to each set of terminals The meter should indicate a low resistance reading of between 1Ω and 5Ω If the meter indicates an open circuit or a high resistance replace the ...

Page 80: ...n the core is rotated 90 degrees the large hole in the core matches the hole in the barrel allowing the maximum amount of gas to flow When the core is rotated past 90 the gas flow is reduced To test a gas control valve 1 Gas leak at the valve a Check to see if either the knob or the valve stem is rubbing the control panel If so align the manifold pipe before replacing the valve If the alignment is...

Page 81: ... see Figure 6 13 N N Manual Shutoff Valve PRESSURE REGULATOR The common causes of pressure regulator failure are a Ruptured diaphragm b Broken or weak valve c Accumulated debris around the valve seat d Plugged vent The pressure regulator is normally replaced rather than serviced since it has few replaceable or serviceable parts and is a relatively inexpensive device Use a manometer or a magnehelic...

Page 82: ... breaker Inspect ignitor and ignitor module Burner or flash tube out of position No power to range ranges with electronic igniters Clean burner Adjust air shutter Check pressure regulator Electronic igniter does not spark Burner flame openings clogged Too much air to burner Not enough gas to burner Pilot opening blocked Pilot light set too low Too much air to burner Not enough gas to burner Clear ...

Page 83: ...t igniter and ignitor module No power to range ranges with electronic igniters Electronic igniter does not spark Fuses blown ranges with glow bar igniter Glow bar igniter faulty Test fuse Thermostat selector switch or safety valve faulty Adjust pilot light Clear pilot opening Control setting incorrect Door misaligned or gasket faulty Burner port openings clogged Thermostat or capillary tube faulty...

Page 84: ...rd Range L1 N BK BK V V R R W W W BK Y Y BK OVEN TEMP SENSOR SURFACE BURNER IGNITOR SWITCHES IGNITOR MODULE DOOR SW OVEN CONTROL TRANSFORMER P3 6 P3 7 P3 3 P4 3 P4 1 P3 4 P2 2 P3 5 P2 1 P4 4 BAKE VALVE BAKE IGNITOR OVEN LIGHT GND GND GN ...

Page 85: ... P4 P1 6 P1 7 P3 1 P2 1 P3 4 P3 2 P2 4 P2 2 LATCH SOLENOID RELAY BROIL RELAY BAKE RELAY LATCH SOLENOID DOOR LATCH SW DOOR LATCH SW BAKE VALVE BROIL VALVE BAKE IGNITOR BROIL IGNITOR IGNITOR MODULE DOOR LIGHT SW OVEN LIGHT TIMER IF EQUIPPED MANUAL OVEN LIGHT SWITCH IF EQUIPPED GND N O N O SURFACE BURNER IGNITOR SWITCHES Self Clean Range ...

Page 86: ...E BAKE IGNITOR BROIL RELAY P3 4 P3 1 P1 6 P1 7 P5 P2 1 P2 4 BAKE STRIP CIRCUITS BROIL L1 N W BK BK BU W V V OVEN CONTROL OVEN CONTROL TRANSFORMER SENSOR BAKE RELAY BROIL VALVE BROIL IGNITOR BROIL RELAY P3 2 P3 1 P1 6 P1 7 P5 P2 1 P2 2 L1 N W BK OVEN CONTROL TRANSFORMER P5 P2 1 CONTROL BOARD POWER ...

Page 87: ...OL OVEN CONTROL TRANSFORMER SENSOR BAKE RELAY BAKE VALVE BAKE IGNITOR BROIL RELAY LATCH RELAY P3 4 P4 P3 1 P1 6 N O DOOR LATCH SWITCH DOOR LATCH SWITCH LATCH SOLENOID P1 5 P1 1 P1 3 P1 7 PULSE 1 SECOND P5 P2 1 P2 4 SELF CLEAN N L1 W W BK OVEN LIGHT OVEN LIGHT ...

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