TABLE OF CONTENTS. 1 General Operation Service and Repair Testing, Adjusting, Troubleshooting Burners and Ignition...

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1 TABLE OF CONTENTS 1 General Applicable Models Data Rating Plate Wiring Diagram Technical Documents to Read Prior to Servicing Recommended Tools and Supplies Important Safety Information Safety Symbols Used In This Manual Safety Precautions to Know Prior to Servicing Operation Control Knobs Standard Burners ExtraLow Burners Griddle Control Knob Grill Control Knob Temperature Selector Knob Five-Position Oven Function Selector Knob Three-Position Oven Function Selector Knob Oven Lamp Switch LED Indicators Automatic Re-Ignition Operation During a Power Outage Maintop Components and Burner Assembly Testing, Adjusting, Troubleshooting Burners and Ignition Before Testing Rangetop Burner Characteristics Rangetop Flame Characteristics Testing Rangetop Burner Ignition Testing Rangetop Burner Ignition Testing the HI, Medium, and Low Settings Testing the XLO Setting Testing Broil Burner Ignition Testing Bake Burner Ignition Adjusting Bake Burner Flame with the Air Shutter Adjusting Rangetop Burner Valves Manually Special Tools Needed Adjusting the Bypass Screws Troubleshooting Burner/Flame, Ignition, and Elements Burner and Flame Diagnostics for Rangetop Burners Ignition Diagnostics for Rangetop Burners Element Diagnostics Safety Practices for Element Diagnostics Element Diagnostic Tips Fault Codes Service and Repair Preparing the Range for Servicing Accessing Components under the Maintop Removing Knobs, Grates, and Burner Assemblies Removing Spill Trays Removing Heat Shields Removing the Burner Support Rail Griddle Removal and Replacement Griddle with Removable Brackets Removal and Replacement _ARA_EN_B Page 2 of 119

2 4.3.2 Griddle with Fixed Brackets Removal and Replacement Grill Components Removal and Replacement Grill Flame Spreader Removal and Replacement Grill Burner Removal and Replacement Grill Hot Surface Igniter Removal and Replacement Grill Electrode Removal and Replacement Grill Thermostat Bulb Removal and Replacement Grill Orifice and Elbow Connector Removal and Replacement Removal and Replacement of Top-Accessible Components Jet Holder Assembly Removal and Replacement Standard Valve Removal and Replacement Microswitch Removal and Replacement Solenoid Valve for XLO Burner - Removal and Replacement Solenoid Valve for Grill Removal and Replacement XLO Valve Removal and Replacement Potentiometer Removal and Replacement Manifold for Rangetop Burners Removal and Replacement Oven Lamp Transformer Removal and Replacement Oven Temperature Selector -- Removal and Replacement Five-Position Oven Function Selector Removal and Replacement Three-Position Oven Function Selector Removal and Replacement Oven Temperature Gauge Removal and Replacement Regulator Removal and Replacement Bi-Metal Gas Valve Removal and Replacement Under Maintop Bake Burner Solenoid Removal and Replacement Under Maintop Control Board Removal and Replacement Control Board Removal and Replacement Main Oven Control Board Removal and Replacement Small Oven Simmer Control Board Removal and Replacement Hot Surface Igniter Board Removal and Replacement DSI Module Removal and Replacement LED Indicator Removal and Replacement Ignition (Spark) Module Removal and Replacement Door Latch Removal and Replacement Plunger Switch Removal and Replacement Griddle / Grill Thermostat Removal and Replacement Control Panel and Bullnose Removal and Replacement Removal and Replacement of Back-Accessible Components Backguard and Island Trim Removal and Replacement Back Panel Removal and Replacement Crossmember Cover Removal and Replacement Dilution Flue Removal and Replacement Terminal Block Removal and Replacement Electrical Wiring Connections at the Terminal Block Cooling Fan Removal and Replacement Air Interlock Switch Removal and Replacement Thermal Fuse Removal and Replacement Manifold Arm Removal and Replacement Back of Range Bake Burner Solenoid Removal and Replacement Back of Range Bi-Metal Gas Valve Removal and Replacement Back of Range Removal and Replacement of Front-Accessible Components Oven Temperature Sensor Removal and Replacement Oven Lamp / Lamp Bulb Removal and Replacement Oven Light Diagnostics Oven Door Removal, Installation, and Alignment Removing the Door _ARA_EN_B Page 3 of 119

3 Installing the Door Aligning the Door Convection Components Removal and Replacement Broil Burner Components Removal and Replacement Hot Surface Igniter for Broil Burner Removal and Replacement Broil Burner Removal and Replacement Bake Burner Components (Large Oven) Removal & Replacement Replacing the Bake Burner Large Oven Replacing the Bake Burner Hot Surface Igniter Large Oven Replacing the Bake Burner Electrode Large Oven Replacing the Bake Burner Orifice Assembly Large Oven Bake Burner Components (Small Oven) Removal & Replacement Replacing the Bake Burner Small Oven Replacing the Bake Burner Hot Surface Igniter Small Oven Replacing the Bake Burner Electrode Small Oven Replacing the Bake Burner Orifice Assembly Small Oven Removing the Bake Burner Box Small Oven Door Handle Components Removal and Replacement Removing Door Handle Components Door Hinge Removal and Replacement Door Gasket Removal and Replacement Kick Panel Removal and Replacement Before Returning Appliance to Service Clean-Up Additional Resources QuickFinder Technical Support _ARA_EN_B Page 4 of 119

4 1 GENERAL Pro Grand LP Gas Range models come with an array of features such as Star burners, convection bake, a 6-pass, 1630-watt electric griddle, a gas grill, and two ExtraLow simmer burners. This range is compatible for use with LP gas only. 1.1 Applicable Models This manual contains information that is necessary for servicing the following Thermador Pro Grand Ranges: PRL304EG PRL364EDG PRL364ELG PRL366EG PRL484ECG PRL486EDG PRL486EDPG PRL486ELG 1.2 Data Rating Plate The data rating plate which shows the model, serial, and FD number is located at the bottom of the range behind the kick panel, as shown in Figure 1. Remove the kick panel to access it. The information on the data rating plate 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). 1.3 Wiring Diagram The Wiring / schematic diagram is located behind the kick panel (see Figure 1). 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. Contact Technical Support for further assistance. Figure 1: Data Rating Plate and Wiring Diagram Locations 1 Data rating plate (behind kick panel) 2 Wiring diagram (back side of kick panel) _ARA_EN_B Page 5 of 119

5 1.4 Technical Documents to Read Prior to Servicing Before you start servicing, check QuickFinder for all documents and information associated with this specific appliance and/or parts. 1.5 Recommended Tools and Supplies The following are recommended to use when servicing this appliance: m Caution Power Drivers If using a power driver, set the clutch to the lowest setting Phillips screwdrivers Flat blade screwdrivers: large, small Precision flat-blade screwdriver with a high-strength blade, 1/8-inch [3.0mm] wide,.020-inch [0.50mm] thickness tip Drivers: T-27, T-20, T-10 1/4 inch nut driver or 1/4 inch socket wrench / ratchet 20 mm socket Adjustable wrenches (2) 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, 11/32 inch, Pipe wrench Socket wrench / ratchet 11/32 inch Swivel head driver with an 11/32 inch, deep-well socket Needle-nose pliers Hammer Protective gloves Gas leak test equipment Pipe sealant Small mirror Air sled or dolly Protective eye wear (such as glasses, goggles) Flashlight Amp meter Thermometer with thermocouple leads Multimeter 1.6 Important Safety Information Before starting to service an appliance, familiarize yourself with all safety information and precautions contained in this manual Safety Symbols Used In This Manual Warnings alert you to dangers that may result in bodily injury or death. m Caution Cautions alert 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 removing the fuse) Turn off the gas supply to the appliance Make sure the range and components are cool before removing or servicing them Wear protective clothes: long sleeves, gloves, safety glasses Replacement Parts Use only authorized 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 bodily injury, death, or damage _ARA_EN_B Page 6 of 119

6 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 griddle is 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. The only exceptions that may require the electrical power on are for XLO valves and bi-metal gas valves. For these components, use extreme caution when performing gas leak testing with electrical power on. Electrical Hazards Before servicing the appliance, remove electrical power by disconnecting the power cord from the wall receptacle, by shutting off the circuit breaker, or by disconnecting the proper fuse. If tests have to be conducted while the appliance is live, always use a residual-current-operated circuit-breaker. The protective conductor connection must not exceed 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 rangetop burner assemblies, maintop, griddle/grill, infrared burners, gas burners, electric elements, hot surface igniters, heat deflector, and interior oven surfaces, or the exterior area immediately surrounding the door. 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 _ARA_EN_B Page 7 of 119

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. 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. Clean the range with caution. Do not use flammable cleaners to clean the range. Avoid steam burns; do not use a wet sponge or cloth to clean the range while it is hot. Do not use any type of aerosol cleaner on or around the rangetop when hot. Some cleaners produce noxious fumes if applied to a hot surface. Follow directions provided by the cleaner manufacturer. Fiberglass Insulation Wear gloves when handling fiberglass insulation. Prior to Returning Appliance to Service Prior to returning the appliance to service, make sure that: All electrical connections are correct and secure All safety grounds (internal and 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 m 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_B Page 8 of 119

8 2 OPERATION 4. In XLO mode, the knob can be set between SIM and XLO for a variable range of low heat (see Figure 3). 2.1 Control Knobs The control knobs each have an icon to identify the location on the range. The two standard burners are located on the right side of the control panel (see Figure 2). The two ExtraLow (XLO) burners are located on the left side (see Figure 3) Standard Burners 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 standard burners, rotate the knob to any setting between HI and SIM. NOTE: The blue LED indicator lights up when burners are lit. Figure 3: XLO Burner Control Knob Griddle Control Knob The griddle knob controls the temperature to the griddle, from 150 F to 500 F (see Figure 4). Press and turn the knob clockwise to select a setting. Figure 2: Standard Burner Control Knob ExtraLow Burners When in XLO mode - the very lowest flame setting, the flame cycles on for approximately 8 seconds and then turns off for 52 seconds of each minute. 3. Press a control knob in, and turn counter-clockwise to HI setting. The igniter for the burner clicks while sparking until flame ignition. Burner should ignite within 4 seconds. Figure 4: Griddle Control Knob _ARA_EN_B Page 9 of 119

9 2.1.4 Grill Control Knob This knob controls the temperature to the grill. Press the control knob and rotate it counterclockwise to the LITE position. After the flame is completely around the burner, adjust the knob to the desired heat setting between HI and LO Five-Position Oven Function Selector Knob On the large oven for 48-inch ranges and for all 30-inch and 36-inch ranges, use this knob for bake, convection bake, broil, and speedclean (see Figure 7). Figure 5: Grill Control Knob Temperature Selector Knob Use this knob for setting the oven temperature, broil, and speed-clean mode. The small oven does not have the speed-clean feature. See Figure 6. Figure 7: 5-Position Oven Function Selector Knob Large Oven Three-Position Oven Function Selector Knob On the small oven for 48-inch ranges only, use this knob for bake and broil (see Figure 8). Figure 8: 3-Position Oven Function Selector Knob Small Oven Figure 6: Temperature Knobs Large Oven (Left), Small Oven (Right) _ARA_EN_B Page 10 of 119

10 2.1.8 Oven Lamp Switch There is an oven lamp switch for each oven. 2.5 Maintop Components and Burner Assembly Figure 9: Oven Light Switch 2.2 LED Indicators The LED indicators illuminate per current cycle. They are also used to indicate fault codes (see Fault Codes, page 19). Figure 10: LED Indicators 2.3 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. 2.4 Operation During a Power Outage When there is a removal of electrical power, the XLO burners, griddle, and grill cannot be used. Do not attempt to light them manually during a power outage. m Caution Power Outage Precautions Ventilate well by opening a door or window, and wait at least five minutes until all the gas dissipates. If you smell gas, comply with the warnings and precautions in the Important Safety Information section (page 6) of this manual. Figure 11: Maintop Components and Burner Assembly 1 Burner cap 7 Heat shield 2 Venturi tube 8 Burner support rail 3 Burner base (brass) 9 Wire guard clip 4 Trim for spill tray 10 Jet holder assembly 5 Spill tray 11 Spring 6 Nut 12 Igniter plug (electrode) _ARA_EN_B Page 11 of 119

11 3 TESTING, ADJUSTING, 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 3.2 Rangetop Burner Characteristics If one or more rangetop burner blows out, the respective igniter electrode automatically re-ignites the flame. The flame should burn through each burner port, completely around the burner cap (see Figure 12). Ignition Hazard Do not touch burners when the igniters are active (sparking). 3.1 Before Testing Before testing rangetop burners and ignition, do the following: 1. Re-install 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 bases and Venturi tubes 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. Figure 12: Burner Ports 1 Burner port 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 _ARA_EN_B Page 12 of 119

12 3.3 Rangetop 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 14). When the flame is properly adjusted, it should burn completely around the burner cap, at each burner port (see Figure 12). Figure 13: Correct Flame Color and Characteristics 1 Dark blue 2 Secondary cone 3 Light blue 4 Primary cone Figure 14: Additional Flame Characteristics NOTE: If rangetop burner/flame characteristics are not adequate, see Troubleshooting Burner/Flame, Ignition, and Element, page _ARA_EN_B Page 13 of 119

13 3.4 Testing Rangetop Burner Ignition Testing Rangetop Burner Ignition Ignition Hazard Do not touch the rangetop 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, Medium, and Low Settings Set the burner knob to HI, and observe flame characteristics (see Figure 13 and Figure 14). If any burner flame burns primarily yellow, verify if the burner cap is positioned properly on the burner base, and then re-test. Repeat test for MEDIUM and SIM settings. If flame characteristics do not improve, 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 a setting between SIM to XLO and observe if the flame cycles correctly it should be on for approximately 8 seconds, and then off for approximately 52 seconds of each minute Testing Broil Burner Ignition Set the mode to BROIL. After seconds (depending on the model) the burner should ignite. The broiler burners do not have an air shutter, and no adjustment is necessary Testing Bake Burner Ignition Set the oven to BAKE at 350 F. After seconds (depending on the model) 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. 3.5 Adjusting Bake Burner Flame with the Air Shutter The bake burner has an air shutter system (see Figure 15) that is factory pre-set to burn optimally, but depending on the quality of the gas available, may require adjustment. Figure 15: Typical Air Shutter 1 Air shutter 2 Adjustment screw(s) 3 Opening Adjust the bake burner air shutter by doing the following: 1. First remove the bake burner from the burner box. For the large oven, see Replacing the Bake Burner Large Oven, page 97. For the small oven, see Replacing the Bake Burner Small Oven, page Loosen the adjustment screw, and then rotate the air shutter to modify the opening as follows: If the flame is lifting or blowing, or is not carrying over, rotate the shutter clockwise to set the opening 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 _ARA_EN_B Page 14 of 119

14 4. Re-install the burner. For the large oven, see Replacing the Bake Burner Large Oven, page 97. For the small oven, see Replacing the Bake Burner Small Oven, page Test to evaluate the flame characteristics. 6. Repeat procedure as needed until flame characteristics are optimal. 3.6 Adjusting Rangetop Burner Valves Manually Figure 16: Bypass Screw on Valve (Control Panel Removed for Clarity) 1 Bypass screw on XLO or Standard valve 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 the valves Special Tools Needed To reposition the bypass screws for minimum flow settings on manual valves, use a precision high-strength blade screwdriver, with a 1/8 inch [3.0mm] wide,.020-inch [0.50mm] thickness tip 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. For newer models: Remove and retain the two bezel mounting screws and remove the bezel. 4. For older models: Valve screws can be accessed directly through the control panel, without removing the bezel mounting screws. 5. To engage the valve screw, insert the precision screwdriver with 1/8 inch blade into the same hole in the bezel that was created by the removal of the right side mounting screw (see Figure 18, page 16). 6. Turn the valve screw clockwise just until "bottom out" position is reached. DO NOT over-tighten the valve screw (see Figure 18). 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. NOTE: The griddle/grill is controlled by a thermostat and does not have a valve that requires adjustment. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. For XLO valves (not standard valves), you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on XLO valves with the electrical power turned on _ARA_EN_B Page 15 of 119

15 3.7 Troubleshooting Burner/Flame, Ignition, and Elements Burner and Flame Diagnostics for Rangetop Burners Figure 17: Removing the Bezel Mounting Screws 1 Bezel mounting screws (2) If a rangetop burner clicks (sparks) constantly or if burner doesn t light correctly and/or has inadequate burner/flame characteristics (per Rangetop Burner Characteristics page 12 and Rangetop Flame Characteristics page 13), then do the following: Check if the manual shut-off valve is open and the unit is receiving gas. 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 (spark) module and electrode, and also check grounding Refer to the Ignition Diagnostics, page 16. Call Thermador technical support at (800) for assistance if any burners fail to light, or any burners continue to burn yellow Ignition Diagnostics for Rangetop Burners The following flowchart applies in the event a burner fails to ignite. Figure 18: Accessing the Bypass Screw on the Valve 1 Bypass screw access location (shown with bezel mounting screws and bezel removed) Before performing steps in the Rangetop Burner - Ignition Diagnostics Flowchart (Figure 19, page 17), remove electrical power from appliance during disassembly and during removal and installation procedures. Restore electrical power when testing the unit if it is re-assembled _ARA_EN_B Page 16 of 119

16 Figure 19: Rangetop Burner Ignition - Diagnostic Flowchart _ARA_EN_B Page 17 of 119

17 3.7.3 Element Diagnostics Use the following element circuit specification for troubleshooting: Cavity Mode Element Watts Volts Amps Ohms 18-inch 30-inch 36-inch 18-inch 30-inch 36-inch 30-inch 36-inch N/A N/A Bake Bake burner HSI Broil Broil burner HSI Convection Bake Bake burner HSI Griddle NOTE: For some 36-inch and 48-inch models Grill Hot Surface Igniter (HSI) NOTE: For specific 36-inch and 48-inch models. Griddle element Grill burner HSI Figure 20: Element Circuit Specification 120 to to to Safety Practices for Element Diagnostics Observe all pertinent safety practices such as warnings, cautions and instructions contained in the Safety Precautions to Know Prior to Servicing section of this manual (page 6), throughout this manual, and the Installation Manual. Ensure compliance with all applicable codes Element Diagnostic Tips General The electrical wiring diagram is located behind the kick panel of the range (see Wiring Diagram, page 5). Bake and broil modes cannot be operated simultaneously in any single oven cavity. Resistance Reading You can perform a resistance reading on an element with the electrical power to the range turned off. Amperage Readings Bake mode: The power to the bake element cycles on and off at pre-set intervals when the bake element is preheating (preheating indicator light is on) and also during regular bake cycle (after preheating). After preheating, the broil element is on for 4 seconds out of every 60 seconds for food browning. Broil mode: Broil element remains on until reaching the maximum temperature, and cycles off and on to maintain that temperature. Electric griddle element and hot surface igniters (HSIs): Check either of element wires with an amp meter and amp clamp. NOTE: Check the HSIs at one of the wire connectors, as the gas burner (attached to HSI) will ignite. NOTE: Although the HSI may be glowing, if not enough current is running through it, the safety valve may fail. Alternatively, you can check the griddle element or HSIs at the wires going to the hot or neutral terminals of the terminal block. Alternatively, you can check the electric griddle element or HSIs from the corresponding I/O relay terminals on the main control board. Depending on the model, you may have to remove the griddle/grill in order to access the control board. Temperature Reading 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_B Page 18 of 119

18 3.8 Fault Codes When a fault is detected, this appliance will display a fault code (see Figure 24, on page 20). 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 21 and Figure 22) will first blink on the left and then the right, and the vertical positioned blue LEDs (see Figure 23) will first blink on the top and then the bottom. For example, if the first LED blinks 4 times followed immediately by the second LED blinking 3 times, that represents a fault code of 43 on the chart (see Figure 24, on page 20). Figure 22: Three Horizontal LED Indicators (Only Blue LEDs Blink) Figure 21: Two Horizontal LED Indicators Figure 23: Two Vertical LED Indicators _ARA_EN_B Page 19 of 119

19 Figure 24: Fault Codes _ARA_EN_B Page 20 of 119

20 4 SERVICE AND REPAIR 3. Remove all trim from the maintop (see Figure 25). 4.1 Preparing the Range for Servicing For most servicing of this appliance (for example, involving disassembly, or component removal / 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 removing the fuse) Make sure the range is not hot Wear protective clothes: long sleeves, gloves, safety glasses Figure 25: Trim 4. Remove all Star burner caps (see Figure 26). 5. Use a 20 mm socket to remove the Venturi tube from the receptacle in the brass burner base (see Figure 26). If testing the appliance requires the use of electrical power and/or an open gas supply, exercise extreme caution. 4.2 Accessing Components under the Maintop This section contains the steps required to gain access to the components located under the maintop(s) Removing Knobs, Grates, and Burner Assemblies To access and service components located underneath the maintops (see Figure 11), first remove the knobs, grates, and burner assemblies. Then remove spilltrays, heat shields, and burner support rail(s). 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. 2. Remove all grates. Figure 26: Star Burner Assembly 1 Burner cap 2 Igniter plug (electrode) with spring 3 Burner base (brass) 4 Venturi tube _ARA_EN_B Page 21 of 119

21 6. Slowly lift to remove the burner base (see Figure 26). m Caution Fragile Component The igniter plug is a ceramic component that can be brittle and crack easily. 7. 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 igniter plug (see Figure 27 and Figure 28). Figure 28: Ignition Plug with Spring Figure 27: Igniter Wire Locking Tab 1 Tab (press it to detach wire from electrode) 8. [Only if the ignition plug needs replacing]: Remove and retain the spring from the ignition plug by rotating the ignition plug clockwise while simultaneously holding the spring with a flat blade screwdriver to prevent its rotation (so that the spring is unscrewed from the plug). You may need to push the spring upward with the screwdriver in order to remove it from the ignition plug (Figure 29). Figure 29: Rotating the Ignition Plug to Detach Spring 9. [Only if the ignition plug needs replacing]: After the spring is detached, remove the igniter plug from the burner base _ARA_EN_B Page 22 of 119

22 4.2.2 Removing Spill Trays m Caution Fragile Component Porcelain enamel spill trays are fragile. 1. Push each ignition wire downward through its respective receptacle, as you carefully lift out each spill tray (see Figure 30 and Figure 31) Removing Heat Shields Figure 32: Typical Heat Shields Sharp Components Gloves Recommended Use gloves when removing or installing a heat shield, as the edges may be sharp. Figure 30: Typical Spill Tray 1. Remove and retain the screws that secure the heat shield onto the range. 2. Use gloves while you carefully lift and remove the heat shield(s). See Figure 33. Figure 31: Removing the Spill Trays (Ignition Wire Shown) Figure 33: Removing the Heat Shield _ARA_EN_B Page 23 of 119

23 4.2.4 Removing the Burner Support Rail 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 under the maintop that need 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 38. and the correct part number when replacing this component. 4. Using a 9/16th 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]: Use a 1/2 inch wrench to hold the bolt on the solenoid valve, while unscrewing the gas tube hex nut with a 9/16th wrench. Be careful not to bend the gas tubes (see Figure 81). [Right side standard valves]: Use a 9/16th inch wrench to remove the gas tubes from the Standard valves. Be careful not to bend the gas tubes. 5. Push each ignition wire downward through its receptacle in the burner support rail. Figure 34: Burner Support Rail 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page Using a 9/16th inch wrench, unscrew the hex nuts to remove the gas tubes from the jet holder assemblies. Be careful not to bend the gas tubes (see Figure 35). Figure 35: Removing Gas Tube from Jet Holder Assembly _ARA_EN_B Page 24 of 119

24 6. Make note of which way the burner support rails are placed on the range chassis before removing, so you can re-install in the correct position in relation to the jet holder assemblies and gas tubes. Sharp Component Gloves Recommended The burner support rail has sharp edges. Avoid injury by using gloves when removing or installing the burner support rail. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 36: Removing Burner Support Rail from Range Chassis 7. Using a large flat-blade screwdriver, push one side of the burner support rail to the other side of the chassis, until the 2 prongs come out from their slots on the chassis (see Figure 36). Then remove burner support rail with the two jet holder assemblies attached (see Figure 37). Figure 37: Burner Support Rail with Jet Holder Assembly Attached _ARA_EN_B Page 25 of 119

25 4.3 Griddle Removal and Replacement Depending on the model and FD number of the range, there are two different procedures for griddle removal. The primary differences between them are the brackets used. Both procedures are presented here for the griddle removal with removable brackets, and for the griddle removal with fixed brackets. and the correct part number when replacing this component Griddle with Removable Brackets Removal and Replacement Griddle Hazard The griddle plate must always be correctly in place when it is on. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Complete steps for Removing Knobs, Grates, and Burner Assemblies, page Remove the griddle plate and grease tray (see Figure 39). Fiberglass Wear gloves when handling fiberglass insulation Figure 39: Griddle Plate and Grease Tray 1 Griddle plate 2 Grease tray 4. Remove and retain the two screws from each of the two element support brackets (see Figure 38, page 26). Figure 38: Element Support Brackets and Screws 1 Screws (2) 2 Element support brackets (1 of 2 shown) _ARA_EN_B Page 26 of 119

26 5. For both right-side and left-side brackets (see Figure 40), remove and retain the following two screws: The screw securing the element flange onto the bracket (see Figure 41) The screw securing the bracket onto the back frame (see Figure 42) 6. Remove right and left brackets by lifting the pins out of the slots on the element tray (see Figure 40). NOTE: Depending on the model and FD number, some ranges will not use the bracket shown in Figure 40, page 27). Figure 41: Removing Element Flange from Bracket 1 Location of screw on element flange that secures the element flange to the bracket Figure 40: Bracket 1 Screw location (attaches to back frame) 2 Screw location (attaches to element flange) 3 Pins (2) Figure 42: Removing Bracket from Back Frame 1 Screw holding bracket onto the back frame _ARA_EN_B Page 27 of 119

27 7. Remove the thermostat bulb by carefully pulling it out of the retaining bracket (see Figure 43, page 28). If necessary, you can remove and retain the two screws from the retaining bracket to remove in order to facilitate the removal of the bulb. NOTE: After removing the thermostat bulb from retaining bracket, do not push the bulb through the receptacle in the element tray yet. 8. Disconnect the 1/4 inch spade connectors of both (right and left) element wires. You may have to pull the element wires out a bit to access the connectors while doing this, be careful not to damage the element wires. 9. Remove the two screws from the element tray (see Figure 44). The insulation support bracket is now detached from under the element tray (see Figure 45, page 29). Figure 43: Removing the Thermostat Bulb from Retaining Bracket 1 Retaining bracket 2 Thermostat bulb Figure 44: Screws on the Element Tray 1 Screws (2) holding element to tray Fiberglass Wear gloves when handling fiberglass insulation _ARA_EN_B Page 28 of 119

28 Figure 45: Detaching the Insulation Support Bracket 10. While lifting up the element tray slightly, carefully push the bulb through the circular receptacle in the element tray (see Figure 46). Figure 47: Removing the Insulation 12. Remove the insulation support bracket by pulling its two prongs out of the slots in the retaining plate (see Figure 48). Figure 46: Receptacle for Removing Thermostat Bulb 11. While removing the insulation (see Figure 47), be careful not to pull on the thermostat bulb. Figure 48: Insulation Support Bracket _ARA_EN_B Page 29 of 119

29 4.3.2 Griddle with Fixed Brackets Removal and Replacement Fiberglass Wear gloves when handling fiberglass insulation 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Complete steps for Removing Knobs, Grates, and Burner Assemblies, page Remove the griddle plate and grease tray (see Figure 39). 4. Carefully remove the bulb from the fixed retaining bracket (see Figure 49). NOTE: After removing the thermostat bulb from retaining bracket, don t push the bulb through the receptacle in the element tray yet. 5. Disconnect the 1/4 inch spade connectors of both right and left element wires. You may have to pull the element wires out a bit to access the connectors while doing this, be careful not to damage the element wires. Figure 49: Removing Thermostat Bulb from Retaining Bracket 1 Retaining bracket 2 Thermostat bulb 3 Receptacle for removing bulb _ARA_EN_B Page 30 of 119

30 6. If the element needs replacing, it snaps out of the fixed brackets on the element tray (see Figure 50). 7. Remove the two screws from the element tray (see Figure 51). 8. Detach the insulation support bracket from under the element tray (see Figure 52). Figure 50: Fixed Element Brackets Figure 52: Detaching Insulation Support Bracket 9. While lifting up the element tray slightly, carefully push the bulb through the circular receptacle in the element tray (see Figure 49, page 30). Fiberglass Wear gloves when handling fiberglass insulation Figure 51: Locations of Screws on Element Tray _ARA_EN_B Page 31 of 119

31 10. While removing the insulation (see Figure 53), be careful not to pull on the thermostat bulb. 4.4 Grill Components Removal and Replacement When diagnosing problems with the grill, also see Hot Surface Igniter Board Removal and Replacement, page 62. For adjustment of the grill burner flame, see Adjusting Bake Burner Flame with the Air Shutter, page 14. and the correct part number when replacing any of these components. Figure 53: Removing the Insulation 11. Remove the insulation support bracket by pulling its two prongs out of the slots in the retaining plate (see Figure 54). Grill Hazards The grill plate must be correctly in place whenever the grill is on Do not service the grill when it is hot 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Complete steps for Accessing Components under the Maintop, page Remove the grill plate and grease tray (see Figure 55). Figure 54: Insulation Support Bracket Figure 55: Grill Plate and Grease Tray 1 Grill plate 2 Grease tray _ARA_EN_B Page 32 of 119

32 4. Remove and retain the screws from the two burner box mounting brackets (see Figure 56). 5. Lift up the grill burner box slightly, and then detach the HSI wire connector and the electrode spade connector from underneath the burner box (see Figure 56) Grill Flame Spreader Removal and Replacement 6. Remove and retain the two screws securing the flame spreader on the grill burner box (see Figure 57), and then remove the flame spreader (see Figure 58, page 33). Figure 56: Grill Burner Box (View of from Underneath) 1 Solenoid valve for grill (attached to gas flex line) 2 Burner box mounting brackets(2) 3 Electrode terminal (connecting wire not shown) 4 HSI wire connector 5 Grill burner (only Venturi tube section is visible) 6 Air shutter (shown with orifice visible inside) 7 Elbow connector (attached to orifice) Figure 57: Grill Burner Box with Flame Spreader Installed 1, 3 Flame spreader screw locations 2 Flame spreader _ARA_EN_B Page 33 of 119

33 Figure 58: Flame Spreader Removed (Grill Burner Shown) Grill Burner Removal and Replacement Figure 59: Removing the Grill Burner 1 Tab at end of grill burner 2 Slot on burner box 7. Lift the grill burner out of the burner box slightly upward, in the direction towards the open end of the burner box so that the tab end is disengaged from the slot in the burner box. See Figure 59. NOTE: For adjustment of the grill burner flame, see Adjusting Bake Burner Flame with the Air Shutter, page 14. Figure 60: Grill Burner _ARA_EN_B Page 34 of 119

34 4.4.3 Grill Hot Surface Igniter Removal and Replacement Grill Electrode Removal and Replacement On the grill, the electrode functions as a flame sensor that is, if the electrode does not heat up enough in a short time frame, the electrode will close the solenoid valve to avoid gas build-up in the grill burner. See Figure 63. Figure 61: Grill Hot Surface Igniter (HSI) 8. Make sure the HSI wire connector has been detached from under the burner box (per step 5). 9. Remove and retain the screw that secures the HSI onto the burner box chassis (see Figure 62), and then gently pull the HSI out (see Figure 61). Figure 63: Electrode 1 Electrode terminal 2 Location of screw that secures electrode onto electrode bracket 10. Make sure the electrode spade connector has been detached from the electrode terminal (from under the burner box). 11. Remove and retain the screw that secures the electrode onto the electrode bracket (see Figure 62 and Figure 63), and then remove the electrode. Figure 62: Screws for Removing the HSI and Electrode 1 Electrode screw (shown securing electrode onto electrode bracket) 2 HSI screw (shown securing HSI onto burner box) _ARA_EN_B Page 35 of 119

35 4.4.5 Grill Thermostat Bulb Removal and Replacement The removal and replacement of the grill thermostat requires removing the bulb from the burner box (per this procedure). It also requires removal of the thermostat switch at the control panel (see Griddle / Grill Thermostat Removal and Replacement, page 68). 12. Remove and retain the screw that secures the side panel of the burner box, and then remove the side panel. The left side panel acts as a shield for the sensor bulb. See Figure 64 and Figure 65. Figure 65: Thermostat Sensor Bulb (Shown with Left Side Panel of Burner Box Removed) Figure 64: Left Side Panel of Grill Burner Box (Shown Attached) 1 Screw securing side panel onto burner box 2 Left side panel of burner box 13. Gently remove the sensor bulb by sliding it out of the bracket (the bracket does not have to be removed). See Figure Bracket 2 Sensor bulb 3 Capillary tube 4 Portal for sensor bulb m Caution You can extend the capillary tube of the thermostat to the needed length, however be careful not to twist or bend it, or it may impede the component s ability to operate properly. 14. Carefully slide the sensor bulb and capillary tube through the portal in the burner box chassis (see Figure 65). 15. If you have not already done so prior, detach the thermostat switch from the control panel (see Griddle / Grill Thermostat Removal and Replacement, page 68), and then remove the grill thermostat assembly from the range _ARA_EN_B Page 36 of 119

36 4.4.6 Grill Orifice and Elbow Connector Removal and Replacement 16. From inside the burner box, remove and retain the two screws securing the burner support (which houses the orifice and elbow connector) onto the front of the burner box (see Figure 66 and Figure 67), and then remove the burner support (see Figure 68). Figure 66: Screws for Connecting Piece 1 Screw locations (2) securing the burner support onto the burner box Figure 68: Burner Support Removed with Orifice and Elbow Connector Attached 1 Elbow connector (shown attached to gas flex line) 2 Burner support 3 Screw hole for screw from grill burner tab 4 Screw holes (2) for screws from burner box 5 Orifice 6 Holes on for burner support screws (2) Figure 69: Elbow Connector Figure 67: Burner Support 1 Portal for orifice 2 Screw holes (2) Figure 70: Typical Orifice _ARA_EN_B Page 37 of 119

37 17. When installing, be sure the orifice is aligned correctly inside the air shutter section of the grill burner, and that the burner support is secured properly onto the tab end of the grill burner (Figure 71). TIP: Correct alignment of the orifice straight into the burner s Venturi tube maximizes air input for best burner performance. NOTE: If converting the range for use with LP gas, make sure to use the orifice provided in the LP conversion kit (PLPKIT). 4.5 Removal and Replacement of Top-Accessible Components This section contains removal and replacement procedures for the top-accessible components, located under the maintop Jet Holder Assembly Removal and Replacement This procedure is for removing and replacing the jet holder assembly from the burner support rail. The assembly includes the jet holder, as well as the orifice (jet) (which is an integral part of the assembly, and is not available separately). NOTE: The jet (orifice) should not be removed. NOTE: If ordering a replacement jet holder assembly, retain the wire clip for use with the replacement assembly. and the correct part number when replacing this component. Figure 71: Orifice Burner Support Elbow Connector Assembly Attached to Air Shutter and Grill Burner Tab 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 72: Jet Holder (left) and Wire Guard Clip (Right) 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 _ARA_EN_B Page 38 of 119

38 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page Remove both gas tubes attached to both jet assemblies on the burner support rail you are to remove (see Figure 35, page 24). NOTE: Although the jet holder can be replaced without removing the burner support rail, it is recommended to always remove the burner support rail prior to replacing the jet holder, so that proper alignment can be verified by seeing the jet holder and wire guard clip placement. 4. Remove burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page To detach the jet assembly from the burner support rail, use an adjustable wrench to remove the nut (see Figure 73). 7. When installing the jet holder, do the following: NOTE: Before attaching the wire guard clip, first install the jet holder onto the burner support rail and tighten the nut, so that the clip doesn t get caught between the base of the jet and the rail. When installing a jet holder, make sure it seats into the correct groove on the rail, so that it faces the right direction. Install the nut with the hollowed end touching the rail, and make sure the nut is fastened tightly. Install the wire guard clip correctly onto the jet holder so that at the lower end it won t interfere when the gas tube is installed and so that at the upper end the clip is seated under the two protruding wings of the jet holder (but not caught in between the jet and the rail). See Figure 74. Figure 73: Removing the Nut on the Burner Support Rail 6. Replace the jet holder assembly if needed. Be sure to retain and re-use the wire guard clip if you are ordering a replacement jet holder assembly. Figure 74: Jet Holder Assembly and Wire Guard Clip 1 Wing (1 of 2 shown) on jet holder 2 Wire guard clip 3 Threaded connection for gas tube 4 Orifice (jet) _ARA_EN_B Page 39 of 119

39 Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Standard Valve Removal and Replacement The standard valves are for the right side, non-xlo burners only. and the correct part number when replacing this component. base, through the corresponding access hole (the oven door must be opened or removed (see Figure 76 and Figure 77). Be careful not to lose the rubber washer attached to the screw. 7. Remove the standard valve and (connected) microswitch from the manifold (see Figure 78, page 41). 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 screw and then pulling the microswitch off the alignment pin on the standard valve (see Figure 78, page 41). 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 75: Typical Standard Valve 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 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 9/16th 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. If a burner support rail obstructs access to the standard valve, then remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Using a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet, remove and retain the valve screw (that secures the standard valve onto the manifold) by accessing it from under the chassis Figure 76: Valve Access Holes on Typical Range _ARA_EN_B Page 40 of 119

40 Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Microswitch Removal and Replacement The microswitches are for the standard (non-xlo) burners only. and the correct part number when replacing this component. Figure 77: Removing the Valve Screw Figure 78: Standard Valve Connected to Microswitch 1 Screw connecting microswitch to standard valve Figure 79: Microswitch 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If a burner support rail obstructs access to the microswitch, then remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove knob from valve stem by slowly pulling knob straight out, away from control panel. 5. Using a 9/16th 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 _ARA_EN_B Page 41 of 119

41 6. Use a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet to remove and retain the valve screw by accessing it from under the chassis base, through the corresponding access hole. The oven door must be opened or removed (see Figure 76 and Figure 77). Be careful not to lose the rubber washer attached to the screw. 7. Remove the standard valve and microswitch (connected together) from the manifold (see Figure 78). Be careful not to lose the red rubber washer attached to the standard valve. 8. First make a note of how the wires (piggyback and single) are connected to the terminals on the microswitch before detaching the wires from the terminals (see Figure 78). NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 9. Detach the standard valve from the microswitch by removing and retaining the screw, and then pulling the microswitch off the alignment pin on the standard valve (see Figure 78, page 41). 10. Replace the microswitch if needed. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component removed, replaced, or otherwise serviced using gas leak detector or bubble test Solenoid Valve for XLO Burner - Removal and Replacement This procedure is for the solenoid valves which are used for the leftside (XLO) burners. For the procedure for the grill solenoid, see Solenoid Valve for Grill Removal and Replacement, page 43. and the correct part number when replacing this component. Figure 80: Solenoid Valve with O Ring (for XLO Burners Only) 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page Remove knob from solenoid valve stem by slowly pulling knob straight out, away from control panel. 4. If obstructing access to the solenoid, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Use a 1/2 inch wrench to hold the nut on the solenoid valve, while unscrewing the gas tube hex nut with a 9/16th inch wrench. 6. 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 81) _ARA_EN_B Page 42 of 119

42 7. 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, wire connectors, and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 8. Use an adjustable wrench to 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 80, page 42). 9. Replace solenoid valve if needed. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Solenoid Valve for Grill Removal and Replacement Access for the solenoid valve for the grill is under the maintop. and the correct part number when replacing this component. For the procedure to remove and replace the solenoid valve for the XLO burners, see Solenoid Valve for XLO Burner - Removal and Replacement, page Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the solenoid, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page At the solenoid valve outlet, use a wrench to detach the gas flex tube remove and retain the compression nut and the sleeve from the gas flex tube (see Figure 161, page 83). 5. At the solenoid valve inlet, detach the gas flex tube that connects the solenoid valve to the elbow connector fitting on the manifold (the elbow connector fitting is supplied as part of the manifold assembly). 6. Replace the solenoid valve if needed. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 81: Removing the Gas Tube from the Solenoid Valve _ARA_EN_B Page 43 of 119

43 4.5.6 XLO Valve Removal and Replacement The XLO valves are for the left-most front and left-most rear burners only. When replacing the XLO valve, on some models you may need to remove the potentiometer together with the XLO valve, while on other models you may snap the potentiometer off the XLO valve. and the correct part number when replacing this component. Figure 82: Solenoid Valve and Respective Fittings for Grill Burner 1 Gas flex tube 2 Compression nut 3 Sleeve 4 Solenoid valve outlet (to gas flex tube / grill burner) 5 Solenoid valve 6 Solenoid valve inlet (connected to gas flex tubing that extends to manifold elbow connector fitting) Figure 83: Typical XLO Valve 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 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. If a burner support rail obstructs access to the XLO valve, then remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page While using a 1/2 inch wrench to hold the nut on the solenoid valve, unscrew the gas tube hex nut with a 9/16th 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 81) _ARA_EN_B Page 44 of 119

44 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, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Use an adjustable wrench to 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 80). 8. Use a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet to remove and retain the valve screw (that secures the XLO valve onto the manifold) by accessing it from under the chassis base, through the corresponding access hole. The oven door must be opened or removed (see Figure 76 and Figure 77). 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. Figure 85: Solenoid XLO Valve Potentiometer Assembly 1 Solenoid valve 2 XLO valve 3 Simmer potentiometer 4 Side connector (to simmer potentiometer) Figure 84: Valve Access Holes on Typical Range (XLO Valve Access Shown) _ARA_EN_B Page 45 of 119

45 10. Remove the white plastic side connector from the potentiometer by pressing on the connector tab. (see Figure 86). 11. Replace the XLO valve if needed. 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 87). Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. For XLO valves, you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on XLO valves with the electrical power turned on. Figure 87: Removing the XLO Valve from the Potentiometer Figure 86: Side Connector Tab 1 Harness connector tab _ARA_EN_B Page 46 of 119

46 4.5.7 Potentiometer Removal and Replacement and the correct part number when replacing this component. The potentiometer (also known as the simmer control potentiometer or XLO potentiometer) is used to control the simmer function of the XLO burners. The potentiometer should not be confused with the temperature selector switch, which is sometimes also referred to as a potentiometer. Figure 88: Typical Potentiometers This procedure is for removing and replacing the potentiometer when accessed from the top of the range (under the maintop). The potentiometer can also be removed and replaced easily through the front of the range (after the front panel has been removed), however front panel removal also requires access from the top of the range. NOTE: If the control panel has already been removed per Control Panel and Bullnose Removal and Replacement procedure on page 69, you can easily remove the potentiometer by detaching the plastic wire connector at the potentiometer and then pulling the potentiometer off of the XLO valve (it should snap off). If the potentiometer to be replaced is located behind the manifold support bracket, first remove and retain the screws on the bracket, and then remove the bracket before pulling the potentiometer off (see Figure 90, page 49). 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 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. If obstructing access to the potentiometer XLO valve solenoid assembly, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Use a 1/2 inch wrench to hold the nut on the solenoid valve, while unscrewing the gas tube hex nut with a 9/16th 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 81). 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, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 7. Use an adjustable wrench to 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 80). 8. Use a 1/4 inch nut driver or a 1/4 inch socket wrench/ratchet to remove and retain the valve screw by accessing it from under the chassis base, through the corresponding access hole. The oven door must be opened or removed (see Figure 76 and Figure 77). 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 _ARA_EN_B Page 47 of 119

47 10. Remove the white plastic side connector from the potentiometer by pressing on the connector s tab. (see Figure 86). 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 87). 12. Replace the potentiometer if needed. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. If potentiometer was accessed by removing an XLO valve, you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on XLO valves with the electrical power turned on. 3. Remove burner support rails (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove the regulator from the manifold (see Regulator Removal and Replacement, page 55). 5. Remove all knobs from their valve stems by slowly pulling knobs straight out, away from control panel. 6. At each of the locations shown in Figure 132 on page 70, remove and retain two screws inside each bezel (see Figure 89) to detach the manifold support brackets at the back of the control panel (see Figure 90 on page 49) Manifold for Rangetop Burners Removal and Replacement Although range components can usually be accessed and replaced without removing the manifold, this procedure is provided if the manifold for the maintop burners needs to be replaced, for example, if damage is sustained due to a gas leak in the manifold, or if the threading on the manifold is bad due to removing the regulator. NOTE: The manifold (for rangetop burners) is sold as an assembly, which comes with XLO and standard valves pre-installed. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page 21. Figure 89: Screws that Attach to Manifold Support Bracket 1 Screws (2) that attach to manifold support bracket 7. Detach all wire connectors to the LED indicators and temperature gauge, and make a note of how all the wires are connected. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 8. Remove the control panel (see Control Panel and Bullnose Removal and Replacement, page 69) _ARA_EN_B Page 48 of 119

48 9. Remove the oven door(s). See Removing the Door, page Remove and retain the two screws from each manifold support bracket that attach to the manifold, and then remove the support brackets from the manifold (see Figure 90). 11. Disconnect the wire connectors from the potentiometers and then detach the potentiometer from the XLO valve by using a small flatblade screwdriver to gently separate the XLO valve from the potentiometer standoffs (see Figure 87, page 46). 12. Slide the potentiometers off the XLO valve stems, and retain the potentiometers. Figure 90: Manifold Support Bracket (Shown with Control Panel Removed) 1 Screws (2) holding manifold support bracket onto manifold 2 Manifold support bracket 3 Holes on manifold support bracket (2) for receiving screws from bezel 13. Detach the wire connectors to the two solenoid valves, and to all the microswitches. Make a note of how the wires are connected. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone) 14. Remove gas tubes from standard valves: Use a 9/16th inch wrench to remove the gas tubes by unscrewing the hex nuts connected to the standard valves and to the jet holder assemblies. Be careful not to bend the gas tubes. 15. Remove gas tubes from solenoid valves: Use a 1/2 inch wrench to hold the nut on a solenoid valve, while unscrewing the attached gas tube hex nut with a 9/16th inch wrench (see Figure 81, page 43). Then remove the other side of the gas tube attached to the jet holder assemblies and remove the gas tubes. Be careful not to bend the gas tubes. 16. Remove the two solenoid valves (see Solenoid Valve for XLO Burner - Removal and Replacement page 42). 17. Detach microswitches from all XLO and standard valves: Remove and retain the small screw that holds the microswitch onto the valve, and then pull the microswitch off the alignment pin on the valve (see Figure 78, page 41). NOTE: If replacing a manifold assembly (which has XLO and standard valves pre-installed), you do not have to remove or reuse the standard and XLO valves from the old manifold. 18. Now remove and retain the screw holding the manifold pipe onto the bracket (near the regulator). You do not have to remove the screw holding the bracket onto the chassis. See Figure Gently lift the manifold out through the area where the control panel was removed. Be careful of the wire harnesses, control boards, and other components _ARA_EN_B Page 49 of 119

49 4.5.9 Oven Lamp Transformer Removal and Replacement Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. To diagnose problems with the oven light, also see Oven Light Diagnostics, page 86. and the correct part number when replacing this component. Figure 91: Manifold Pipe Bracket on Chassis Base 1 Bracket 2 Manifold pipe Figure 92: Typical Oven Lamp Transformer 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the oven lamp transformer, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail procedure, page First make a note how the wires are connected to the transformer terminals before detaching the wire connectors. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 5. Remove and retain the two screws securing the transformer onto the range chassis. 6. Replace the transformer if necessary _ARA_EN_B Page 50 of 119

50 Oven Temperature Selector -- Removal and Replacement For 48-inch ranges, there is a dedicated oven temperature selector for each of the two ovens. This procedure covers the removal and replacement for both oven temperature selectors. Depending on the FD number and model, the oven temperature selector may or may not be fastened with a clip-shaped bracket (see Figure 94). and the correct part number when replacing this component. Figure 95: Large Oven Temperature Selector (Typical Models Shown) Figure 93: Small Oven Temperature Selector (Typical Models Shown) Figure 96: Front and Back of Large Oven Temperature Selector (Typical Model Shown with Retaining Bracket) 1 Retaining bracket Figure 94: Front and Back of Small Oven Temperature Selector (Typical Model Shown with Retaining Bracket) 1 Retaining bracket 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 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. If obstructing access to the oven temperature selector, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page _ARA_EN_B Page 51 of 119

51 5. From the back of the control panel, first make a note of how the wires are connected to the oven temperature selector terminals, and then remove the wire connectors from the terminals (see Figure 94 and Figure 96 on page 51). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 6. At the front of the control panel, remove and retain the two screws through the bezel that attach to the oven temperature selector (see Figure 97), and then remove the bezel. 7. At the back of the control panel, remove the oven temperature selector, and replace it if necessary Five-Position Oven Function Selector Removal and Replacement The Five-Position Oven Function Selector switch is for the large oven on 48-inch ranges only. Depending on the range model and FD number, the Five-Position Oven Function Selector switch may or may not be fastened with a clip-shaped bracket (see Figure 99). NOTE: When installing the Five-Position Oven Function Selector, make sure to attach the wire connector correctly onto all of the pins. and the correct part number when replacing this component. Figure 98: Five-Position Oven Function Selector (Typical Models) Figure 97: Screw Locations on Bezel 1 Location of screws (2) Figure 99: Front and Back of Five-Position Oven Function Selector (Typical Model Shown with Retaining Bracket) 1 Retaining bracket _ARA_EN_B Page 52 of 119

52 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 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. If obstructing access to the Five-Position Oven Function Selector, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page At the back of the control panel, disconnect the plastic multi-pin connector from the pins on the five-position oven function selector (see Figure 99). 6. At the front of the control panel, remove and retain the two T-20 screws on the bezel which are attached to the Five-Position Oven Function Selector (see Figure 100), and then remove the bezel Three-Position Oven Function Selector Removal and Replacement The Three-Position Oven Function Selector is for the small oven on 48-inch ranges, as well as on 30-inch and 36-inch ranges. NOTE: Depending on the range model and FD number, the Three- Position Oven Function Selector switch may or may not be fastened with a clip-shaped bracket (see Figure 102). and the correct part number when replacing this component. Figure 101: Three-Position Oven Function Selector (Typical Models Shown) Figure 100: Screws on Bezel of Oven Function Selector 7. At the back of the control panel, remove the five-position oven function selector and replace it if necessary. Figure 102: Front and Back of Three-Position Oven Function Selector (Typical Model Shown with Retaining Bracket) 1 Retaining bracket _ARA_EN_B Page 53 of 119

53 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page 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. If obstructing access, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail procedure, page At the back of the control panel, disconnect the plastic multi-pin connector from the pins on the Three-Position Oven Function Selector (see Figure 102, page 53). 6. At the front of the control panel, remove and retain the two T-20 screws on the bezel which are attached to the Three-Position Oven Function Selector, and then remove the bezel. 7. At the back of the control panel, remove the Three-Position Oven Function Selector and replace it if necessary NOTE: When installing the Three-Position Oven Function Selector, make sure to attach the connector correctly onto all pins Oven Temperature Gauge Removal and Replacement For 48-inch model ranges, the temperature gauge is for the large oven only. and the correct part number when replacing this component. Figure 103: Oven Temperature Gauge 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the temperature gauge, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page At the back side of the control panel, detach the four-pin wire connector from the gauge (see Figure 104). 5. Remove and retain the two nuts with lockwashers from their respective studs, and then remove the mounting bracket (see Figure 104). 6. Push the gauge outward (towards the front of the range) to remove it. 7. Replace the gauge if necessary _ARA_EN_B Page 54 of 119

54 Regulator Removal and Replacement and the correct part number when replacing this component. Figure 104: Oven Temperature Gauge (Back Side Shown) 1 Nuts with lockwashers (2) on studs (2) 2 Temperature gauge 3 Mounting bracket 4 Four-pin wire connector Figure 105: Regulator in Typical Range with Fittings and Gas Flex Line 1 Gas flex line 2 Hex nut on gas flex line 3 Flared adapter 4 Large nut on regulator 5 Regulator 6 Connecting pipe 7 T-connector 8 Manifold pipe 9 Flared adapter _ARA_EN_B Page 55 of 119

55 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page 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 Use two wrenches (open-end, or adjustable) and hold the large nut on the regulator steady with one wrench, while you simultaneously rotate the flared adapter with the other wrench until you can remove the flared adapter from the regulator (see Figure 105). 5. Use a wrench to hold the connecting pipe, while you simultaneously rotate the regulator until you can detach it (see Figure 105). 6. Replace the regulator if needed. NOTE: When replacing the regulator or associated fittings, use pipe sealant on pipe threads only - such as the manifold pipe to T-connector, T-connector to connecting pipe, connecting pipe to regulator, and regulator to flared adapter (threaded end only). Never use pipe sealant on flair connections or pressure fittings, such as the flared end of the flared adapter. 7. When replacing the regulator, make sure it is positioned correctly with its cap fitting facing upward, as shown in Figure 105. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Bi-Metal Gas Valve Removal and Replacement Under Maintop There is an individual bi-metal gas valve for each broil burner. For 30-inch and 36-inch ranges, the bi-metal gas valves are located under the maintop, and accessible from the top of the range. For 48-inch ranges, the bi-metal gas valves are located at the back of the range (see Bi-Metal Gas Valve Removal and Replacement Back of Range, page 83). and the correct part number when replacing this component. Figure 106: Typical Bi-Metal Gas Valves Under Maintop 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the bi-metal gas valve, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail procedure, page Disconnect the two spade connectors from the bi-metal gas valve, and make a note of which wires are connected to each of the two different terminals (see Figure 107). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone) _ARA_EN_B Page 56 of 119

56 Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. For bi-metal gas valves you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on bi-metal gas valves with the electrical power turned on. Figure 107: BI-Metal Gas Valve and Connections 1 Spade wire connectors (2) 2 Bi-metal gas valve 3 Screws (2) that hold bi-metal valve to range chassis 4 Compression nut on gas tube at inlet 5 Compression nut on gas tube at outlet 5. Use an adjustable wrench to remove the compression nuts and then detach the gas tubes at the inlet and outlet. Be careful not to bend the gas tubes (see Figure 107). 6. Remove and retain the screws that secure to the single valve onto the range chassis (see Figure 107). 7. Remove and replace the bi-metal valve if necessary. Figure 108: Bi-Metal Gas Valve (Shown Under Maintop) 1 Bi-metal valve _ARA_EN_B Page 57 of 119

57 Bake Burner Solenoid Removal and Replacement Under Maintop Access for the bake burner solenoid is under the maintop for all 36-inch and 30-inch models, or at the back of the range for all 48-inch models (see Bake Burner Solenoid Removal and Replacement Back of Range, page 82). For the procedure for replacing the XLO burner solenoids, see Solenoid Valve for XLO Burner - Removal and Replacement page 42. and the correct part number when replacing this component. 3. If obstructing access to the solenoid, remove the burner support rail (with jet holder assemblies attached) by following the steps in the Removing the Burner Support Rail procedure, page At the solenoid valve outlet, use a wrench to remove and retain the 9/16th inch compression nut and the sleeve from the 3/8th inch diameter gas flex tube (see Figure 110). 5. At the solenoid valve inlet, use a wrench to secure the solenoid hex nut, while you simultaneously use another wrench to rotate the hex nut on the reducer bushing until it is detached from the solenoid (see Figure 110). 6. Replace the solenoid if needed. NOTE: Use pipe sealant on pipe threads only. Never use pipe sealant on flair connections or pressure fittings. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 109: Solenoid for Bake Burner and Fittings Under the Maintop 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page _ARA_EN_B Page 58 of 119

58 Control Board Removal and Replacement The 48-inch range has a dedicated control board for each of the two ovens. and the correct part number when replacing this component. Figure 110: Solenoid Valve and Fittings for Bake Burner Under the Maintop 1 Gas flex tube 2 Compression nut 3 Sleeve 4 Solenoid valve outlet (to gas flex tube / bake burner) 5 Solenoid valve 6 Solenoid valve inlet 7 Reducer bushing 8 Elbow connection piece Control Board Removal and Replacement Main Oven This procedure is for the oven control boards of 36-inch and 30-inch ranges, as well as for the large oven control boards of 48-inch ranges. For replacing the small oven control board of 48-inch ranges, see Control Board Removal and Replacement Small Oven, page Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the large oven control board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove and retain the screws holding the control board shield onto the range chassis and then remove the control board shield (see Figure 111). 5. Remove all multi-pin wire connectors from the control board as well as the spade connector of the ground wire (see Figure 111). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone) _ARA_EN_B Page 59 of 119

59 m Caution Fragile Components Be careful not to exert too much pressure on the standoffs or the control board, as these are fragile components. 6. Using a needle nose pliers, disengage the control board from all the plastic standoffs by lightly pressing the tiny protruding clip on each standoff, while simultaneously pulling the control board off the standoff. 7. Replace the control board only if needed. Figure 111: Control Boards and Shield 1 Control board for main (large) oven 2 Control board shield with fault code instructions 3 Control board for auxiliary (small) oven Control Board Removal and Replacement Small Oven This procedure is for the oven control boards of the small ovens on the 48-inch ranges. For replacing the control boards on the large ovens of 48-inch ranges or the ovens of 30-inch and 36-inch ranges, see Control Board Removal and Replacement Main Oven, page 59. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the small oven control board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove all wire connectors from the control board relays and terminals (see Figure 111 and Figure 112). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone). m Caution Fragile Components Be careful not to exert too much pressure on the standoffs or the control board, as these are fragile components. 5. Using a needle nose pliers, disengage the control board from all the plastic standoffs by lightly pressing the tiny protruding clip on each standoff, while simultaneously pulling the control board off the standoff. 6. Replace the small oven control board only if needed _ARA_EN_B Page 60 of 119

60 5. Using a needle nose pliers, disengage the control board from all the plastic standoffs by lightly pressing the tiny protruding clip on each standoff, while simultaneously pulling the simmer board off the standoff (see Figure 113). 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. Figure 112: Control Board for Small Oven Simmer Control Board Removal and Replacement and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the simmer control board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove and retain the screw to detach the ground wire from the chassis (see Figure 113). m Caution Fragile Components Be careful not to exert too much pressure on the standoffs or the simmer control board, as these are fragile components. Figure 113: Simmer Control Board 1 Multi-pin wire connectors (2) 2 Standoffs (4) 3 Ground wire (shown attached to screw on chassis) _ARA_EN_B Page 61 of 119

61 Hot Surface Igniter Board Removal and Replacement The hot surface igniter (HSI) control boards are for the broil burners and gas grill burner. For broil burner issues, also see Broil Burner Components Removal and Replacement, page 93. For grill burner issues, also see Grill Hot Surface Igniter Removal and Replacement, page 35. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the HSI board, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove and retain the screws holding the HSI board shield onto the range chassis, and then remove the shield (see Figure 114). 5. Remove the multi-pin wire connector from the HSI board (see Figure 115). 6. Remove and retain the two screws that affix the HSI board onto the chassis (see Figure 115). 7. Replace the HSI board only if needed. Figure 114: Typical Shield for HSI Board(s) Figure 115: HSI Board (Dual HSI Boards Shown) _ARA_EN_B Page 62 of 119

62 DSI Module Removal and Replacement The direct spark ignition (DSI) module is used when the electrode is the igniter for the bake burner (whether or not the broil burner uses the HSI or electrode as the igniter). and the correct part number when replacing this component LED Indicator Removal and Replacement and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the LED harness, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page While holding the two plastic wire connectors, rotate them and pull to detach (see Figure 117). 5. Push the protruding clip at the front end of the LED indicator while you simultaneously push the LED indicator frontward through the hole in the control panel (see Figure 118). 6. Replace the LED indicator if needed. Figure 116: DSI Module 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page Remove and retain the screws securing the DSI module shield onto the range chassis, then remove the shield. 4. If obstructing access to the DSI module, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Remove the wire connector. 6. Remove and retain the two screws securing the DSI module onto the chassis floor. 7. Remove, and then replace the DSI module if needed. Figure 117: LED Indicator Wire Connectors _ARA_EN_B Page 63 of 119

63 Figure 119: Ignition (Spark) Module Typical Models Shown Figure 118: LED Indicator Ignition (Spark) Module Removal and Replacement and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page If obstructing access to the ignition module, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page Pull to detach the side connectors from the ignition module (see Figure 119, page 64). 5. Remove and retain the two screws securing the ignition module to the range chassis. 6. Replace the ignition module if needed Door Latch Removal and Replacement Removing and replacing the door latch requires access from both the top and front of the range. Depending on the model and FD number of the range, a replacement door latch may or may not require an adapter harness to be installed. and the correct part number when replacing this component. Figure 120: Typical Door Latch 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page Remove the corresponding oven door (see Oven Door Removal, Installation, page 88) _ARA_EN_B Page 64 of 119

64 4. If obstructing access to the door latch access panel, remove the burner support rail (with jet holder assemblies attached) by following the steps in Removing the Burner Support Rail, page 24. NOTE: Depending on the model range, if the door latch and/or plunger switch is located under the griddle/grill you need you may need to remove the griddle/grill first in order to gain access. See Griddle Removal and Replacement, page 26 and Grill Components Removal and Replacement, page Remove and retain the single screw that holds the access panel to the range chassis (see Figure 121). 6. Lift the access panel up, and detach its two tabs from the chassis (see Figure 121, page 65). 7. Remove and retain the two T-20 screws under the front control panel (see Figure 122). 8. Gently lift the latch out of the cavity (see Figure 123). Figure 122: Door Latch, Screws, and Plunger Switch 1 T-20 screws (2) 2 Door latch 3 Plunger switch Figure 121: Door Latch Access Panel (Small Oven Access Panel Shown) 1 Tabs (2) 2 Screw _ARA_EN_B Page 65 of 119

65 Figure 123: Removing the Door Latch 1 Plunger switch 9. Detach the spade wire connectors from the latch and the white plastic piggyback wire connector on the door latch s microswitch (see Figure 124, page 66). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone). Figure 124: Door Latch (Shown Removed from Cavity) 1 Spade connectors (2) 2 Piggyback wire connector 3 Door latch 10. Replace the door latch if needed. NOTE: If replacing the plunger switch, it must be done before the door latch is re-installed (see Plunger Switch Removal and Replacement, page 67) _ARA_EN_B Page 66 of 119

66 Plunger Switch Removal and Replacement Removing and replacing the plunger switch requires access from both the top and front of the range. These instructions are for the plunger switch shown in Figure 125. and the correct part number when replacing this component. 4. In order to remove the plunger switch, from inside the cavity press the two metal tabs on the sides of the plunger switch (see Figure 125) as you pull the plunger switch outward from the front of the range. You may need to pry the bezel of the plunger switch out with a flat-blade screwdriver in order to pull it out (see Figure 127, page 68). 5. Replace the plunger switch if needed. Figure 125: Plunger Switch 1 Tabs (2) press both to release plunger switch 1. First follow steps 1 through 8 of the Door Latch Removal and Replacement procedure, starting on page [For small oven plunger switch only] Detach the two wire connectors from the two wider blade terminals of the plunger switch (there are four blade terminals on the plunger switch). See Figure 126, page [For large oven plunger switch only] Detach the four wire connectors from the four terminals on the plunger switch. See Figure 123, page 66. NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph prior to disconnecting (for example, with your mobile phone). Figure 126: Plunger Switch in Cavity (Small Oven of 48-Inch Model Shown) _ARA_EN_B Page 67 of 119

67 m Caution When installing the thermostat, extend the capillary 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. Figure 127: Prying out Plunger Switch Bezel Griddle / Grill Thermostat Removal and Replacement Both the griddle and grill require a thermostat. For models with both griddle and grill, there are two thermostats. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in the Preparing the Range for Servicing, page First make a note how the wires are connected to the thermostat on the back side of the control panel, and then disconnect the wire harnesses and connectors. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 3. Remove and retain the two screws on the bezel of the griddle/grill thermostat (see Figure 130, page 69). 4. [For griddle]: Remove thermostat bulb from the retaining bracket, and then gently pull it through the receptacle (see Griddle Removal and Replacement, page 26 and Figure 129). 5. [For grill]: Remove the thermostat bulb from the grill burner box (see Grill Components Removal and Replacement, page 32). 6. Remove the thermostat from the back of the control panel, and replace it if needed. Figure 128: Typical Griddle/Grill Thermostat _ARA_EN_B Page 68 of 119

68 Control Panel and Bullnose Removal and Replacement Figure 131: Bullnose and Control Panel (Shown with Knobs Removed) Access to the control panel and bullnose is from the top and front of the range. This procedure is 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. and the correct part number when replacing this component. Figure 129: Removing the Thermostat Bulb from Retaining Bracket 1 Retaining bracket 2 Thermostat bulb Figure 130: Screws on Bezel of Griddle Thermostat 1 Screw locations (2) 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Follow all steps in Accessing Components under the Maintop, page From the back of the control panel, first make a note of how the wires are connected, and then detach only the wire connectors for all the LED indicators, as well as the wire connector for the temperature gauge. You do not have to detach the wire connectors for other knob components. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). NOTE: LED indicators can stay on control panel as long as their connectors are detached. 4. Remove all knobs from the control panel _ARA_EN_B Page 69 of 119

69 Figure 133: Three Nuts / Lockwashers (Right Side of Range Shown) Figure 132: Locations to Remove Knobs and Manifold Support Bracket Screws 9. Remove and retain the screw at the right and left side panels (see Figure 134). 1 Location attached to manifold support bracket 2 Location attached to manifold support bracket 5. Unscrew and remove the bezels for the oven lamp switches. 6. At the bezels on the control panel, remove and retain the screws that connect to the two manifold support brackets (see Figure 132). 7. At the bezels on the control panel, remove the bezel screws and bezels that connect to the following components: five-position oven function selector, three-position oven function selector, griddle/grill control(s), oven temperature select switch(es). 8. Use a swivel head driver or an open end wrench to remove and retain the three nuts with lockwashers from both sides of the range (see Figure 133). Figure 134: Removing Screws at Sides 1 Screws (1 per side) to remove at right and left sides _ARA_EN_B Page 70 of 119

70 10. While holding the control panel to support it from falling, remove and retain the screws from under the control panel (see Figure 135 Figure 136: Tabs and Bracket Studs Shown on Control Panel 1 Tab 2 Studs (3) on bracket (left side shown) Figure 135: Removing Screws Under the Control Panel 1 Screws to remove from under the control panel 11. Carefully pull away the control panel from the range in a forward direction to detach the two metal tabs from the chassis (see Figure 136) and remove the control panel with bullnose attached (see Figure 137, page 72). 12. After the control panel with bullnose attached has been removed (see Figure 137, page 72), before replacing it remove the temperature gauge (see Oven Temperature Gauge Removal and Replacement, page 54) and the LED indicators (see LED Indicator Removal and Replacement, page 63). 13. Use a flat blade screwdriver to pry out the two brackets (right and left sides of control panel). The bracket is pliable and may be fastened with double-sided tape, so it should come out without using any force (see Figure 138, page 72 and Figure 139, page 72). NOTE: The studs are affixed onto the brackets and are not to be removed. NOTE: Depending on the range model, the brackets will have either two or three studs _ARA_EN_B Page 71 of 119

71 Figure 137: Control Panel Removed (Attached to Bullnose) 1 Tab 2 Studs (3) on bracket (left side shown) Figure 139: Bracket (Shown Removed) 14. At the back side of the control panel and bullnose, remove and retain the screws that secure the bullnose onto the control panel. 15. Pull the bullnose off of the control panel, and replace either or both of these parts if needed. 16. When installing, it may be easier to affix the brackets to the bullnose and control panel by placing a piece of double-sided tape on the bracket. This enables you to have the brackets affixed so they don t fall out when positioning the control panel / bullnose on the range (see Figure 140). Figure 140: Bracket (Shown with Tape) Figure 138: Removing a Bracket _ARA_EN_B Page 72 of 119

72 4.6 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 moving the appliance, installing the anti-tip bracket, and other important installation and safety 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 immense weight of the range, using an air sled or dolly to move it may reduce the risk of injury and/or damage. For 48-inch ranges, it is recommended to have more than one person move the appliance Backguard and Island Trim Removal and Replacement This procedure applies for all backguards (Lowback, High Backguard models (with and without shelf), as well as for the Island Trim. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove and retain the screws on the front-facing side of the backguard / Island Trim (see Figure 141). 3. Remove and retain the screws on the on the back side of the backguard / Island Trim (see Figure 142, page 74), and then remove the backguard. 4. Lift the backguard / Island Trim straight up to remove (see Figure 143, page 74). NOTE: When re-installing, the back-facing side of the backguard / Island Trim needs to be placed inside of the two guide channels (see Figure 143, page 74). 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 Instructions manual. Always check local building codes for the proper method of installation. Local codes vary. Installation, electrical connections and grounding must comply with all applicable codes. In the absence of local codes the appliance should be installed in accordance with the 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 141: High Backguard on Typical Range Showing Frontal Screw Locations 1 Screw locations (varies per backguard size) on front of backguard _ARA_EN_B Page 73 of 119

73 4.6.2 Back Panel Removal and Replacement and the correct part number when replacing this component. Figure 142: Backguard, Back Panel, Crossmember Cover 1 Backguard 2 Back panel 3 Crossmember cover Figure 144: Typical Back Panel 1 Screw locations (number varies per panel model) 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 73. m Caution Be careful not to damage any components at the back of the range when removing or installing the back panels. Figure 143: Backguard Installed Inside Guide Channels 1 Backguard (or Island Trim) 2 Guide channels (2) 3. Remove and retain the screws from the back panels, and remove the panel (see Figure 144 and Figure 145, page 75). 4. Replace the back panel if needed _ARA_EN_B Page 74 of 119

74 3. [If removing the crossmember cover]: Push the power cord through the receptacle on the crossmember cover, so that you can remove it without having to detach the power cord wiring at the terminal block. 4. [If replacing the crossmember cover] You will need to detach the power cord from the terminal block first (see Electrical Wiring Connections at the Terminal Block, page 77), and then replace the crossmember cover Dilution Flue Removal and Replacement Figure 145: Back Panel 1 Screws (number depends on model) You may need to remove the dilution flue if you need access a broil burner assembly. and the correct part number when replacing this component Crossmember Cover Removal and Replacement You will need to remove the crossmember cover if you are removing a wire connector to the bake burner HSI or bake burner electrode. and the correct part number when replacing this component. Figure 146: Crossmember Cover 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove and retain the screws from the crossmember cover (see Figure 146 and Figure 142, page 74). Figure 147: Dilution Flue 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page _ARA_EN_B Page 75 of 119

75 3. Remove and retain the single screw from the left side, and the two screws from the right side (see Figure 148 and Figure 149). 4. Remove the dilution flue, and replace if necessary. Figure 148: Dilution Flue (Shown Attached) 1 Screw on left side of dilution flue 2 Screws (2) on right side of dilution flue Figure 149: Dilution Flue Removed 1 Location of screw at left side bracket 2 Location of screws (2) at right side bracket _ARA_EN_B Page 76 of 119

76 4.6.5 Terminal Block 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. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Detach the wire leads from each terminal on the terminal block (see Figure 150). Retain the washers and nuts (see Figure 151), and make a note of how all the wires are connected to the different terminals. Figure 151: Securing Power Supply Wire to Terminal 1 Flat washer 2 Supply wire 3 Cupped wire 4 Upper nut Figure 150: Typical Terminal Block Positioned In the Terminal Box 1 Ground wire (green) 2 Terminal block 3 Neutral wire (white) 4 L1 power supply wire (black) NOTE: It is always recommended to label and tag all wires and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 3. Remove and retain the two screws that secure the terminal block onto the terminal box. 4. When replacing the terminal block, refer to Electrical Wiring Connections at the Terminal Block, page 77) Electrical Wiring Connections at the Terminal Block For detailed electrical wiring requirements and safety precautions, refer to the Installation Instructions manual for this appliance. NOTE: The electrical wiring diagram is located on the back side of the kick panel (see Wiring Diagram, page 5) _ARA_EN_B Page 77 of 119

77 4.6.7 Cooling Fan Removal and Replacement Some models use a cooling fan with a Hall Effect sensor attached, which is a part of the cooling fan assembly. Other models use a cooling fan with an air interlock switch installed (see Air Interlock Switch Removal and Replacement, page 79). and the correct part number when replacing this component. Sharp Component Use Gloves Use gloves when handling the cooling fan, as it has sharp edges 3. Remove back panel, per Back Panel Removal and Replacement procedure, page At the back of the range, detach the wire connectors from the fan s Hall Effect sensor, and make a note of which wires are connected to each of the two different terminals (see Figure 153, page 78). NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 5. Remove and retain the two screws that secure the cooling fan (mounting plate) onto the range chassis (see Figure 152). 6. Using gloves, remove the cooling fan. 7. Replace the cooling fan if needed. Figure 152: Cooling Fan with Mounting Plate Shown 1 Screws (2) that secure fan onto range chassis 2 Studs (2) that hold mounting plate onto fan housing 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page 73. Figure 153: Cooling Fan 1 Wire connectors (2) _ARA_EN_B Page 78 of 119

78 Air Interlock Switch Removal and Replacement The air interlock switch can be removed and replaced independently of the cooling fan. and the correct part number when replacing this component. Figure 154: Air Interlock Switch Figure 156: Air Interlock Switch on Cooling Fan Figure 155: Bracket 1 Bracket 2 Air interlock switch 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard, per Backguard and Island Trim Removal and Replacement procedure, page Remove back panel, per Back Panel Removal and Replacement procedure, page At the cooling fan, remove and retain the nuts securing the air interlock switch onto its bracket (see Figure 154, Figure 155, and Figure 156). 5. Replace the air interlock switch if needed _ARA_EN_B Page 79 of 119

79 4.6.8 Thermal Fuse Removal and Replacement When the range temperature reaches the maximum temperature threshold, the thermal fuse breaks the electrical circuit in order to protect the electronics from abnormally high heat conditions. Some model ranges have thermal fuses installed, while other models do not, as they are protected from adverse heat conditions by cavity venting. Thermal fuses are installed at the back of the range. and the correct part number when replacing this component. 5. Detach the wire connectors from the terminals and make a note of how the wires are connected. NOTE: It is always recommended to label and tag all wires, wire connectors and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone 6. Remove and retain the screw(s) securing the thermal fuse to the range chassis. 7. Replace the thermal fuse if needed Manifold Arm Removal and Replacement Back of Range Figure 157: Typical Thermal Fuses 1. Follow all safety precautions and steps in the Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. Depending on the model range, you may have to remove the crossmember cover (see Crossmember Cover Removal and Replacement, page 75). Figure 158: Typical Manifold Arm Models for Bake and Broil Burners Accessible from the back of the range on 48-inch range models only, the manifold arm is for bake and broil burners. Although bake and broil components can be accessed and replaced without removing the manifold arm, this procedure is provided if the manifold arm needs to be replaced, for example, due to a gas leak in the manifold arm, if the threading on the manifold arm is bad, or if there is other damage to the manifold arm. and the correct part number when replacing this component _ARA_EN_B Page 80 of 119

80 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. To detach the gas flex tube, use one adjustable or open-end wrench to hold the flared adapter, while you simultaneously use another adjustable (or open-end) wrench to loosen the compression nut on the flared adapter (see Figure 159). 5. Use an adjustable or open-end wrench to remove the compression nuts on the gas tubes, and then remove the gas tubes from the manifold arm. Be careful not to bend the gas tubes (see Figure 159). 6. Remove the two solenoid valves from the manifold (see Bake Burner Solenoid Removal and Replacement Back of Range, page 82). NOTE: Use pipe sealant on pipe threads only (for example, on the threaded end of the flared adapter, and the threaded outlets on the manifold arm). Never use pipe sealant on the flair connections or pressure fittings, such as the flared end of the flared adapter. Figure 159: Typical Manifold Arm for Bake and Broil Burners 1 Gas flex tube 2 Flared adapter 3 Manifold arm brackets (2) - welded on manifold arm 4 Manifold arm 7. Remove and retain the screws on each of the two manifold arm brackets to detach the manifold from the range chassis. 8. Replace the manifold arm if needed. Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test _ARA_EN_B Page 81 of 119

81 Bake Burner Solenoid Removal and Replacement Back of Range Access for the bake burner solenoid valve is at the back of the range for all 48-inch models, or from the top of the range under the maintop for all 36-inch and 30-inch models (see Bake Burner Solenoid Removal and Replacement Under Maintop, page 58). For the procedure for the XLO burner solenoids, see Solenoid Valve for XLO Burner - Removal and Replacement page 42. NOTE: For 48-inch ranges, part numbers differ for the main (large) oven and auxiliary (small) oven solenoid valves. and the correct part number when replacing this component. Figure 160: Bake Solenoids and Bake / Broil Manifold Assembly 1 Gas flex tube to small oven bake burner 2 Solenoid valve for small oven bake burner 3 Solenoid valve for large oven bake burner 4 Gas flex tube to large oven bake burner 5 Manifold for bake and broil burners 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. Remove solenoid valves from manifold arm (see Figure 160). NOTE: When removing a solenoid valve from the manifold arm (see Figure 160), since it is secured with pipe sealant you may need to use a hammer to tap at the wrench affixed to the nut at the inlet valve until it can be rotated. NOTE: When installing a solenoid valve, the inlet must be sealed with pipe sealant at the manifold 5. At the solenoid valve outlet, remove and retain the fittings: When removing the main oven solenoid valve: At the outlet, a sleeve and a 9/16th inch compression nut attach to the respective 3/8th inch diameter gas flex tube (see Figure 161, page 83). When removing the auxiliary oven solenoid valve: At the outlet, a sleeve and a 1/2 inch compression nut attach to the respective 5/16th inch diameter gas flex tube (see Figure 161, page 83). 6. Replace the solenoid if needed. NOTE: Use pipe sealant on pipe threads only (for example, on the solenoid valve inlet (at their outlets on the manifold arm). Never use pipe sealant on the flair connections or pressure fittings, such as the flared end of the flared adapter _ARA_EN_B Page 82 of 119

82 and the correct part number when replacing this component. Figure 162: Typical Bi-Metal Gas Valves Figure 161: Solenoid Valve and Fittings for Bake Burner at Back of Range 1 Gas flex tube 2 Compression nut 3 Sleeve 4 Solenoid valve outlet (to gas flex tube / bake burner) 5 Solenoid valve 6 Solenoid valve inlet (from manifold arm) Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Bi-Metal Gas Valve Removal and Replacement Back of Range There is a dedicated bi-metal gas valve for each individual broil burner. For 48-inch ranges, the bi-metal gas valves are located and accessible at the back of the range. For 30-inch and 36-inch ranges, the bi-metal gas valves are located under the maintop (see Bi-Metal Gas Valve Removal and Replacement Under Maintop, page 56). Figure 163: Bi-Metal Gas Valve and Connections 1 Spade wire connectors (2) 2 Bi-metal gas valve 3 Screws (2) that hold bi-metal valve to range chassis 4 Compression nut on gas tube at inlet 5 Compression nut on gas tube at outlet _ARA_EN_B Page 83 of 119

83 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panel (see Back Panel Removal and Replacement, page 74). 4. Disconnect the two spade connectors from the bi-metal gas valve, and make a note of which wires are connected to each of the two different terminals (see Figure 164). NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them, so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). 5. Use an adjustable wrench to remove the compression nuts and then detach the gas tubes at the inlet and outlet. Be careful not to bend the gas tubes (see Figure 164). 6. Remove and retain the two screws that secure to the bi-metal gas valve onto the range chassis (see Figure 164). 7. Remove and replace the single valve if necessary. Figure 164: Bi-Metal Gas Valve (Shown at Back of Range) 1 Bi-metal valve Gas Leaks With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. For bi-metal gas valves you may need the electrical power to be on when testing for gas leaks. Use extreme caution when performing gas leak testing on bi-metal gas valves with the electrical power turned on _ARA_EN_B Page 84 of 119

84 4.7 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 Oven Temperature Sensor Removal and Replacement The oven temperature sensor is located inside each oven cavity (see Figure 165). Access is needed from both the front and back of the range in order to replace the sensor bulb. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. Remove oven door (see Oven Door Removal, Installation, page 88). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components. 5. Remove oven trays. 6. From inside the oven cavity, remove and retain the two screws (see Figure 165, page 85). 7. At the back of the range, detach the sensor wire connectors. 8. At 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. 9. At the front of the range, gently pull the sensor connector wires through the portal. 10. Replace the sensor if necessary. Figure 165: Sensor and Lamp Locations Inside Oven Cavity 1 Lamp 2 Lamp screw 3 Oven temperature sensor screws (2) 4 Oven temperature sensor Fiberglass Wear gloves when handling fiberglass insulation _ARA_EN_B Page 85 of 119

85 4.7.2 Oven Lamp / Lamp Bulb Removal and Replacement Figure 166: Typical Oven Lamp Assembly 1 Wire connectors 2 Bulb 3 Lens (shown removed) The oven lamp is located inside each oven cavity (see Figure 165). Access is needed from both the front and back of the range in order to replace the oven lamp. Replacing the bulb only requires access from the front of the range. NOTE: The bulb can be replaced without replacing the lamp assembly. Refer to the Use and Care manual for the bulb type. and correct part numbers when replacing any of these components. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. Remove oven door (see Oven Door Removal, Installation, page 88). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door and latch components. 5. Remove the oven trays. 6. From the back of the range, detach the lamp wire connectors. 7. From inside the oven cavity, remove and retain the screw that holds the lamp onto the oven cavity (see Figure 165, page 85). 8. Remove the fixing clip and lens (transparent cover) of the oven lamp assembly. 9. Replace the bulb if needed. Fiberglass Insulation Wear gloves when handling fiberglass insulation. 10. 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. 11. From the front of the range, gently pull the lamp connector wires through the sensor portal. 12. Replace the lamp if needed Oven Light Diagnostics To diagnose problems with the oven light, see Oven Light Diagnostics, page 86. Also see Oven Lamp Transformer Removal and Replacement, page _ARA_EN_B Page 86 of 119

86 Figure 167: Oven Light Diagnostics _ARA_EN_B Page 87 of 119

87 4.7.3 Oven Door Removal, Installation, and Alignment and correct part numbers when replacing any of these components. 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 firmly 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 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Open the door fully and use a flat blade screwdriver to pry the locking levers downward (towards you) as far as it goes (see Figure 168, page 88). Figure 168: Prying Locking Lever Downward with Screwdriver 3. Close the door until it stops against the locking levers while firmly grasping the door with both hands. The open locking levers will hold the door open at a slight angle. 4. Grasp the door firmly on the ends of the door handle, and lift the door up (there will be some spring resistance to overcome). When the door is lifted sufficiently to clear the hinge hooks, pull the door straight out (see Figure 169), and place it in a safe location. Figure 169: Hinge Shown Removed Installing the Door 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page While firmly grasping the door on both sides, position the door at a slight angle and insert both hinges into their respective slots. The hinges will be securely hooked into the slots when properly installed. NOTE: Be careful not to let the door fall. Do not force or bend the door. TIP: Rest the door on your foot while using your leg for stability. 3. Open the door fully and then use a flat blade screwdriver to push the locking levers upward all the way (away from you) into the hinge slots. Careful not to scratch the range during this process. 4. Open and close the door to make sure the door is positioned properly and closes with a tight fit. Do not force the door to open or close. If the door is properly installed, it should move smoothly and _ARA_EN_B Page 88 of 119

88 rest straight on the front of the range when closed. If the door does not operate correctly, verify that the hinges are properly seated into the hinge slots, and that the locking levers are fully engaged into the slots. If the door is not aligned correctly, see Aligning the Door Aligning the Door On models that have an alignment mechanism as a part of the hinge receiver, you can adjust the door alignment by using the alignment screw that is located below each hinge / hinge receiver slot. 1. Make sure the door is installed correctly so it will not pose any danger by falling while adjusting the screw (see Installing the Door, page 88). 2. Locate the alignment screw below the door hinge (see Figure 170 and Figure 171). 3. Use a T-27 driver to turn the alignment screw until the door is properly aligned. Figure 171: Alignment Screw (Shown with Door Removed for Clarity) 1 Slot for hinge 2 Hinge receiver screw (do not rotate this screw as it is not for door alignment) 3 Door alignment screw Figure 170: Alignment Screw (View at Small Door of 48-Inch Range) 1 Alignment screw _ARA_EN_B Page 89 of 119

89 4.7.4 Convection Components Removal and Replacement Although most convection components are accessed from the front of the range, you may also need access from the back of the range (such as for the convection motor wire connectors). and correct part numbers when replacing any of these components. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. Remove oven doors (see Oven Door Removal, Installation, page 88). NOTE: It is recommended to remove the door, to prevent weight or force applied from damaging the door / latch components. 5. Remove all the oven racks. 6. Remove and retain the four screws and remove the front cover (see Figure 173). NOTE: When re-installing front cover, it must be positioned with the cover arrow-shaped vents facing to the right, as shown in Figure 173. Figure 172: Convection Components 1 Motor 2 Bracket 3 Insulation 4 Plate 5 Shim ring 6 Fan 7 Nut 8 Cover Figure 173: Screws Securing Front Cover and Cover Position 1 Screw locations (4) _ARA_EN_B Page 90 of 119

90 7. Wearing gloves, remove the nut, and then remove the convection fan. Retain the shim ring if it falls out when removing the fan (see Figure 174). Figure 174: Fan, Nut, Shim Ring and Washer 1 Shim ring and washer 2 Fan 3 Nut Figure 175: Convection Motor Wire Connectors 9. Remove the six 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 176 and Figure 181, page 93. Fiberglass Wear gloves when handling fiberglass insulation. 8. From the back of the range, detach the two convection motor blade connectors (see Figure 175). 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 re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). Figure 176: Screws on Rear Cover Shield 1 Screw locations (6) 10. To detach the motor assembly from the bracket, first remove and retain the shim ring and washer (see Figure 177, page 92). 11. Remove and retain the four screws from the rear cover shield that are attached to the bracket (see Figure 178, page 92) _ARA_EN_B Page 91 of 119

91 12. Remove the bracket (with fiberglass insulation) attached to motor (see Figure 179). Figure 177: Removing the Washer and Shim Ring 1 Washer 2 Shim ring Figure 179: Bracket and Insulation 1 Screw locations (4) that attach to rear cover shield 2 Fiberglass insulation 13. Wearing gloves, remove and retain the fiberglass insulation. 14. Remove and retain the three screws securing the bracket onto the motor (see Figure 180 and Figure 181), and then remove the motor. Figure 178: Removing Bracket Screws on Rear Cover Shield 1 Screws (4) securing rear cover shield to bracket Figure 180: Three Screws Connecting Bracket to Motor 1 Screws (3) securing the bracket to the motor _ARA_EN_B Page 92 of 119

92 Eye Protection To protect your eyes from debris, it 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. Figure 181: Rear Cover Shield and Motor (Back-of-Range View) 1 Screws securing bracket to rear cover shield (4) 2 Screws securing motor to bracket (3) Gas Leak Testing 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. 15. Replace the convection motor, if needed Broil Burner Components Removal and Replacement This procedure requires access from both the front and the back of the range. The broil burner removal and replacement procedure is the same for broil burner components in both the small and large ovens. For broil burner issues that may be related to the HSI control board, see Hot Surface Igniter Board Removal and Replacement, page 62. and correct part numbers when replacing any of these components. Hot Surfaces The oven broil burner and interior surfaces of the oven may be hot and can cause burns. Do not service the range when these components are hot. Figure 182: Broil Burners (Large Oven Shown) Fiberglass Wear gloves when handling fiberglass insulation _ARA_EN_B Page 93 of 119

93 Figure 183: HSI for Broil Burner 1 Location of screws (2) and nuts with lock washers (2) that secure the HSI onto HSI retaining bracket 2 Spade wire connectors (2) on HSI 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove all trays from the oven. 3. Remove oven doors (see Oven Door Removal, Installation, page 88). 4. Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 5. Remove the two back panels (see Back Panel Removal and Replacement, page 74). 6. From the back of the range, disconnect the hot surface igniter (HSI) wire (spade) connectors (see Figure 183 and Figure 184) and make a note of which wires are connected to each of the two different terminals. NOTE: It is always recommended to label and tag all wires, wire connectors, and harnesses prior to disconnecting them so as to correctly identify their connections/locations when re-assembling. Alternatively, you can photograph the wire connections prior to disconnecting (for example, with your mobile phone). Figure 184: HSI Wires at Broil Burner 1 HSI wire with spade connector (2) Hot Surface Igniter for Broil Burner Removal and Replacement and the correct part number when replacing this component. 1. Follow all steps in Broil Burner Components Removal and Replacement, page From inside of the range, remove and retain the two screws and respective nuts with lock washers that hold the HSI onto the HSI retaining bracket (see Figure 183 and Figure 185) _ARA_EN_B Page 94 of 119

94 Broil Burner Removal and Replacement and the correct part number when replacing this component. Figure 185: HSI on HSI Retaining Bracket (Shown Attached to Broil Burner) 1 HSI retaining bracket 2 Screw (2) and nut with lock washer (2) securing HSI onto HSI retaining bracket 3 Nut with lock washer (2) securing HSI retaining bracket onto broil burner 3. From inside the range, slowly and carefully pull the HSI outward (towards you) as the two wires with spade connectors pass through the receptacle and insulation at the back of the range. 4. Replace the HSI if necessary. Figure 186: Broil Burner Assembly 1 Broil Burner 2 Venturi tube 3 Orifice holder bracket 4 Elbow connector with orifice attached 1. Follow all steps in Broil Burner Components Removal and Replacement, page From the back of the range, use an adjustable wrench to detach the compression nuts from the elbow connector and bi-metal valve (see Figure 187, page 96), and then remove the gas tube. 3. From the back of the range, remove and retain the screws on the bracket located at the receptacle for the broil burner, and then remove the bracket (see Figure 188 and Figure 189) _ARA_EN_B Page 95 of 119

95 Figure 187: Removing Gas Tubes from Bi-Metal Gas Valve 1 Compression nut on gas tube at inlet 2 Compression nut on gas tube at outlet Figure 189: Bracket at Broil Burner Receptacle 4. From inside of the range, use a 9 mm open end wrench to remove and retain the two nuts with lock washers that secure the HSI retaining bracket onto the broil burner studs (see Figure 185 on page 95, and Figure 190), and then remove the HSI retaining bracket. NOTE: If you have not removed the HSI, you ll now remove the HSI retaining bracket with the HSI attached to it. Figure 188: Bracket at Broil Burner Receptacle 1 Bracket at broil burner receptacle Figure 190: Broil Burner Screws and Studs (Rear of Burner Shown) 1 Studs (2) fastening HSI retaining bracket to broil burner 2 Rear screw fastening broil burner to top of oven cavity _ARA_EN_B Page 96 of 119

96 5. Remove and retain the rear and front screws on the broil burner that fasten it to the top of the oven cavity (see Figure 190, page 96 and Figure 191). Be sure to hold the burner so that it doesn t drop until the broil burner is removed from the oven cavity). Figure 191: Broil Burner Screws (Front of Burner Shown) 1 Front screw fastening broil burner to top of oven cavity 6. While holding the broil burner, first pull it downward (out of the ceiling of the cavity), and then pull it outward (towards you) very carefully, as the broil burner s Venturi tube and orifice assembly will pass through the insulation at the back of the range. NOTE: Do not detach the elbow connector and orifice from the orifice holder bracket. If either the elbow connector or the orifice needs replacing, replace the broil burner assembly Bake Burner Components (Large Oven) Removal & Replacement Both the large and small oven have bake burners, whose components require access from both the front and back of the range Replacing the Bake Burner Large Oven and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panels (see Back Panel Removal and Replacement, page 74). 4. Remove oven doors (see Oven Door Removal, Installation, page 88). 5. Remove all the oven racks. 6. Remove and retain the four screws on the bottom cover that secure it to the oven cavity and reflector, and then remove the cover (see Figure 193). Figure 193: Bottom Cover of Oven Cavity (Shown for Large Oven) 1 Screws (4) on bottom cover of oven cavity Figure 192: Broil Burner Assembly (Shown Removed) _ARA_EN_B Page 97 of 119

97 Sharp Components Wear gloves and be careful when handling sharp bake burner components 7. Remove the reflector from the burner box (see Figure 194). Figure 196: Inside Bake Burner Box (Shown with Reflector Removed) Figure 194: Reflector 1 Brackets that attach to reflector 2 Bake burner bracket and two screws 3 Hot Surface Igniter (HSI) 4 Electrode (flame sensor) 5 Bake burner 8. Remove and retain the two screws to remove the straight bracket (see Figure 197, page 99). Figure 195: Reflector _ARA_EN_B Page 98 of 119

98 Figure 197: Bake Burner Brackets 1 U-shaped (fixed) bracket 2 Straight bracket with two screws Figure 198: Screws at Ends of Bake Burner 1 Screws (2) at ends of bake burner 9. Remove and retain the two screws holding the two ends of the burner onto the burner box chassis (see Figure 198). 10. Pull the burner out gently from the burner box, and replace burner or adjust air shutter if needed (see Figure 199). NOTE: Although the air shutter is optimally set in the factory, it may be adjusted by unscrewing the adjustment screw and rotating the air shutter so that its opening is more open or closed (see Figure 199 and Adjusting Bake Burner Flame on page 14). 11. NOTE: When installing the bake burner make sure that it snaps correctly into place, so that the air shutter (Figure 199) is aligned with the orifice assembly (see Figure 210, page 104 and Figure 211, page 104), and so the back end of the bake burner fits all the way into the U-shaped bracket (see Figure 197). Figure 199: Large Oven Bake Burner 1 Air shutter (adjustment screw not shown) _ARA_EN_B Page 99 of 119

99 Gas Leak Testing 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 Replacing the Bake Burner Hot Surface Igniter Large Oven In some range models a hot surface igniter (HSI) ignites the bake burner, while in other models an electrode ignites the bake burner. For the models that use the electrode as an igniter as well as the models that use the HSI as an igniter, the electrode also functions as a flame sensor that is, if the electrode does not heat up enough in a short time frame, the electrode will close the solenoid valve to avoid gas build-up in the burner. and the correct part number when replacing this component. 1. Perform all steps in Replacing the Bake Burner Large Oven, page From the back of the range remove the crossmember panel (see Crossmember Cover Removal and Replacement, page 75) 3. From the back of the range detach the HSI wire connector (see Figure 200). 4. [Only on specific models]: Remove and retain the two screws securing the HSI shield onto the burner box chassis, and then remove the shield (see Figure 201). Figure 200: HSI Wire Connector (Shown Detached) Figure 201: HSI Shield 5. Remove and retain the screw that secures the HSI onto the chassis (see Figure 202, page 101), and then remove the HSI and its small bracket (see Figure 203, page 101). Be careful so that the small bracket doesn t fall into the burner box _ARA_EN_B Page 100 of 119

100 Figure 204: Small Bracket Shown Removed from HSI (Left), and Position when Attached to HSI (Right) Figure 202: HSI with Screw Shown NOTE: When installing the HSI, feed the harness with wire connector through the portal at the back of the range, as shown in Figure 205. Figure 203: Small Bracket on HSI 6. Now remove the HSI by gently pulling its harness and wire connector out (towards you) through the burner box. 7. Replace the HSI if needed. NOTE: When installing the HSI onto the burner box, make sure the small bracket is secured onto the HSI as shown in Figure 204. The screw goes through the holes on both the HSI and the small bracket, fastening them both onto the burner box. Figure 205: Portal for HSI Harness with Wire Connector _ARA_EN_B Page 101 of 119

101 Gas Leak Testing 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 Replacing the Bake Burner Electrode Large Oven In some models an electrode ignites the bake burner while in other models a hot surface igniter (HSI) ignites the bake burner. For the models that use the electrode as an igniter as well as the models that use the HSI as an igniter, the electrode also functions as a flame sensor that is, if the electrode does not heat up enough in a short time frame, the electrode will close the solenoid valve to avoid gas build-up in the burner. The direct spark ignition (DSI) module is used whenever the electrode is the igniter for the bake burner (whether or not the broil burner uses the HSI or electrode as the igniter). See DSI Module Removal and Replacement, page 63. and the correct part number when replacing this component. Figure 206: Electrode / Flame Sensor (Shown on Burner Box) 1. Perform all steps in Replacing the Bake Burner Large Oven, page At back of the range, use gloves to reach underneath and detach the wire spade connector (on the green wire) from the electrode terminal (see Figure 207 and Figure 208 on page 103) _ARA_EN_B Page 102 of 119

102 Figure 208: Electrode 1 Electrode terminal 2 Location of screw that secures electrode onto bracket Figure 207: Electrode Wire and Portal 1 Portal for electrode wire 2 Electrode wire (green) 3. Remove and retain the single screw that secures the electrode to the bracket (see Figure 208), as well as the two screws that secure the bracket to the burner box chassis (see Figure 209). Then remove the electrode and bracket. 4. Replace the electrode if needed. Figure 209: Electrode Bracket 1 Location of screw that secures electrode onto bracket 2 Location of screws (2) that secure bracket to burner box Gas Leak Testing 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 _ARA_EN_B Page 103 of 119

103 Replacing the Bake Burner Orifice Assembly Large Oven NOTE: When replacing the orifice assembly (orifice and elbow connector) or the bracket that retains the orifice assembly, you do not have to remove the bake burner box from the cavity. and the correct part number when replacing this component. 1. Perform all steps in Replacing the Bake Burner Large Oven, page From the back of the range remove the crossmember panel (see Crossmember Cover Removal and Replacement, page 75). 3. From inside the burner box, remove and retain the two bracket screws (see Figure 210 and Figure 211). 4. When the bracket screws are removed, the bracket with elbow connector and orifice attached should drop and be accessible at the front side of the burner box (see Figure 211). Figure 210: Frontal View of Burner Box (Shown Removed from Cavity for Reasons of Clarity) 1 Screw locations (2) that attach to orifice assembly bracket (screws are removed and installed from inside of the burner box, and the bracket is mounted onto the front of the burner box). 2 Portal for aligning orifice assembly and bake burner 3 Bracket (underneath burner box) 4 Receptacle on bracket for (green) electrode wire Figure 211: Bracket with Orifice Assembly 1 Orifice 2 Elbow connector 3 Location of screws (2) on bracket NOTE: Although you should be able to access and remove the bracket and orifice assembly without removing the bake burner box, if you lift the burner box out of the cavity, be careful not to damage the surrounding insulation (see Figure 212, page 105) _ARA_EN_B Page 104 of 119

104 4.7.7 Bake Burner Components (Small Oven) Removal & Replacement On the 48-inch ranges, both the large and small oven have bake burners, whose components require access from both the front and back of the range. Figure 212: Cavity for Bake Burner Box Large Oven 1 Insulation in burner box cavity 5. From underneath the burner box, gently pull out the bracket with orifice and elbow connector attached. 6. Use an adjustable wrench to remove the compression nut at the elbow connector, and then detach the flex tube from the elbow connector. 7. While holding the hex nut on the orifice with an adjustable wrench, rotate the elbow connector to detach the elbow connector and orifice from the bracket, and then replace the component(s) if needed Replacing the Bake Burner Small Oven and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panel (see Back Panel Removal and Replacement, page 74). 4. Remove the crossmember panel (see 5. Remove oven doors (see Oven Door Removal, Installation, page 88). 6. Remove all the oven racks. 7. Remove and retain the two screws attaching the bottom cover of the bake burner cavity to the rim of the small oven burner box (see Figure 213). Gas Leak Testing 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. Figure 213: Bottom Cover of Bake Burner Cavity Small Oven 1 Screws (2) on bottom cover of oven cavity _ARA_EN_B Page 105 of 119

105 Sharp Components Wear gloves and be careful when handling sharp bake burner components Figure 216: Burner Box with Baffle Removed Figure 214: Bottom Cover Removed 8. Pull the baffle out of the burner box (see Figure 215 and Figure 216). 9. From inside the burner box, remove and retain the four screws on the cover plate, and then slide the cover plate out of the burner box (see Figure 217 and Figure 218 on page 107). 10. At the back of the range, detach the HSI wire connector (see Figure 219 on page 107). 11. At the back of the range, use gloves to reach underneath the burner box and detach the electrode wire connector (on the green wire) from the electrode terminal (see Figure 219 on page 107). Figure 215: Baffle _ARA_EN_B Page 106 of 119

106 Figure 217: Inside Bake Burner Box 1 Hot Surface Igniter (HSI) 2 Electrode 3 Bake burner 4 Cover plate (with 2 of 4 screws shown) Figure 219: Bake Burner HSI Wire Connector and Electrode Wire Portal (Shown from Back of Range) 1 Burner box 2 HSI wire connector 3 Portal for green electrode wire (wire shown) 12. From inside the burner box, remove and retain the two screws that secure the bracket onto the front of the burner box (see Figure 220 on page 108). This bracket holds one end of the bake burner, and also holds the orifice-elbow connector assembly. NOTE: In order to remove the bake burner, first the bracket must be detached (and therefore drop), so that the small pin on the bracket becomes detached from the receiving receptacle on the bake burner (see Figure 221 and Figure 222 on page 108). Figure 218: Cover Plate 1 Location of screws (4) _ARA_EN_B Page 107 of 119

107 Figure 220: Screws Securing Bracket for Bake Burner and Orifice Assembly (Burner Box Shown Removed for Reasons of Clarity) 1 Screws holding bracket for the bake burner and orifice -elbow connector assembly Figure 221: Bake Burner 1 Tab (inserts into slot in burner box) 2 Receptacle that receives bracket pin 3 Air shutter adjusting screw 4 Air shutter opening Figure 222: Bracket 1 Pin (holds end of bake burner) 2 Screws (2) that attach to front of burner box 3 Receptacle for retaining elbow connector and orifice _ARA_EN_B Page 108 of 119

108 13. After the bracket with elbow connector and orifice attached drops, remove the tab from the slot in the burner box (see Figure 223), and gently pull it out. 14. Replace the burner, or adjust the air shutter if necessary. NOTE: Although the air shutter is optimally set in the factory, it may be adjusted by unscrewing the adjustment screw and rotating the air shutter so that its opening is more open or closed (see Figure 221 on page 108, and Adjusting Bake Burner Flame on page 14). 15. When installing a bake burner: a. Insert the burner s tab into the respective slot on the burner box (see Figure 221 on page 108, and Figure 223). b. Then you will need either a third hand to assist or something non-abrasive (like a glove) to prop up the bake burner, so that it is secured in its correct installed position, while you install the pin of the bracket (with elbow connector and orifice securely attached) onto the burner receptacle. c. From inside the burner box, re-attach the two screws through the burner box chassis onto the respective bracket holes (see Figure 222 on page 108, and Figure 223). Both sets of holes must be aligned. Be careful so that the bracket s pin doesn t move out of the receptacle on the bake burner. Gas Leak Testing 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. Figure 223: Burner Box (Shown with Bracket Detached) 1 Slot that receives the bake burner tab 2 Screw locations (2) holding bracket onto burner box Replacing the Bake Burner Hot Surface Igniter Small Oven In some range models a hot surface igniter (HSI) ignites the bake burner, while in other models an electrode ignites the bake burner. For the models that use the electrode as an igniter as well as the models that use the HSI as an igniter, the electrode also functions as a flame sensor that is, if the electrode does not heat up enough in a short time frame, the electrode will close the solenoid valve to avoid gas build-up in the burner. and the correct part number when replacing this component _ARA_EN_B Page 109 of 119

109 1. Perform all the steps in Replacing the Bake Burner Small Oven, page From the back of the range remove the crossmember panel (see Crossmember Cover Removal and Replacement, page 75). 3. From the back of the range, detach the HSI wire connector (see Figure 219, page 107). 4. [Only on specific models]: Remove and retain the two screws securing the HSI shield onto the burner box chassis, and then remove the shield (see Figure 201, page 100). 5. Remove and retain the screw that secures the HSI onto the burner box (see Figure 224), and then remove the HSI and its small bracket (see Figure 203, page 101). Be careful so that the small bracket doesn t fall into the burner box. 6. Now remove the HSI by gently pulling its harness and wire connector out (towards you) through the burner box. 7. Replace the HSI if needed. NOTE: When installing the HSI onto the burner box, make sure the small bracket is secured onto the HSI as shown in Figure 204, page 101. The screw goes through the holes on both the HSI and the small bracket, fastening them both onto the burner box. NOTE: When installing the HSI, feed the harness with wire connector through the portal at the back of the range, as shown in Figure 219, page 107). Gas Leak Testing With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test. Figure 224: HSI and Electrode on Bake Burner Box Small Oven 1 Screw securing HSI and small bracket onto burner box 2 Screw securing electrode bracket onto burner box 3 Screw securing electrode onto electrode bracket 4 Screw securing electrode bracket onto burner box Replacing the Bake Burner Electrode Small Oven In some models an electrode ignites the bake burner while in other models a hot surface igniter (HSI) ignites the bake burner. For the models that use the electrode as an igniter as well as the models that use the HSI as an igniter, the electrode also functions as a flame sensor that is, if the electrode does not heat up enough in a short time frame, the electrode will close the solenoid valve to avoid gas build-up in the burner _ARA_EN_B Page 110 of 119

110 The direct spark ignition (DSI) module is used whenever the electrode is the igniter for the bake burner (whether or not the broil burner uses the HSI or electrode as the igniter). See DSI Module Removal and Replacement, page 63. and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the backguard (see Backguard and Island Trim Removal and Replacement, page 73). 3. Remove the back panel (see Back Panel Removal and Replacement, page 74). 4. Remove the crossmember panel (see Crossmember Cover Removal and Replacement, page 75). 5. Remove oven doors (see Oven Door Removal, Installation, page 88). 6. Remove all the oven racks. 7. Remove and retain the two screws attaching the bottom cover of the bake burner cavity to the rim of the small oven burner box (see Figure 213, page 105). Sharp Components Wear gloves and be careful when handling sharp bake burner components 8. At the back of the range, use gloves to reach underneath the burner box and detach the electrode wire connector (on the green wire) from the electrode terminal (see Figure 219, page 107). 9. Remove and retain the single screw that secures the electrode to the bracket (see Figure 208, page 103), as well as the two screws that secure the bracket to the burner box chassis (see Figure 209, page 103). Then remove the electrode and bracket. 10. Replace the electrode if needed. Gas Leak Testing With electrical power off, carefully check for gas leaks at each gas component that was removed, replaced, or otherwise serviced using a gas leak detector or bubble test Replacing the Bake Burner Orifice Assembly Small Oven and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Replacing the Bake Burner Small Oven, page Pull the bracket with orifice assembly connected (orifice and elbow connector) out from under the front of the range. NOTE: You do not need to lift the bake burner out of the burner box. 3. Use an adjustable wrench to remove the compression nut at the elbow connector, and then detach the gas flex tube from the elbow connector (see Figure 225, page 112). 4. While holding the hex nut on the orifice with an adjustable wrench, rotate the elbow connector to detach the elbow connector and orifice from the bracket (see Figure 226, page 112). 5. Remove and replace orifice or elbow connector if necessary. Gas Leak Testing 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 _ARA_EN_B Page 111 of 119

111 Figure 225: Elbow Connector on Bracket Removing the Bake Burner Box Small Oven and correct part numbers when replacing any of these components. You should be able to access and remove the bake burner, bracket and orifice assembly without removing the bake burner box. If you need to lift the burner box out of the cavity for another reason, do the following: 1. Per respective procedures, make sure the burner has been removed, wire connections for the HSI and electrode have been detached, and that the orifice assembly is not in the way. 2. Wearing gloves, push the side frames of the burner box inward and then pull the burner box out of the cavity. Be careful not to damage the surrounding insulation that lines the cavity (see Figure 227). Figure 227: Cavity for Bake Burner Box (Insulation Shown) Figure 226: Orifice on Bracket _ARA_EN_B Page 112 of 119

112 Gas Leak Testing 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 Door Handle Components Removal and Replacement and correct part numbers when replacing any of these components Removing Door Handle Components 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove the oven door (follow all warnings and steps for the Oven Door Removal, Installation procedure, page 88). 3. Remove the oven trays. 4. Gently place the door on a flat, stable, and non-abrasive surface. 5. Remove and retain the three screws at the top of the door (see Figure 229). Figure 229: Screws at Top of Door Figure 228: Door Handle Components 1 Location of screws (3) at top of door _ARA_EN_B Page 113 of 119

113 6. Remove and retain the three screws at the bottom of the door (see Figure 230). Figure 231: Hex Head Cap Screws and Washers Figure 230: Screws at Bottom of Door 1 Location of screws (3) at bottom of door 7. Gently lift front door panel off the door. 8. At the back side of the front door panel, at both the left and right sides remove and retain the two hex head cap screws and washers (see Figure 231). This will detach the endcaps from the door assembly. 9. After removing the right and left endcaps, pull the door handle tube out from the endcaps. 10. Replace the door handle components if needed. 11. After replacing door handle components, install the oven door and test for proper positioning - follow all warnings and steps for Installing the Door, page Hex head cap screws and washers (4 of each) left side shown Door Hinge Removal and Replacement and the correct part number when replacing this component. 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. Sharp Components Wear gloves when removing the door hinge _ARA_EN_B Page 114 of 119

114 1. Follow steps 1 through 7 of the Door Handle Components Removal and Replacement procedure, page Place the back door panel on a flat, stable, and non-abrasive surface, with the porcelain side facing upward (see Figure 232). The hinge and locking lever are in a specific position that occurs after the oven door has been removed (as shown in Figure 232). In this position, do not move the hinge with your hands. 5. With the deep-well socket or similar tool still pressing on the hinge thumb, slowly release it, bringing the hinge and locking lever all the way forward to the safe position for hinge removal. The locking lever will have dropped into the slot (see Figure 234). Figure 233: Removing the Hinge (Shown Moving Hinge Downward) Figure 232: Door Hinge (Shown in the Position after Door Removal) 1 Hinge locking lever 2 Hinge thumb 3. Use a large deep-well socket or similar tool to securely place over the hinge thumb and then press the tool downward just a little bit (towards the base of the door - see Figure 233) and hold it there. 4. While still holding the hinge in the downward position, use a tool (not your fingers) like a flat-blade screwdriver to press the hinge locking lever inward (towards the hinge) as far as it goes. See Figure 233. Figure 234: Hinge (Shown in Safe Position for Hinge Removal) _ARA_EN_B Page 115 of 119

115 6. Remove and retain the screws as shown in Figure 235 and Figure 236. Figure 235: Screws for Hinge Removal 1 Screws (2) 7. Repeat steps 3 through 6 for the hinge at the other side of the door. 8. Turn the door upside-down, so that the porcelain surface is facing down. 9. Remove the four screws from the inner panel (see Figure 238, page 117). 10. Lift the inner panel off of the door, and then remove the hinge (see Figure 239, page 117). 11. Replace hinges if needed. Figure 236: Screws for Hinge Removal 1 Screws (2) Figure 237: Typical Hinge _ARA_EN_B Page 116 of 119

116 Door Gasket Removal and Replacement and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove oven door (see Oven Door Removal, Installation, page 88). 3. Remove and retain the screws on the bracket, and then remove the bracket (see Figure 240 and Figure 241, page 118). Figure 238: Inner Panel and Screws 1 Screws (4) 2 Inner panel Figure 240: Bracket 4. 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 242, page After replacing the gasket, check to make sure the door is positioned correctly, and closes with a tight fit. 6. Re-install the bracket. Figure 239: Removing the Hinge _ARA_EN_B Page 117 of 119

117 Kick Panel Removal and Replacement and the correct part number when replacing this component. 1. Follow all safety precautions and steps in Preparing the Range for Servicing, page Remove both oven doors (see Oven Door Removal, Installation, page 88). 3. Remove and retain the screws from the kick panel (see Figure 243), and then lift the kick panel off the range chassis. Figure 241: Screws on Bracket Figure 243: Typical Kick Panel 1 Location of screws (2) NOTE: The wiring diagram for the range is located on the back side of the kick panel (see Wiring Diagram, page 5). 5 BEFORE RETURNING APPLIANCE TO SERVICE Figure 242: Oven Gasket and Bracket 1 Gasket 2 Bracket 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 _ARA_EN_B Page 118 of 119