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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 6 of 92

1.3 Wiring Diagram

The wiring diagram is located on the back side of the kick panel
(see Figure 2).

Figure 2: Wiring Diagram Location

Kick panel (wiring diagram located on back side)

1.4 Recommended Tools and Supplies

The following are recommended to use when servicing this appliance:

Caution

Power Drivers

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

Flat blade screwdrivers: 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 inch long (min.) swivel head extension

6 inch long (min.) flex extension

5/16 inch deep-well socket

1/4 inch nut driver

Adjustable wrenches (2)

Strap wrench

Open-end wrench sizes: 1/4 inch, 9 mm, 11 mm, 1/2 inch,

9/16 inch, 5/8 inch, 3/4 inch, 5/16 inch

Pipe wrench

Needle-nose pliers

Clean putty knife

Protective gloves

Gas leak test equipment

Pipe sealant

Small mirror

Air lifter / air dolly

Floor protection

Protective eye wear (such as glasses, goggles)

Flashlight

Amp meter

Thermometer

with thermocouple leads

Multimeter

Clean, non-abrasive cleaning cloth & flexible brush

Содержание PRG486JDG/01

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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