SERVICE MANUAL. Thermador Pro Harmony Range. Model: PRL364GDH/01

Transcription

1 SERVICE MANUAL Thermador Pro Harmony Range Model: PRL364GDH/01

2 TABLE OF CONTENTS 1 General Technical Documents to Read Prior to Servicing Wiring Diagram Data Rating Plate Recommended Tools and Supplies Important Safety Information Safety Symbols Used In This Manual Safety Precautions to Know Prior to Servicing Operation Control Knobs ExtraLow Feature Griddle Control Knob Temperature Selector Knob Position Oven Function Selector Knob Automatic Re-Ignition Operation during a Power Outage Cooling Fan Automatic Operation Burner Assembly and Maintop Components Testing, Setting, Troubleshooting - Burners and Ignition Before Testing Oven Temperature Testing Burner Characteristics Flame Characteristics Testing Burner Ignition Testing Cooktop Burner Ignition Testing the HI Setting Testing the SIM Setting Testing the XLO Setting Testing Bake Burner Ignition Testing Broil Burner Ignition Manually Setting Burner Valves Tools Needed Adjusting the Bypass Screws Burner, Flame, and Ignition Troubleshooting Cooktop Burners Burner and Flame Diagnostics Uneven Flame Distribution & Flame Noise Diagnostics Ignition Diagnostics Oven Light Diagnostics Fault Codes Service and Repair Preparing the Range for Servicing Accessing Components under the Maintop Removing Knobs, Grates, Griddle, and Burner Assemblies Removing the Maintops Removing the Heat Shield Griddle Removal and Replacement Burner Support Rail Removal and Replacement Removal and Replacement of Top-Accessible Components Jet Holder Assembly Removal and Replacement Manifold Removal and Replacement _ARA_EN_D Page 2 of 68

3 6.3.3 Standard Valve Removal and Replacement Microswitch Removal and Replacement Solenoid Valve Removal and Replacement XLO Valve Removal and Replacement Potentiometer Removal and Replacement Temperature Selector Removal and Replacement Position Oven Function Selector Removal and Replacement Dual Valve Removal and Replacement Regulator Removal and Replacement Ignition Device Removal and Replacement LED Indicator Removal and Replacement Control Board Removal and Replacement Simmer Control Board Removal and Replacement Removal and Replacement of Back-Accessible Components Backguard and Island Trim Removal and Replacement Back Panel Removal and Replacement Terminal Block Removal and Replacement Electrical Wiring Connections at the Terminal Block Cooling Fan Removal and Replacement Broil Burner Assembly Removal and Replacement Convection Components Removal and Replacement Removal and Replacement of Front-Accessible Components Control Panel Removal and Replacement Bake Burner Components Removal and Replacement Oven Temperature Sensor Removal and Replacement Oven Lamp Removal and Replacement Door Removal and Installation Removing the Door Installing the Door Door Handle Components - Removal and Replacement Removing Door Handle Components Installing Door Handle Components Door Gasket Removal and Replacement Kick Panel Removal and Replacement Bottom Plate of Front Frame Removal and Replacement Door Hinge Receiver Removal and Replacement Door Hinge Removal and Replacement Thermostat Removal and Replacement Before Returning Appliance to Service Clean-Up Additional Resources QuickFinder Technical Support _ARA_EN_D Page 3 of 68

4 1 GENERAL This manual contains information that is necessary for servicing the following Thermador Pro Harmony Range: PRL364GDH/01 Due to the complexity and the risk of high-voltage electrical shock, customers should not service their appliances. The information provided in this document is intended for trained, qualified personnel only. The proper function and the safety of the appliance can be affected by an improper repair, and even serious threats to life or physical 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. For authorized servicers, additional assistance is available by contacting Technical Support at (800) Data Rating Plate The data rating plate which shows the model, serial, and FD number is located underneath the control panel, as shown in Figure 1. This information is required when calling for technical or customer service. The first two digits of the FD number indicate the year the appliance was produced. To get the year, add 20 to the first two digits (for example, an FD number beginning with 87 was produced in 2007; a number that begins with 88 was produced in 2008). The last 2 digits of the FD number indicate the month the product was produced (for example, 06 indicates the appliance was produced in June). 1.1 Technical Documents to Read Prior to Servicing Before you start servicing, check QuickFinder for all other technical documents associated with this specific appliance. 1.2 Wiring Diagram Figure 1: Data Rating Plate and Wiring Diagram Locations The Wiring / schematic diagram is located behind the kick panel (see Figure 1) _ARA_EN_D Page 4 of 68

5 1.4 Recommended Tools and Supplies The following tools and supplies are recommended to use when servicing this appliance: Caution Power Drivers If using a power driver, set the clutch to the lowest setting Driver sizes: T-10, T-20, T-25, T-30 1/4 inch nut driver or 1/4 inch socket wrench / ratchet Wrench sizes: 1/2 inch, 1/4 inch, 5/16 inch, 11/32 inch open-end Socket wrench / ratchet 11/32 inch Swivel head driver with an 11/32 inch, deep-well socket Large nut driver (1 inch min.) with a deep-well socket Long, hand-held T-20 driver Adjustable wrench Pipe wrench Precision screwdriver with a high-strength blade, 1/8-inch (3.0 mm) wide,.020-inch (0.50 mm) thickness tip Flat blade screwdrivers: large, small Slip joint pliers Needle-Nose pliers Hook or non-straight hex key (Allen wrench) Protective gloves Gas leak test equipment Pipe sealant Small mirror Protective eye wear (such as glasses or goggles) Flashlight Amp meter Thermometer with thermocouple leads Multimeter Air lifter / air dolly 1.5 Important Safety Information Before starting to service an appliance, familiarize yourself with all safety information and precautions contained in this manual Safety Symbols Used In This Manual This symbol alerts you to dangers that may result in bodily injury or death. Caution This symbol alerts you to actions that may result in damage to the product, or property Safety Precautions to Know Prior to Servicing Before You Start Servicing the Appliance Before disassembly, removal or installation of any component, do the following: Turn off electrical power by removing the power cord from the electrical outlet, and putting the circuit breaker in the OFF position or by removing the fuse. Turn off the gas supply to the appliance. Make sure grates and burner assemblies are cool before removing them _ARA_EN_D Page 5 of 68

6 Replacement Parts Use only authorized replacement parts per catalog 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 bodily injury, death, or damage. Fire / Explosion Hazards Make sure the gas valve at the wall is closed before removing and installing any gas components. Do not store or use any flammable vapors, liquids, or combustible materials in the vicinity of this appliance. Do not use water on grease fires. Turn appliance off and smother the fire with baking soda or use a dry chemical or foam-type extinguisher. Griddle Hazard The griddle plate must always be correctly in place when the griddle is turned on. What to Do If You Smell Gas Do not try to light any appliance Do not touch any electrical switch Do not use any phone or cell phone in the building Installation and service must be performed by a qualified installer, service agency, or the gas supplier. Testing for Gas Leaks Do not ever use a flame to test for gas leaks, as doing so may result in explosion, injury, death, and/or damage to the appliance and property. 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. 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 the recommended values. When repairs are complete, perform a function test in accordance with the appropriate regulations. Do not under any circumstances cut or remove the separate ground wire or the third (ground) prong from the power cord plug. Improper grounding or reverse polarization will cause malfunction (such as continuous sparking of the igniters), which can damage the appliance and create an electrical shock hazard. Make sure the circuit is properly grounded and polarized in accordance with applicable local codes and ordinances. Receptacle replacement 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 cooktop burners, infrared broil burner, bake burner, heat deflector, and interior oven surfaces _ARA_EN_D Page 6 of 68

7 In Case of Power Outage 1. If for any reason a control knob is on when there is any failure or removal of electrical power from the appliance (such as a power outage), immediately turn all control knob(s) to the OFF position. 2. Ventilate by opening a door or window, and wait at least 5 minutes for all the gas to dissipate. 3. If you smell gas, refer to the applicable safety precautions stated in this manual. Sharp Components This appliance has sheet metal and other components which often have sharp edges. When working on this appliance, avoid cutting yourself and other injury by handling these parts with care and using adequate protective measures, such as gloves. Clean-up Hazards Don t allow any cleaning or polishing solutions/compounds, disinfectants or bleaches to remain in contact with the stainless steel surfaces for long periods, or after clean-up. These may contain chemicals or materials which could release harmful inhalants and can damage the appliance. After cleaning or polishing, always rinse the cleaning/polishing materials with clear water and wipe dry with a clean soft, non-abrasive cloth. 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 external) are correctly and securely connected All gas connections are secure and have been leak tested using a gas leak detector or bubble test. All panels and components are properly and securely reassembled Caution Code Compliance Local codes vary. Installation, electrical connections, gas connections, and grounding must comply with all applicable codes. TESTED IN ACCORDANCE WITH ANSI Z21.1, THE STANDARD FOR HOUSEHOLD COOKING GAS APPLIANCES. IN CANADA TESTED IN ACCORDANCE WITH CAN/CGA1.1 M81, THE STANDARD FOR DOMESTIC GAS RANGES. Check your local building codes for the proper method of installation. In the absence of local codes, this unit should be installed in accordance with the National Fuel Gas Code No. Z223.1/ NFPA 54 current issue and the National Electrical Code ANSI/NFPA No. 70 current issue or the Can B149 Installation Codes for Gas Burning Appliances and C22.1 Canadian Electrical Code Part 1. It is the responsibility of the owner and the installer to determine if additional requirements apply in specific installations _ARA_EN_D Page 7 of 68

8 2 OPERATION 2.1 Control Knobs The knob can also be set between SIM and XLO for a variable range of low heat, with the flame cycling on and off at a different frequency than the XLO setting (see Figure 3). The control knobs for each of the burners are located on the control panel, with an icon to identify the location on the range (see Figure 2). The left-most front and left-most rear burners have the ExtraLow (XLO) feature. Figure 3: XLO Settings Griddle Control Knob Figure 2: Burner Control Knobs 1. Press a control knob in, and turn counter-clockwise to HI setting. The igniter for the burner clicks while sparking until flame ignition. Burner should ignite within 4 seconds. 2. For the non-xlo burners, rotate the knob to any setting between HI and SIM. For the XLO (left front and left rear) burners, rotate the knob to any setting between HI and XLO. NOTE: The blue LED indicator lights up when burners are lit. The griddle knob controls the temperature to the griddle, from 150 F to 500 F (see Figure 4). There are no fixed settings on the knob. Press and turn the knob clockwise to select a setting ExtraLow Feature When the knob is set to XLO - the very lowest setting, the flame cycles on for approximately 8 seconds and then turns off for 52 seconds of each minute. Figure 4: Griddle Control Knob _ARA_EN_D Page 8 of 68

9 2.1.3 Temperature Selector Knob For each oven, use the respective Temperature Selector knob (see Figure 5). 2.2 Automatic Re-Ignition Each burner has its own electronic igniter that sparks when the burner is turned on. If one or more burner blows out, the respective igniter/electrode automatically re-ignites the flame. 2.3 Operation during a Power Outage When there is a removal of electrical power, the XLO burners cannot be used. Do not attempt to light them manually. Caution Figure 5: Temperature Selector Knob Position Oven Function Selector Knob Use this knob for oven bake, extended bake (Sabbath mode), convection bake, and broil (see Figure 6). 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 with the warnings and precautions in the Important Safety Information section (page 5) of this manual Cooling Fan Automatic Operation Cooling Fan - Automatic Operation Pro Range equipped with original control part # The cooling fan energizes when the oven cavity reaches 425 Deg F. During cool down the fan de-energizes when the cavity cools to 375 Deg F. Pro Range equipped with replacement control part # The cooling fan energizes when the oven cavity reaches 300 Deg F. During cool down the fan de-energizes when the cavity cools to 250 Deg F. Figure 6: 5-Position Oven Function Selector Knob Part # is standard on most Pro Ranges FD # 9112 and later _ARA_EN_D Page 9 of 68

10 2.4 Burner Assembly and Maintop Components Ignition Hazard Do not touch burners when the igniters are active (sparking). 3.1 Before Testing Before testing the burners and ignition, do the following: Figure 7: Burner Assembly and Maintop Components 3 TESTING, SETTING, TROUBLESHOOTING - BURNERS AND IGNITION Servicing Burners and Ignition Burner and ignition servicing must be performed by a qualified technician. Improper adjustments may be dangerous, cause damage or harmful by-products, and may void the appliance warranty. 1. Reinstall any loose components that may have been removed earlier, such as burner caps, griddle, and grates. Be certain that burner caps seat properly into the burner bases, burner pedestal and Venturi tube are aligned 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 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 Oven Temperature Testing **Do not remove the thermocouple prematurely when the oven is hot. Test oven temperature using a thermometer with a thermocouple lead. If you leave the thermocouple in the oven during a speed clean cycle, keep in mind it will take a few hours before the oven is cool enough to retrieve the thermocouple. Convection Bake For convection bake, you can visually inspect if the convection fan is working. The convection fan only works after the preheating finishes, thus it may take less time to test the convection fan on the lowest bake convection setting _ARA_EN_D Page 10 of 68

11 3.2 Burner Characteristics If one or more burner blows out, the respective igniter electrode automatically re-ignites the flame. At each burner port the flame should burn completely around the burner cap. It is normal to hear the following during burner operation: A slight sound that is associated with gas combustion and ignition. There should not be a loud noise. A clicking noise every time the gas cycles, coming from the solenoid valves of the two left burners For LP gas, a slight pop sound may be heard at the burner ports a few seconds after the burner has been turned off NOTE: If burner characteristics are not adequate, see Burner, Flame, and Ignition Troubleshooting, page 13. Figure 8: Burner Ports Flame Characteristics LP gas: Slight 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 produced from burning airborne debris, which is normal at startup, and should dissipate in a few minutes (see Figure 9). When the flame is properly adjusted, it should burn at each burner port, completely around the burner cap (see Figure 8). NOTE: If flame characteristics are not adequate, see Burner, Flame, and Ignition Troubleshooting, page 13. Figure 9: Additional Flame Characteristics _ARA_EN_D Page 11 of 68

12 3.3 Testing Burner Ignition Testing Cooktop Burner Ignition Ignition Hazard Do not touch the cooktop burners when the igniters are sparking. For each burner, push the control knob in and then turn counterclockwise to HI. The igniter should produce a clicking sound as the burner is sparking, and the burner should light within four seconds Testing the HI Setting Set the burner knob to HI, and observe flame characteristics (see Figure 9). If any burner flame burns primarily yellow, verify if the burner cap is positioned properly on the burner base, and then re-test. If flame characteristics do not improve, call Thermador technical support at (800) Testing the SIM Setting Set the burner knob to SIM. Make sure that the flame completely surrounds the burner. There should be a flame at each burner port and there should not be an air gap between the flame and the burner. If the flame does not extend completely around any of the burners, call Thermador technical support at (800) Testing the XLO Setting The left-front and left-back burners have the XLO feature. Set the burner knob to XLO and observe if the flame cycles correctly - on for approximately 8 seconds, and then off for 52 seconds of each minute Testing Bake Burner Ignition Set the oven to BAKE at 350 F. After seconds the burner should ignite and stay lit until 350 F is reached. Then it should shut off. From this point forward, the burner should cycle on and off to maintain the temperature. NOTE: The air shutter for the bake burner is factory pre-set at a fullyopened position for all conditions, and doesn t require adjustment Testing Broil Burner Ignition Set the mode to BROIL. After seconds the burner should ignite. The infrared ceramic broiler does not require any adjustment. 3.4 Manually Setting Burner Valves Although pre-adjusted, if you need to set the XLO valves and standard valves for the lowest possible flame setting, then manually adjust the bypass screws on all valves Tools Needed T-20 driver A precision high-strength blade screwdriver, with 1/8 inch (3.0mm) wide,.020 inch (0.50mm) thickness tip should be used to reposition the bypass screws for minimum flow settings on manual valves Adjusting the Bypass Screws 1. Turn off electrical power by unplugging the power cord, or putting the circuit breaker in the OFF position. 2. Remove knobs from valve stems by slowly pulling knobs straight out, away from control panel. 3. Remove and retain the bezel mounting screw located to the right of the valve stem, using a T-20 driver (see Figure 10, page 13). 4. To engage the valve screw, insert the precision screwdriver with 1/8-inch blade into the same hole in the bezel that was created by the removal of the mounting screw (see Figure 11, page 13). 5. Turn the valve screw clockwise just until "bottom out" position is reached. DO NOT over-tighten the valve screw (see Figure 11). NOTE: The two valves for XLO operation (farthest left on control panel) must be in the OFF position for proper access to the valve screws through clearance holes in the XLO potentiometers _ARA_EN_D Page 12 of 68

13 3.5 Burner, Flame, and Ignition Troubleshooting Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 10: Removing the Bezel Mounting Screw Figure 11: Accessing and Setting the Bypass Screw Cooktop Burners Burner and Flame Diagnostics If a burner clicks (sparks) constantly, or if burner doesn t light correctly and/or has inadequate burner/flame characteristics (per Burner Characteristics page 11 and Flame Characteristics page 11), then do the following: Check if the manual shut-off valve is open and the unit is receiving gas (natural gas or liquid propane). Check if the burner cap is properly 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 wiring connections at ignition device and electrode, and also check grounding Refer to the Ignition Diagnostics, page 14. Call Thermador technical support at (800) for assistance if any burners fail to light, or any burners continue to burn yellow Uneven Flame Distribution & Flame Noise Diagnostics If there is an uneven flame distribution around the burner ports and/or a loud noise emanating from the flame, it could be caused by bad combustion due to a misalignment of the gas jet assembly and Venturi tube. For optimal combustion, the jet needs to be centered inside of the Venturi tube. A misalignment of these two components can be caused by either the pedestal burner base and/or jet assembly not positioned correctly onto the maintop resulting in a poor mixture of gas and air. Perform the following diagnostic steps: _ARA_EN_D Page 13 of 68

14 Hot Burner Components Always use a pot holder to handle a hot burner cap, Venturi tube, or any other burner assembly component to prevent injury. Figure 13: Incorrect Jet Assembly-to-Maintop Alignment (Left Image) and Proper Jet Assembly-to-Maintop Position (Right Image) Figure 12: Problematic Burner on High with Gaps and Uneven Flame (Left Image) and on Low (Right Image) 1. Check if the burner cap is properly installed. 2. If problem persists, switch the burner cap with one from a burner that is operating correctly. If problem is still not resolved, proceed to the next steps: 3. Remove the star burner top and then the pedestal burner base per the Removing Knobs, Grates, Griddle, and Burner Assemblies procedure, page Make sure the jet assembly is correctly seated so that the raised part protrudes through the respective contour on the maintop (see Figure 13) and that the electrode ignition wire moves freely through the hole in the maintop (see Figure 24, page 20). 5. Reinstall the pedestal burner base (without the Venturi tube). Be careful not to over torque the screw on the pedestal burner base. 6. Insert the Venturi tube inside the pedestal burner base and make sure it can slide up and down freely without grinding or catching (see Figure 14). 7. Reinstall the rest of the burner assembly, and test the flame on low and high settings. Figure 14: Pedestal Burner Base Jet Centered Inside Venturi Tube Ignition Diagnostics The following flowchart applies in the event a burner fails to ignite. Before performing steps in the Cooktop Burner - Ignition Diagnostics Flowchart (Figure 15, page 15), remove electrical power from appliance during disassembly and during removal and installation procedures. Restore electrical power when testing the unit if it is reassembled _ARA_EN_D Page 14 of 68

15 No (XLO burners) 110V DC into Solenoid Valve? Yes Replace Solenoid Valve No ignition Burner LED Indicator is on? Yes Sparking? Yes Is gas present at burner? No (Standard burners) No 5V from Potentiometer to Simmer Control Board? Yes Replace Simmer Control Board No Problem persists after checking electrical power supply (circuit breaker/ fuse, power cord, wiring at terminal box)? No Problem persists after checking wire connection to electrode, and checking if electrode is free of debris? Yes Check burner ports for blockage, check if burner cap is aligned on base Gas supply into Regulator? No Yes No Problem persists after checking all connections on Potentiometer? Yes Replace Potentiometer Yes Yes Contact the gas supplier Replace Regulator Yes Replace Microswitch Yes 120 VAC into Microswitch checks out ok? No Replace LED Indicator Yes 120 VAC into Ignition Device checks out ok? Replace Spark Module (Ignition Device) No (Standard burners) No (XLO burners) 5V from Potentiometer to Simmer Control Board? Check wiring from Microswitch to Spark Module (Ignition Device) Yes No Problem persists after checking all connections on Simmer Control Board? XLO BURNERS STANDARD BURNERS L1 120V Potentiometer 5V Simmer Controller Board 110V DC 120V Spark Module (Ignition Device) Electrode Burner L1 120V Standard Valve 120V Spark Module (Ignition Device) Electrode Burner Diode LED Indicator Solenoid Valve N N Diode LED Indicator N Figure 15: Ignition Diagnostics Flowchart _ARA_EN_D Page 15 of 68

16 4 OVEN LIGHT DIAGNOSTICS OVEN LIGHT DIAGNOSTICS 1 Turn light switch OFF and then open oven door. Is oven light illuminated? No Close oven door and turn light switch ON Is oven light illuminated? Yes Make sure plunger doesn t get stuck in closed position. Check wiring and connections. Replace plunger switch if necessary. Yes No Go to Oven Light Diagnostics 2 Go to Oven Light Diagnostics 2 OVEN LIGHT DIAGNOSTICS 2 NOTE: All tests in Oven Light Diagnostics 2 must be performed with the oven door closed, or with the plunger switch pressed in. TOOLS NEEDED: Multimeter Replace light switch No Turn light switch OFF and then remove light bulb. Continuity across bulb? Yes Turn light switch ON Is there 12V DC across socket? No Remove light wires at control board Is there 120V AC across CB outlet? No Replace light wires at control board Is there 120V AC across light switch? No Yes Yes Yes Replace bulb Make sure contacts are clean. Replace bulb if necessary. Check transformer (120V AC input, and 12V DC output). Check wire continuity. Check if wires making connections. Trace wire for short. Replace control board if necessary. Figure 16: Oven Light Diagnostics _ARA_EN_D Page 16 of 68

17 5 FAULT CODES When a fault is detected, this appliance will display a fault code (see Figure 20, on page 18). The fault codes are represented by the manner in which two blue LED indicators are blinking. Depending on the range model, the blue LEDs that blink are located either horizontally or vertically on the control panel. The horizontal positioned blue LEDs (see Figure 17 and Figure 18) will first blink on the left and then the right, and the vertical positioned blue LEDs (see Figure 19) will first blink on the top and then the bottom. For example, if the first LED blinks 4 consecutive times followed immediately by the second LED blinking 3 times, that represents a fault code of 43 on the chart (see Figure 20, on page 18). Figure 18: Three Horizontal LED Indicators (Only Blue LEDs Blink) Figure 17: Two Horizontal LED Indicators Figure 19: Two Vertical LED Indicators _ARA_EN_D Page 17 of 68

18 Figure 20: Fault Codes _ARA_EN_D Page 18 of 68

19 6 SERVICE AND REPAIR 6.1 Preparing the Range for Servicing For most servicing of this appliance (for example, involving disassembly, removal or installation), you will need to do the following prior to starting: Turn off the gas supply to the range by closing the gas valve at the wall. Turn off the electrical power to the range by removing the power cord from the electrical outlet, and putting the circuit breaker in the OFF position or by removing the fuse. Make sure the range is not hot. 2. Remove grates. 3. Remove all Star burner caps. 4. Remove and retain the two T-30 screws from each brass Star burner base (see Figure 21). If testing the appliance requires the use of electrical power and/or an open gas supply, exercise extreme caution. 6.2 Accessing Components under the Maintop This section contains the steps required to gain access to the components located under the maintop Removing Knobs, Grates, Griddle, and Burner Assemblies To access and service components located underneath the maintop (see Figure 7), remove the knobs, grates, griddle, burner assemblies, maintop, and heat shield: Figure 21: Star Burner Base (Generation 5 Design Shown) Caution Fragile Component The electrode is a ceramic component that can be brittle and crack easily. 1. [Optional only if a component attached to a knob needs replacing] Remove knob from valve stem by slowly pulling knob straight out, away from control panel _ARA_EN_D Page 19 of 68

20 5. While lifting the brass burner base, carefully depress the locking tab on the female terminal of the igniter wire, and gently pull to detach from the electrode (see Figure 22 and Figure 23). 6. If the electrode needs replacing, remove and retain the small T-10 screw to detach it from the brass burner base. If not, leave it attached to the brass burner base. 7. Remove and retain the T-30 screw holding the cast iron pedestal burner to the maintop. 8. Remove the pedestal burner with the Venturi tube still attached to it, while gently pulling the ignition wire through (see Figure 24). -OR- Alternatively, you can first lift the Venturi tube out from the pedestal burner, before removing the pedestal burner from the maintop. Figure 22: Igniter Wire Attached to Electrode Press tab to detach from electrode Figure 24: Pedestal Burner with Venturi Tube Figure 23: Igniter Wire Locking Tab _ARA_EN_D Page 20 of 68

21 9. Remove the following (see Figure 25): Grease tray (move back, and then lift upward to remove from griddle plate) Griddle plate 3. Push each ignition wire downward through its respective receptacle, as you carefully lift out each maintop, in a frontward direction. Figure 25: Griddle Plate and Grease Tray Removing the Maintops Caution Fragile Component The porcelain enamel maintops are fragile. To prevent damage such as chipping: Carefully remove maintops Do not over torque the screw holding the burner pedestal to the maintop when reinstalling a maintop 1. Remove and retain the three T-20 screws located on the front-facing side of the backguard (see Figure 26). 2. For each maintop, carefully place a tool such as a hook or a non-straight Allen wrench in a circular receptacle on the maintop (not in a receptacle for the jet holder or the ignition wire), and pry up maintop enough until you can grasp it with your hand (see Figure 27). Figure 26: Screws on Front of Backguard Figure 27: Removing a Maintop _ARA_EN_D Page 21 of 68

22 6.2.3 Removing the Heat Shield Griddle Removal and Replacement The next step in accessing components under the maintop is to remove the griddle, if needed. Sharp Components Gloves Recommended Sheet metal components such as the heat shield have sharp edges. Avoid injury by handling with care. It is recommended to use gloves when removing or installing the heat shield. 1. Complete steps for Removing Knobs, Grates, Griddle, and Burner Assemblies, page Remove and retain the two T-20 screws from each of the two element support brackets (see Figure 29). 1. Carefully lift and remove the heat shield (see Figure 28). Figure 29: Element Support Bracket Screws Figure 28: Removing the Heat Shield 3. Remove and retain the two T-20 screws fastened to each (right and left side) support bracket (see Figure 30): The screw securing the element flange onto the front of support bracket (see Figure 31) The screw holding the support bracket onto the back frame (see Figure 31) _ARA_EN_D Page 22 of 68

23 4. Remove support brackets (see Figure 30) by lifting the pins out of the slots on the element tray. 5. Remove the thermostat bulb by carefully pulling it out of the retaining bracket (see Figure 32) NOTE: After removing the thermostat bulb from retaining bracket, do not push the bulb through the receptacle in the element tray yet. 6. Disconnect the male-female ¼ 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. Figure 31: Removing 2 Screws from Support Bracket Figure 30: Support Bracket Figure 32: Removing the Thermostat Bulb from Retaining Bracket _ARA_EN_D Page 23 of 68

24 7. Remove the two T-20 screws from the element tray (see Figure 33). The insulation support bracket is now detached from under the element tray (see Figure 34). 8. While lifting up the element tray slightly, carefully push the bulb through the circular receptacle in the element tray (see Figure 35). Figure 35: Receptacle for Removing Thermostat Bulb Figure 33: Location of Screws on Element Tray Fiberglass Wear gloves when handling fiberglass insulation Figure 34: Detaching Insulation Support Bracket _ARA_EN_D Page 24 of 68

25 9. While removing the insulation (see Figure 36), be careful not to pull on the thermostat bulb Burner Support Rail Removal and Replacement This procedure is for the removal of the burner support rail with the jet holder assemblies attached, which may be necessary in order to gain access to components for servicing. If a jet holder assembly needs to be removed from the burner support rail or needs to be replaced, see Jet Holder Assembly Removal and Replacement, page 27. Figure 38: Burner Support Rail Figure 36: Removing the Insulation 10. Remove the insulation support bracket by pulling its two prongs out of the slots in the retaining plate (see Figure 37). 2. Using a 9/16 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 39). Figure 39: Removing Gas Tube from Jet Holder Assembly Figure 37: Insulation Support Bracket _ARA_EN_D Page 25 of 68

26 3. Using a 9/16 inch wrench, unscrew the hex nut to remove the other end of the gas tubes from their respective valve as follows: [Left-side XLO valves]: While using a 1/2 inch wrench to hold the bolt on the solenoid valve, unscrew the gas tube hex nut with a 9/16 inch wrench. Don t bend the gas tube (Figure 52). [Right side standard valves]: Using a 9/16 inch wrench, remove the gas tubes from the Standard valves. Be careful not to bend the gas tube. 4. Push each ignition wire downward through its respective receptacles in the burner support rail. 5. Make note of burner support rail placement on the range chassis (before removing the rails) so you can reinstall afterwards in the correct position. NOTE: It is important to reinstall the correct burner support rails in the correct position in order to correctly match up the jet holder assemblies to the gas tubes. Figure 40: Removing Burner Support Rail from Range Chassis Sharp Component Gloves Recommended The burner support rail has sharp edges. Avoid injury by using gloves when removing or installing the burner support rail. 6. 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 from their slots on the chassis (see Figure 40). Then remove burner support rail with the two jet holder assemblies attached (see Figure 41). Gas Leaks Figure 41: Burner Support Rail with Jet Holder Assemblies Attached Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test _ARA_EN_D Page 26 of 68

27 6.3 Removal and Replacement of Top-Accessible Components This section contains removal and replacement procedures for the top-accessible components, located under the maintop Jet Holder Assembly Removal and Replacement This procedure is for removing the jet holder assembly from the burner support rail, in the event that a jet holder assembly needs replacing. -OR- Alternatively, use a slip joint pliers and gloves to disengage the alignment boss and rotate the jet holder assembly until it can be removed (see Figure 42 and Figure 43). Alignment boss Wire guard clip Sharp Components Gloves Recommended The burner support rail may have sharp edges. Avoid injury by handling with care. It is recommended to use gloves when removing or installing the burner support rail. 2. Follow all steps in Accessing Components under the Maintop, page Remove the wire guard clip from each jet holder assembly prior to removing the jet holder assembly from the burner support rail (see Figure 42). NOTE: The jet holders are secured to the burner support rails with a tight fit. 4. As necessary, use a flat-bladed screwdriver to pry the jet holder assembly out until the alignment boss is disengaged from the circular receptacle on the burner support rail. Then rotate the jet holder assembly (gloves recommended) until it can be removed through the corresponding grooves in the burner support rail (see Figure 42 and Figure 43). Figure 42: Jet Holder Assembly Detaching Boss from Rail Figure 43: Jet Holder Assembly Rotating and Removal from Rail _ARA_EN_D Page 27 of 68

28 5. Replace the jet holder assembly if needed. NOTE: If replacing the jet holder assembly, first install the jet holder assembly onto the burner support rail before attaching the wire guard clip. Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Manifold Removal and Replacement Although range components can be accessed and replaced without removing the manifold, this procedure is provided if the manifold needs to be replaced due to a gas leak in the manifold, or if the threading on the manifold is bad due to removing the regulator. 2. Follow all steps in Accessing Components under the Maintop, page Be sure to remove the two knobs that are connected to the respective manifold support brackets on the back side of the control panel (see Figure 44). Remove the knobs from their valve stems by slowly pulling knobs straight out, away from control panel. 4. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page 25. Figure 44: Knobs to Remove 5. Remove the regulator from the manifold (see Regulator Removal and Replacement, page 39). 6. Remove the microswitch and standard valve attached to the right-side center knob (see Figure 44). See Microswitch Removal and Replacement page 31, and Standard Valve Removal and Replacement, page Remove the solenoid valve, XLO valve and potentiometer attached to the left-side center knob (see Figure 44). See Solenoid Valve Removal and Replacement page 32, XLO Valve Removal and Replacement page 33, and Potentiometer Removal and Replacement, page _ARA_EN_D Page 28 of 68

29 8. Now remove the manifold support brackets by removing and retaining the following screws with a T-20 driver: The two screws holding the manifold support bracket onto the chassis base near the regulator (see Figure 46) The two screws from each bezel of the two inner knobs (see Figure 44 and Figure 45) to detach the manifold support brackets from the back of the control panel (see Figure 47) 9. After removing all brackets, gently lift the manifold out, being careful of the wires and harnesses and other components. Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 46: Manifold Support Bracket on Chassis Base Figure 47: Manifold Support Bracket on Back of Control Panel Figure 45: Manifold Support Bracket Screws on Bezel _ARA_EN_D Page 29 of 68

30 6.3.3 Standard Valve Removal and Replacement The standard valves are for the right side burners only. 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. Using a 9/16 inch wrench, remove the gas tube by unscrewing the hex nuts connected to the standard valve and to the jet holder assembly. Be careful not to bend the gas tube. 5. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the standard valve onto the manifold (see Figure 49). Be careful not to lose the rubber washer attached to the screw. -OR- Using a 1/4 inch nut driver, remove and retain the self-tapping screw by accessing it from under the chassis base, through the corresponding access hole (the oven door must be opened or removed) - see Figure 49. Be careful not to lose the rubber washer attached to the screw. 7. Remove the (connected) standard valve and microswitch from the manifold (see Figure 50 on page 31). Be careful not to lose the red rubber washer attached to the standard valve. 8. Detach the standard valve from the microswitch by removing and retaining the T-10 screw and then pulling the microswitch off the alignment pin on the standard valve (see Figure 51 on page 31). NOTE: You do not have to detach the wires connected to the microswitch terminals if you are just servicing the standard valve. 9. Replace the standard valve if needed. Figure 48: Access Holes on Typical Range (XLO Valve Access Shown) Using 1/4 inch nut driver Figure 49: Removing the Self-Tapping Screw Using 1/4 inch socket wrench _ARA_EN_D Page 30 of 68

31 Figure 50: Standard Valve Connected to Microswitch Figure 51: Screw Connecting Standard Valve to Microswitch Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Microswitch Removal and Replacement The microswitches are for the right-side burners only. 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. Using a 9/16 inch wrench, remove the gas tube by unscrewing the hex nuts connected to the standard valve and to the jet holder assembly. Be careful not to bend the gas tube. 5. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the standard valve onto the manifold (see Figure 49). Be careful not to lose the rubber washer attached to the screw. -OR- Using a 1/4 inch nut driver, remove and retain the self-tapping screw by accessing it from under the chassis base, through the corresponding access hole (the oven door must be opened or removed) - see Figure 49. Be careful not to lose the rubber washer attached to the screw. 7. Remove the (connected) standard valve and microswitch from the manifold (see Figure 50). Be careful not to lose the red rubber washer attached to the standard valve _ARA_EN_D Page 31 of 68

32 8. First make a note of how the wires (piggyback and single) are connected to the two terminals on the microswitch, and then disconnect these wires from the terminals (see Figure 50). 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 9. Detach the standard valve from the microswitch by removing and retaining the T-10 screw, and then pulling the microswitch off the alignment pin on the standard valve (see Figure 51). 10. Replace the microswitch if needed. 6. First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals. 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Using an adjustable wrench, unscrew the large hex nut on the solenoid and remove the solenoid valve from the XLO valve. Be careful not to lose the plastic O ring inside the large hex nut of the solenoid valve, as it may fall out easily (see Figure 53, page 33). 8. Replace solenoid valve if needed. Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Solenoid Valve Removal and Replacement The solenoid valves are for the left-side (XLO) burners only. 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. While using a 1/2 inch wrench to hold the nut on the solenoid valve, unscrew the gas tube hex nut with a 9/16 inch wrench. Then unscrew the other side of the gas tube attached to the jet holder assembly and remove the gas tube. Be careful not to bend the gas tube (see Figure 52). 5. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page 25. Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 52: Removing the Gas Tube from the Solenoid Valve _ARA_EN_D Page 32 of 68

33 Figure 53: Solenoid Valve with O Ring XLO Valve Removal and Replacement The XLO valves are for the left-most front and left-most rear burners only. In order to replace the XLO valve, you must remove the potentiometer together with the XLO valve. 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. While using a 1/2 inch wrench to hold the nut on the solenoid valve, unscrew the gas tube hex nut with a 9/16 inch wrench. Then unscrew the other side of the gas tube attached to the jet holder assembly and remove the gas tube. Be careful not to bend the gas tube (see Figure 52). 5. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals. 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Using an adjustable wrench, unscrew the large hex nut on the solenoid and remove the solenoid valve from the XLO valve. Be careful not to lose the plastic O ring positioned inside the large hex nut of the solenoid valve, as it may fall out easily (see Figure 53). 8. Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the XLO valve onto the manifold (see Figure 49). Be careful not to lose the rubber washer attached to the screw. -OR- Using a 1/4 inch nut driver, remove and retain the self-tapping screw by accessing it from under the chassis base, through the corresponding access hole (the oven door must be opened or removed) - see Figure 49. Be careful not to lose the rubber washer attached to the screw. 9. Gently lift the protruding part of the XLO valve out of the receptacle on the manifold (don t lose the red rubber washer attached to the XLO valve), and slightly bring out the (connected) XLO valve/potentiometer assembly from under the front panel. Be aware of the side connector that is attached (see Figure 54, page 34) _ARA_EN_D Page 33 of 68

34 12. Detach the XLO valve from the potentiometer by using a small flat-blade screwdriver to gently remove the XLO valve from the potentiometer standoffs. Then slide the potentiometer off the valve stem (see Figure 56). Figure 54: Solenoid XLO Valve Potentiometer Assembly 10. Remove the white plastic side connector from the potentiometer by pressing on the connector s tab. (see Figure 55). Figure 56: Removing the XLO Valve from the Potentiometer Side connector tab Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 55: Side Connector Tab 11. Replace the XLO valve if needed _ARA_EN_D Page 34 of 68

35 6.3.7 Potentiometer Removal and Replacement The potentiometer (also known as the Simmer Control potentiometer or XLO potentiometer) is used to control the simmer function of the XLO burners (left front and left rear burners). NOTE: The potentiometer should not be confused with the Temperature Selector, which is sometimes also referred to as a potentiometer. 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. While using a 1/2 inch wrench to hold the nut on the solenoid valve, unscrew the gas tube hex nut with a 9/16 inch wrench. Then unscrew the other side of the gas tube attached to the jet holder assembly and remove the gas tube. Be careful not to bend the gas tube (see Figure 52). 5. Remove the burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page First make a note of how the wires are connected to the solenoid valve terminals, and then remove the wires from the terminals. 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Using an adjustable wrench, unscrew the large hex nut on the solenoid and remove the solenoid valve from the XLO valve. Be careful not to lose the plastic O ring positioned inside the large hex nut of the solenoid valve, as it may fall out easily (see Figure 53). 8. Using a 1/4 inch socket wrench/ratchet, remove and retain the self-tapping screw located under the manifold that secures the XLO valve onto the manifold (see Figure 49). Be careful not to lose the rubber washer attached to the screw. -OR- Using a 1/4 inch nut driver, remove and retain the self-tapping screw by accessing it from under the chassis base, through the corresponding access hole (the oven door must be opened or removed) - see Figure 49. Be careful not to lose the rubber washer attached to the screw. 9. Gently lift the protruding part of the XLO valve out of the receptacle on the manifold (don t lose the red rubber washer attached to the XLO valve), and slightly bring out the (connected) XLO valve/potentiometer assembly from under the front panel. Be aware of the side connector that is attached. 10. Remove the white plastic side connector from the potentiometer by pressing on the connector s tab. (see Figure 55). 11. Detach the XLO valve from the potentiometer by using a small flat-blade screwdriver to remove the XLO valve from the potentiometer standoffs. Then slide the potentiometer off the valve stem (see Figure 56). 12. Replace the potentiometer if needed. Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test _ARA_EN_D Page 35 of 68

36 6.3.8 Temperature Selector Removal and Replacement Figure 57: Temperature Selector and Knob NOTE: For PRL364GDH/01, the Temperature Selector may or may not be secured to the back of the control panel with a clamp. If a clamped Temperature Selector needs replacing, the replacement part (used without clamp) is fully compatible. 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. From the back of the control panel, first make a note of how the connector wires are connected to the Temperature Selector terminals, and then remove the wires from the terminals (see Figure 59). 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 5. From the front of the control panel, remove and retain the two screws on the bezel which are attached to the Temperature Selector (see Figure 58). Figure 58: Temperature Selector Screws on Bezel 6. Remove the blade connectors from the Temperature Selector at the back side of the control panel (see Figure 59). Figure 59: Temperature Selector _ARA_EN_D Page 36 of 68

37 7. Remove clamp (if there is one) by folding the left and right clamp wings up about 45 degrees (see Figure 60). 8. Pull out the Temperature Selector Position Oven Function Selector Removal and Replacement Figure 61: 5-Position Oven Function Selector (Typical Models Shown) and Knob NOTE: For PRL364GDH/01, the 5-Position Oven Function Selector may or may not be secured to the back of the control panel with a clamp. If a clamped 5-Position Oven Function Selector needs replacing, the replacement part (used without clamp) is fully compatible. Figure 60: Removing the Clamp 2. Follow all steps in Accessing Components under the Maintop, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 4. From the front of the control panel, remove and retain the two screws on the bezel which are attached to the 5-Position Oven Function Selector (see Figure 62). 5. From the back of the control panel, disconnect the plastic multi-pin connector from the pins on the 5-Position Oven Function Selector (see Figure 63). 6. Remove clamp (if there is one) by folding the left and right clamp wings up about 45 degrees (see Figure 60). 7. Pull out the 5-Position Oven Function Selector _ARA_EN_D Page 37 of 68

38 Caution When installing the 5-Position Oven Function Selector, make sure to attach the connector correctly onto all of the pins Dual Valve Removal and Replacement There is one dual valve on the 36-inch range. Prior to Servicing the Dual Valve Turn off the gas supply to the appliance Turn off electrical power to the appliance Figure 62: Oven Function Selector Screws on Bezel Figure 63: Multi-Pin Connector on 5-Position Oven Function Selector 2. Follow all steps in Accessing Components under the Maintop, page Disconnect all four blade connectors from the dual valve, and make a note of which wires are connected to each of the different terminals (see Figure 64, page 39). 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 4. Use a 1/4 inch wrench to unscrew the gas tube hex nut from each of the three gas tubes attached to the dual valve. Be careful not to bend the gas tubes (see Figure 64, page 39). 5. Remove and retain the two T-20 screws on the side of the support bracket that is secured to the dual valve (see Figure 65, page 39). You do not have to remove the screws securing the support bracket to the chassis. NOTE: For PRL364GDH/01, the support bracket will either have two or three screws securing it to the chassis (see Figure 65, page 39). 6. Remove and replace the dual valve if necessary _ARA_EN_D Page 38 of 68

39 Regulator Removal and Replacement Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 64: Dual Valve Prior to Servicing the Regulator Turn off the gas supply to the appliance Turn off electrical power to the appliance 2. Follow all steps in Accessing Components under the Maintop, page Remove the left-side burner support rail (with jet holder assemblies attached) by following the steps in Burner Support Rail Removal and Replacement, page Using two wrenches (such as pipe wrench, adjustable wrench) hold the left-side protruding receptacle of the regulator steady with one wrench, while simultaneously rotating the flared adapter with the other wrench until you can remove the flared adapter from the regulator (see Figure 66, page 40). 5. Now use a wrench to secure the connecting pipe, while you simultaneously rotate the regulator until you can remove it (see Figure 66, page 40). 6. Replace the regulator if needed. 7. When replacing the regulator or associated fittings, use pipe sealant on pipe threads only - such as the manifold to T connector, T connector to connecting pipe, connecting pipe to regulator, and regulator to flared adapter (threaded end only). Figure 65: Dual Valve Support Bracket (Typical Models Shown) Never use pipe sealant on the flair connections or pressure fittings, such as the flair end of the flared adapter _ARA_EN_D Page 39 of 68

40 8. When replacing the regulator, make sure its cap fitting is facing upward, so it can be easily accessed (see Figure 66) Ignition Device Removal and Replacement 2. Follow all steps in Accessing Components under the Maintop, page Pull to detach the two plastic side connectors from the ignition device (see Figure 67). 4. Using a T-20 driver, remove and retain the two screws securing the ignition device to the range chassis. 5. Replace the ignition device if needed. Figure 66: Regulator with Fittings and Gas Flex Line Figure 67: Ignition Devices Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test LED Indicator Removal and Replacement 2. Follow all steps in Accessing Components under the Maintop, page Pull to disconnect the white plastic male and female wire connectors of the LED indicator (see Figure 68, page 41) _ARA_EN_D Page 40 of 68

41 4. While pushing the protruding clip at the front end of the LED indicator, push the LED indicator frontward through the hole in the control panel (see Figure 69). 5. Replace the LED indicator if needed Control Board Removal and Replacement 2. Follow all steps in Accessing Components under the Maintop, page 19. NOTE: On some models, the simmer board may be attached to the side of the control board shield. 3. Remove and retain the T-20 screw(s) holding the control board shield onto the range chassis and then remove the control board shield (see Figure 70). Screw Figure 68: LED Indicator Connectors Figure 70: Control Board Shield Figure 69: LED Indicator Protruding clip 4. Remove all multi-pin connectors and individual tab connectors from the control board (see Figure 71). 5. At the control board, detach the green ground wire from the ground screw on the range chassis. -OR- Alternatively, at the control board, detach the single red blade connector (for the green ground wire) from the control board (see Figure 71, page 42) _ARA_EN_D Page 41 of 68

42 6. Use a needle nose pliers to carefully remove the control board from the plastic standoffs. 7. Replace the control board only if needed. NOTE: When installing the control board, make sure the green ground wire is secured from the control board to the ground screw on the chassis. Figure 72: Simmer Control Board Figure 71: Control Board Simmer Control Board Removal and Replacement 2. Follow all steps in Accessing Components under the Maintop, page Using a T-20 driver, unscrew and detach the ground wire connected to the range chassis. Retain the screw if you remove the screw from the chassis. 4. Gently pull to detach the two plastic multi-pin side connectors from the simmer control board (see Figure 72). 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 simmer control board from the plastic standoffs by lightly pressing the tiny protruding clip on each plastic standoff, while simultaneously pulling the simmer control board off the standoff. 6. Remove and replace the simmer control board if needed. NOTE: Please explore other possible causes before replacing the simmer control board. Approximately 75% of all simmer control boards returned to the factory turn out to be ok _ARA_EN_D Page 42 of 68

43 6.4 Removal and Replacement of Back-Accessible Components This section contains removal and replacement procedures for the components that can be accessed from the back of the range. NOTE: Before and after servicing the range from the back side, refer to the Installation Manual for instructions on removing and installing the anti-tip bracket, as well as other important installation information. Moving the Range For servicing that requires access from the back of the range, it may be necessary to move the range. Due to the weight of the range, using an air sled or oven dolly to move it may reduce the risk of injury and/or damage. 2. Remove and retain the T-20 screws on the front-facing side of the backguard / Island Trim (see Figure 26, on page 21). 3. Remove and retain the T-20 screws on the back side of the backguard / Island Trim (see Figure 74, Figure 75). 4. Lift the backguard straight up to remove (see Figure 73). NOTE: When reinstalling, the backguard / Island Trim must be placed inside of the two guide channels (see Figure 73) Backguard and Island Trim Removal and Replacement This procedure applies for the backguards (the Lowback, and the 22-inch High Backguard), as well as for the Island Trim. If replacing with a different backguard or Island Trim model, the installation must be performed with adherence to all procedures and warnings/cautions in the Installation 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 National Fuel Gas Code ANSI Z223.1/NFPA 54 current issue and National Electrical Code ANSI/NFPA 70-current issue. In Canada, installation must be in accordance with the CAN 1-B149.1 and.2 Installation Codes for Gas Burning Appliances and/or local codes. Figure 73: Guide Channels for Backguard and Back Panels (Typical range and Island Trim Shown) _ARA_EN_D Page 43 of 68

44 Caution Be very careful not to damage the gas flex line or terminal box (junction box) components and wiring when removing or installing the back panel. Figure 74: 22-Inch High Backguard (Back Side Shown) 4. Carefully remove the back panel out of the right and left side guide channels, in an upward direction (see Figure 73), and detach it from the gas flex line. NOTE: When reinstalling the back panel, the back panel must be placed on the inside of the two guide channels (see Figure 73). Figure 75: Island Trim Back Panel Removal and Replacement 2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page Remove and retain the screws from the back panel, as shown in Figure 76. Figure 76: Back Panel Screw Locations _ARA_EN_D Page 44 of 68

45 6.4.3 Terminal Block Removal and Replacement Replace the terminal block (main power connector) in the event the terminal threads are stripped, or if there is any other damage to the component. 2. Detach the wire leads from each terminal on the terminal block (see Figure 77). Retain the washers and nuts, and make a note of which wires are connected to each different terminal. 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 3. Remove and retain the two T-20 screws securing the terminal block onto the terminal box (junction box). See Figure When replacing the terminal block, refer to Electrical Wiring Connections at the Terminal Block, page 45) Electrical Wiring Connections at the Terminal Block For electrical wiring requirements and safety precautions, refer to the Installation Manual for this appliance. NOTE: The electrical wiring diagram is located on the back side of the kick panel (see Wiring Diagram, page 4) Cooling Fan Removal and Replacement Figure 78: Cooling Fan 2. Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 43. Figure 77: Terminal Block _ARA_EN_D Page 45 of 68

46 3. From the back of the range, detach the three wire connectors (see Figure 79). Figure 80: Cooling Fan Access Holes in Chassis (Typical Range Chassis Shown) Figure 79: Wire Connectors (Typical Fan Shown) Sharp Component Use Gloves Use gloves as the fan has sharp edges 4. From the two access holes in the chassis (see Figure 80), use a long T-20 driver to remove the screws that secure the cooling fan onto the bracket if they cannot be removed from the back of the range (see Figure 78, Figure 80 and Figure 81). 5. Using gloves, remove the cooling fan. 6. Replace the cooling fan if needed. Figure 81: Removing Cooling Fan Screws _ARA_EN_D Page 46 of 68

47 6.4.6 Broil Burner Assembly Removal and Replacement 6. From the back of the range, disconnect the hot surface igniter (HSI) blade connectors (see Figure 83). 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. Figure 83: Hot Surface Igniter (HSI) Connectors Figure 82: Broil Burner Assembly 2. Remove both oven doors (see Door Removal and Installation, page 60). 3. Remove all trays from the oven. 4. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 43). 5. Remove the back panel (see Back Panel Removal and Replacement, page 44). Figure 84: Hot Surface Igniter Eye Protection To protect your eyes from debris, it is recommended to wear protective eye wear when removing or installing components inside the oven cavity, such as the broil burner brackets, or the broil burner _ARA_EN_D Page 47 of 68

48 7. From inside the oven cavity, remove and retain the nut and shim ring from the right and left sides of the HSI support bracket to remove the HSI-support bracket assembly from the infrared broil burner (see Figure 85). Figure 86: Screws Attaching HSI to HSI Bracket Figure 85: Infrared Burner, Nuts and Shim Rings on HSI Bracket 8. [Only if replacing the igniter]: Turn over the HSI-support bracketassembly and remove the 2 nuts and shim rings (see Figure 86) to detach the HSI from the bracket. 9. Gently pull the HSI (or HSI-support bracket assembly) forward (out of the oven cavity), with the HSI wires and blade connectors passing through the portal holes at the back of the range. 10. Replace the HSI if necessary. 11. From inside the oven cavity, remove the five retaining brackets by removing and retaining the respective T-20 screws (see Figure 87, page 48). Figure 87: Infrared Burner, Brackets, Screw Positions 12. From the back of the range, use a wrench to rotate and detach the gas line (hex nut) from the elbow connector (see Figure 88) _ARA_EN_D Page 48 of 68

49 6.4.7 Convection Components Removal and Replacement The convection components are accessed from both the back and the front of the range. Figure 88: Elbow Connector Attached to Gas Line 13. Now gently pull out the infrared broil burner from the ceiling of the cavity. Be careful not to bend the orifice holder bracket at the end of the Venturi tube (see Figure 89). NOTE: Do not detach the elbow connector and orifice from the orifice holder bracket (see Figure 89). If the elbow connector or orifice needs replacing, replace the broil burner assembly. Figure 90: Convection Components Figure 89: Venturi Tube Shown with Elbow Connector and Orifice Attached to Bracket _ARA_EN_D Page 49 of 68

50 2. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 43). 3. Remove the back panel (see Back Panel Removal and Replacement, page 44). 4. Remove oven door (see Door Removal and Installation, page 60). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door / latch components. 5. Remove all the oven racks. 6. Remove and retain the four T-20 screws and remove the front cover (see Figure 91). NOTE: When reinstalling front cover, it must be positioned with the cover vents facing to the right (see Figure 91). Fiberglass Wear gloves when handling fiberglass insulation. 8. From the back of the range, detach the two convection motor blade connectors (see Figure 92). Be sure to first make a note of how they are connected. 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). Figure 92: Convection Motor Wire Connectors Figure 91: Screws Securing Front Cover 7. Remove the nut, and then remove the convection fan. Retain the shim ring if it falls out when removing the fan (see Figure 90). 9. Remove the six T-20 screws on the rear cover shield, and pull the rear cover shield (attached to motor assembly) forward through the oven cavity to remove it (see Figure 93 and Figure 94). 10. To detach the motor assembly from the bracket, first remove and retain the shim ring (see Figure 95, page 51) _ARA_EN_D Page 50 of 68

51 Figure 93: Rear Cover Shield Screws Figure 95: Removing Shim Ring Figure 94: Rear Cover Shield / Motor Assembly (Back Side View) 11. Remove and retain the three T-20 screws from the rear cover shield (Figure 95 and Figure 96, page33), then remove the rear cover shield from the bracket and fiberglass insulation (see Figure 97, page 52). Figure 96: Screws Attaching Rear Cover Shield to Motor Bracket 12. Wearing gloves, remove and retain the fiberglass insulation, and then remove and retain the three T-20 screws securing the bracket onto the motor (see Figure 98) _ARA_EN_D Page 51 of 68

52 6.5 Removal and Replacement of Front-Accessible Components This section contains removal and replacement procedures for the components that can be accessed from the front of the range Control Panel Removal and Replacement Figure 97: Bracket (Typical Model Shown) and Insulation Figure 99: Control Panel The following procedures for removal and replacement of the control panel are provided primarily in the event the control panel is damaged and needs replacing. Most components can be accessed and serviced without the need to remove the control panel. NOTE: When removing and replacing the control panel, you must first disconnect all wire and harness connections, and remove all manifold support brackets connected to the back side of the control panel. Figure 98: Screws Connecting Bracket to Motor 13. Replace the convection motor, if needed. NOTE: When installing, the front cover must be positioned with the cover vents facing to the right (see Figure 91). 2. Follow all steps in Accessing Components under the Maintop, page _ARA_EN_D Page 52 of 68

53 3. Before disconnecting the wire harness connectors, first make a note of how they are connected to all components that are housed at the back side of the control panel (solenoid valves, LED indicators, microswitches, and potentiometers). 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 reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 4. Remove all valves, components and respective wiring connectors: as follows: Standard valves (see Standard Valve Removal and Replacement, page 30) Microswitches (see Microswitch Removal and Replacement, page 31) Solenoid valves (see Solenoid Valve Removal and Replacement, page 32) XLO valves (see XLO Valve Removal and Replacement, page 33) Potentiometers (see Potentiometer Removal and Replacement, page 35) LED indicators (see LED Indicator Removal and Replacement, page 40) NOTE: LED indicators can stay on control panel as long as their connectors are detached. 5. At the location of the two knobs connected to the manifold brackets (see Figure 44), use a T-20 driver to remove and retain the two screws from the bezels (see Figure 45) in order to detach the manifold support brackets on the back side of the control panel (see Figure 47). NOTE: When removing or replacing the control panel you do not have to remove the manifold support bracket on the chassis base near the regulator (see Figure 46). 6. Remove and retain the two T-20 screws from the control panel bracket (see Figure 99). 7. Using a swivel head driver with a 11/32 inch deep well socket or a 11/32 inch open end wrench, remove and retain the three screws/nuts from the inner, left and right sides of the chassis (see Figure 100). Figure 100: Screw/Nut on Inner Chassis (Upper Screw/Nut Shown) 8. Carefully lift the control panel slightly upward to detach from the lip on the range chassis (see Figure 101), and then pull away in a forward direction to remove the metal tabs from the chassis (see Figure 99 and Figure 102). 9. Replace the control panel if needed. Gas Leaks Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test _ARA_EN_D Page 53 of 68

54 6.5.2 Bake Burner Components Removal and Replacement Hot Surfaces The oven bake burner and interior surfaces of the oven may be hot and can cause burns. Do not service the range if these components are hot. Figure 101: Detaching Control Panel from Lip 2. Remove the oven door (see Door Removal and Installation, page 60). 3. Remove all trays from the oven. 4. Remove the kick panel (see Kick Panel Removal and Replacement, page 62). Figure 102: Detaching Control Panel Tabs from Chassis _ARA_EN_D Page 54 of 68

55 5. Detach the bottom plate of the front frame. First remove and retain the larger T-20 screws, and then remove and retain the smaller T-20 screws (see Figure 103). Figure 104: Screws on Rim of Cavity Base 7. Lift the cavity base slightly up and then out (towards you). Be careful not to scratch the porcelain finish of the cavity. 8. The deflector (flame spreader) is attached to the cavity base. Only detach the deflector if it needs replacing by removing and retaining the four T-20 screws from the center of the cavity base (see Figure 105, page 55). Caution Set the cavity base on a flat, protected surface so that the deflector does not get bent, and so the screws don t damage any surface. Figure 103: Screws on Bottom Plate of Front Frame 6. Remove and retain the five T-20 screws from around the rim (not the center) of the cavity base (see Figure 104). Figure 105: Deflector Attached to Cavity Base _ARA_EN_D Page 55 of 68

56 Figure 106: Bake Burner with Cavity Base Removed 9. Detach the orifice fitting assembly from the gas flex line by using a wrench to hold the small brass hex nut on the gas flex line, while simultaneously using another wrench to rotate the orifice holder (large aluminum 7/8-inch hex nut) until the gas flex line is released (see Figure 107 and Figure 108). 10. Unscrew the slip nut on the orifice fitting assembly to remove it from the air shutter (see Figure 107 and Figure 108). NOTE: When installing an orifice fitting assembly, make sure to use pipe sealant on the orifice threads. Make sure no pipe sealant gets on the slip nut, as it must spin freely to screw into the air shutter. Figure 107: Orifice Fitting Assembly 11. Remove and retain the two T-20 screws from the bake burner bracket (see Figure 106). 12. Gently pull bake burner out of the slot in the oven cavity with the hot surface igniter (HSI) attached. See Figure _ARA_EN_D Page 56 of 68

57 Figure 108: Orifice Fitting Assembly Connections Figure 109: Removing Bake Burner with HSI Attached 13. Detach the HSI from the bake burner by removing and retaining the two screws that secure the HSI onto the HSI support bracket (see Figure 110 and Figure 111). Figure 110: Hot Surface Igniter (HSI) Figure 111: Removing the HSI from the Bake Burner 14. Replace the bake burner if needed. NOTE: When installing the bake burner, there is no need to adjust the air shutter, as it is pre-set in the factory to the fully-opened position. 15. [If replacing the HSI]: Detach the HSI blade connectors (see Figure 109 and Figure 110). 16. [If replacing the HSI]: Using a needle-nose pliers, squeeze the ends of the plastic tie, and pull the plastic tie out to release the HSI wires (see Figure 109). 17. Replace the HSI if needed _ARA_EN_D Page 57 of 68

58 6.5.3 Oven Temperature Sensor Removal and Replacement The oven temperature sensor is located inside the oven cavity (see Figure 112). Figure 113: Sensor Wire Connectors and Portal Figure 112: Sensor and Lamp Locations inside the Oven Cavity 2. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 43). 3. Remove the back panel (see Back Panel Removal and Replacement, page 44). 4. Remove oven door (see Door Removal and Installation, page 60). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components. 5. From the back of the range, at the left side, detach the connectors to the purple and white sensor wires (see Figure 113). 6. From inside the oven cavity, remove and retain the two T-20 screws (see Figure 114). Figure 114: Sensor _ARA_EN_D Page 58 of 68

59 Fiberglass Insulation Wear gloves when handling fiberglass insulation. 7. From the back of the range, while wearing gloves, clear a path in the fiber glass insulation so the sensor wire connectors can be pulled through the sensor portal (see Figure 113). 8. From the front of the range, gently pull the sensor connector wires through the portal. 9. Replace the sensor if necessary. Fiberglass Insulation Wear gloves when handling fiberglass insulation. 7. From the back of the range, while wearing gloves, clear a path in the fiber glass insulation so the lamp wire connectors can be pulled through the sensor portal (see Figure 115). 8. From the front of the range, gently pull the lamp connector wires through the portal. 9. Replace the lamp Oven Lamp Removal and Replacement The oven lamp is located inside the oven cavity (see Figure 112). NOTE: Before servicing the oven lamp, see Oven Light Diagnostics, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 43). 3. Remove the back panel (see Back Panel Removal and Replacement, page 44). 4. Remove oven door (see Door Removal and Installation, page 60). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components. 5. From the back of the range, detach the lamp wire connectors (see Figure 115). 6. From inside the oven cavity, remove and retain the T-20 screw. Figure 115: Lamp Wire Connectors For bulb replacement, you can use any commercially available bulb with the following specification: 120 or 130 VAC, 50 W max., G8 base, Halogen maximum?), G8 base _ARA_EN_D Page 59 of 68

60 6.5.5 Door Removal and Installation Failure to comply with these warnings can result in injury and/or damage: Before removing the oven door, make sure the gas supply and electrical power to the range are turned off, and that the door and oven are not hot. Be careful when removing the oven door as it is very heavy. Use both hands to remove or replace the oven door, and grasp both sides of the door when handling it. When the door is removed from the range, never release locking levers or try to close the hinges. Without the weight of the door, the powerful springs will snap the hinges shut with great force Removing the Door 2. Open the door fully, and then push both hinge locks downward (towards you) as far as they go, until they stop. 3. Firmly grasp the heavy door on both sides, and gently close the door until it stops against the hinge locks (at about a 45 angle). 4. Be careful not to let the door fall. While still grasping the door firmly on both sides, exert a bit more force to continue closing the door another few inches, and when the door is about 10 inches from being fully closed, it will stop. 5. Pull the door upward to lift it off the range Installing the Door 2. Firmly grasp the heavy door on both sides, and with the door open about 10 inches, carefully guide the hinge arms into the hinge receiver slots. 3. Slowly open the door a few inches until it stops against the hinge locks (at about 45 ). If the door doesn t stop and can be opened more, the hinges are not seated properly - it may be necessary to press the door inward towards the receiver slots, while using a slight rocking motion to seat the hinges. 4. Be careful not to let the door fall. While still grasping the door firmly on both sides, exert a bit more force to continue opening the door fully. Then push the hinge locks upward (away from you) as far as they go to lock the door onto the range. 5. Open and close the door to make sure the door is positioned properly and closes with a tight fit Door Handle Components - Removal and Replacement _ARA_EN_D Page 60 of 68

61 Figure 116: Installing the Door Handle Components Removing Door Handle Components 2. Remove the oven door (follow all warnings and steps for the Door Removal and Installation procedure, page 60). 3. From the upper, back side of the door, remove and retain the two T-20 screws and round washers attached to their respective standoffs. 4. From the bottom of the door, remove and retain the four T-20 screws and washers. 5. From the glass door panel, remove and retain the two T-20 screws and angled washers. Then use a 1/2 inch wrench to remove the two standoffs. 6. Remove door handle tube, left and right endcaps. 6. Install the oven door and test for proper positioning (follow all warnings and steps for Installing the Door, page 60) Door Gasket Removal and Replacement Check for applicable technical documents for this appliance in QuickFinder before replacing the door gasket. 2. Remove oven door (see Door Removal and Installation, page 60). 3. Starting from one end of the gasket while carefully working your way to the other end, gently pull the gasket clips out of the receptacles on the oven frame (see Figure 117). 4. After replacing the gasket, check to make sure the door closes with a tight fit Installing Door Handle Components NOTE: Prior to door reassembly, clean the door window. 2. Assemble endcaps onto door handle tube. 3. Use a 1/2 inch wrench to fasten the 2 standoffs through the glass door panel, onto the endcap standoff receptacles 4. Install the T-20 screws and angled washers through the glass door panel, onto the endcap screw receptacles. 5. Install the two T-20 washers and screws through the back side of the door, onto the standoffs. Then install the other four washers and screws onto the bottom of the door. Figure 117: Removing the Gasket (Typical Oven Shown) _ARA_EN_D Page 61 of 68

62 6.5.8 Kick Panel Removal and Replacement 2. Remove oven door (see Door Removal and Installation, page 60). 3. Remove and retain the two T-20 screws from the kick plate (see Figure 118), and then lift the kick plate upward to detach from the two standoffs on the range chassis (see Figure 119). Figure 119: Lifting the Kick Plate off the Standoffs Figure 118: Removing Kick Plate Screws 4. The wiring diagram for the range is located on the back side of the kick plate (see Figure 120). Figure 120: Wiring Diagram _ARA_EN_D Page 62 of 68

63 6.5.9 Bottom Plate of Front Frame Removal and Replacement 2. Remove oven door (see Door Removal and Installation, page 60). 3. Remove only the ends of the gasket from the respective holes in the bottom plate of the front frame (see Figure 121). You do not have to remove the entire gasket. Figure 122: Removing Initial Screws - Bottom Plate of Front Frame Figure 121: Removing the Gasket Ends 4. First remove the three T-20 screws from both the right and left sides of the bottom plate of front frame (see Figure 122). 5. Then remove the T-20 screw from both the right and left sides of the bottom plate of front frame (see Figure 123). 6. Remove the bottom plate of the front frame by pulling it out horizontally (toward you). Figure 123: Removing Next Screw - Bottom Plate of Front Frame _ARA_EN_D Page 63 of 68

64 Door Hinge Receiver Removal and Replacement Check QuickFinder for applicable technical documents and information before replacing the door hinge receiver. Figure 125: Removing Hinge Receiver Screws Figure 124: Door Hinge Receiver 6. Using gloves, remove the hinge receiver (see Figure 126). 2. Remove oven door (see Door Removal and Installation, page 60). 3. Follow all steps in the Door Gasket Removal and Replacement procedure, page Follow all steps in the Bottom Plate of Front Frame Removal and Replacement procedure, page Remove and retain the two T-20 screws that secure the hinge receiver onto the range frame (see Figure 125). Fiberglass Insulation Wear gloves when handling fiberglass insulation. Figure 126: Removing the Hinge Receiver _ARA_EN_D Page 64 of 68

65 Door Hinge Removal and Replacement Check for applicable technical documents for this appliance in QuickFinder before replacing the Door Hinge. 4. Lift and remove the stainless steel door cover (see Figure 128). When the door is removed from the range, never release locking levers or try to close the hinges. Without the weight of the door, the powerful springs will snap the hinges shut with great force. NOTE: You may be required to replace both hinges, as well as the oven gasket (see Door Gasket Removal and Replacement, page 61). Read the Technical Service Bulletin and all other applicable documents for this appliance listed in QuickFinder. 2. Remove oven door (see Door Removal and Installation, page 60). 3. Gently place the door (porcelain side facing down) on a flat, stable surface. Then remove and retain the T-20 screws on the base of the door (see Figure 127). Figure 128: Removing the Stainless Steel Door Cover 5. Turn the door over, with porcelain side facing upward. 6. For each hinge, remove and retain the three T-20 screws that hold the hinge onto the door (see Figure 129). Figure 127: Door (Typical Model Shown) Figure 129: Screws Holding Hinge onto Door _ARA_EN_D Page 65 of 68

66 Thermostat Removal and Replacement Sharp Components Wear gloves when removing the door hinge Caution The upper part of the porcelain door panel has two screws fastened with Loctite adhesive, which should not be removed. Therefore, when removing the hinge, open the door only as much as needed to remove the hinge, as opening the door too much may damage the door. 7. With one hand, raise the porcelain door panel upward (to separate it from the rest of the door) just enough to remove the hinge, while you simultaneously remove the hinge with the other hand. NOTE: It may be advantageous to place a wooden block in-between the door panels when removing the hinge. The thermostat controls the griddle temperature. Check QuickFinder to order the correct Thermostat. 1. Follow all safety precautions and steps in the Preparing the Range for 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 and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when reassembling. HINT: Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 3. Using a T-20 driver, remove and retain the two screws on the bezel of the griddle control knob (see Figure 131). Figure 130: Hinge Figure 131: Screws Attached to Thermostat _ARA_EN_D Page 66 of 68

67 4. Remove the thermostat from the back of the control panel (see Figure 132). Figure 132: Thermostat (Typical Model Shown) 7 BEFORE RETURNING APPLIANCE TO SERVICE After you have finished all testing and servicing, always do the following before returning the appliance to service: Carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Make sure all electrical connections are correct and secure. Make sure all safety grounds (internal and external) are correctly and securely connected. Make sure all panels and components are properly and securely reassembled. Make sure the range is level and adjust accordingly. If the range was pulled away from the wall for servicing, cleaning, or any other reason, make sure that the range is properly secured onto the anti-tip device when the range is pushed back against the wall. Refer to the Installation Manual for details on anti-tip device installation. 8 CLEAN-UP After you have finished servicing an appliance, clean up grease, fingerprints, and other residue that is present as the result of servicing the appliance. Clean-up Hazards Don t allow any cleaning or polishing solutions/compounds, disinfectants or bleaches to remain in contact with the stainless steel surfaces for long periods, or after clean-up. These may contain chemicals or materials which could release harmful inhalants or may damage the appliance. After cleaning or polishing, always rinse the cleaning/polishing materials with clear water and wipe dry with a clean, soft, non-abrasive cloth _ARA_EN_D Page 67 of 68