Thermador PRG486JDG/01 User manual

Service Manual for the Thermador Pro Grand Next Generation 48-Inch Natural Gas and LP Gas Ranges, Models: PRG486JDG/01, PRL486JDG/01
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TABLE OF CONTENTS
1General .................................................................................................... 5
1.1 Technical Documents to Read Prior to Servicing.......................................... 5
1.2 Data Rating Plate.......................................................................................... 5
1.3 Wiring Diagram ............................................................................................. 6
1.4 Recommended Tools and Supplies .............................................................. 6
1.5 Important Safety Information......................................................................... 7
1.5.1 Safety Symbols Used In This Manual.................................................... 7
1.5.2 Safety Precautions to Know Prior to Servicing....................................... 7
2Operation and Controls ....................................................................... 10
2.1 Knobs and Controls..................................................................................... 10
2.1.1 Standard Burner Knob......................................................................... 10
2.1.2 ExtraLow (XLO) and ExtraHi (XHI) Burner Knobs................................ 10
2.1.3 Griddle / Grill Control Knob.................................................................. 10
2.1.4 Temperature / Function Selector Knob for Large Oven ....................... 10
2.1.5 Temperature / Function Selector Knob for Small Oven........................ 11
2.1.6 Oven Light and Panel Light Switches .................................................. 11
2.2 LED Indicators............................................................................................. 11
2.3 Automatic Re-Ignition.................................................................................. 11
2.4 Operation during a Power Outage............................................................... 11
2.5 Rangetop Burner Assembly and Maintop Components .............................. 11
3Testing, Adjusting, and Troubleshooting Rangetop Burners and
Ignition................................................................................................... 12
3.1 Before Testing............................................................................................. 12
3.2 Rangetop Burner Characteristics................................................................ 12
3.3 Rangetop Flame Characteristics................................................................. 13
3.4 Testing Ignition for Burners......................................................................... 14
3.4.1 Time to Ignite....................................................................................... 14
3.4.2 Testing Ignition for Standard Burner Settings (HI, MEDIUM, SIM)....... 14
3.4.3 Testing Ignition for XLO Burner Settings.............................................. 14
3.4.4 Testing Broil Burner Ignition................................................................. 14
3.4.5 Testing Bake Burner Ignition................................................................ 14
3.5 Adjusting Bake Burner Flame with the Air Shutter...................................... 14
3.6 Adjusting Rangetop Burner Valves Manually.............................................. 15
3.6.1 Special Tools Needed.......................................................................... 15
3.6.2 Adjusting the Bypass Screws............................................................... 16
3.7 Troubleshooting Burners, Flame, and Ignition ............................................ 16
3.7.1 Burner and Flame Diagnostics for Rangetop Burners.......................... 16
3.7.2 Ignition Diagnostics for Rangetop Burners........................................... 16
4Diagnosing Hot Surface Igniters, Griddle / Grill Element, Oven
Lights, Temp Sensors.......................................................................... 18
4.1 HSI and Element Diagnostics ..................................................................... 18
4.1.1 Cycle/Circuit Specification.................................................................... 18
4.1.2 Safety Practices for HSI and Element Diagnostics .............................. 18
4.1.3 HSI and Element Diagnostic Tips ........................................................ 18
4.2 Oven Light Diagnostics............................................................................... 18
4.3 Oven Temperature Sensor Diagnostics...................................................... 20
4.3.1 Resistance and Temperature Values for the Oven Temperature Sensor
20
5Fault Messages..................................................................................... 21
6Service and Repair ............................................................................... 22
6.1 Preparing the Range for Servicing.............................................................. 22
6.2 Component Removal Videos ...................................................................... 22
6.3 Accessing Components under the Maintop................................................. 22
6.3.1 Removing Knobs, Grates, Rangetop Burner Assemblies, Maintops,
Heat Shields, Burner Support Rails ..................................................... 22

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6.3.2 Removing the Maintops....................................................................... 24
6.3.3 Removing the Heat Shields.................................................................. 25
6.3.4 Removing the Burner Support Rails..................................................... 25
6.4 Griddle / Grill Removal and Replacement................................................... 27
6.5 Side Panel Removal and Replacement....................................................... 29
6.6 Control Panel Removal and Replacement.................................................. 32
6.7 Removal and Replacement of Top-Accessible Components...................... 34
6.7.1 Jet Holder Assembly Removal and Replacement................................ 34
6.7.2 Standard Valve Removal and Replacement........................................ 36
6.7.3 Microswitch Removal and Replacement.............................................. 37
6.7.4 Solenoid Valve Removal and Replacement......................................... 37
6.7.5 XLO Valve Removal and Replacement................................................ 39
6.7.6 Potentiometer Removal and Replacement .......................................... 40
6.7.7 Manifold for Rangetop Burners – Removal and Replacement............. 40
6.7.8 Manifold for Bake and Broil Burners – Removal and Replacement ..... 43
6.7.9 Regulator Removal and Replacement................................................. 45
6.7.10 Bi-Metal Gas Valves – Removal and Replacement ............................. 46
6.7.11 Oven Lamp Transformer Removal and Replacement.......................... 47
6.7.12 Selector Switch for Oven Function and Oven Temperature – Removal
and Replacement................................................................................. 48
6.7.13 Oven Temperature Gauge Removal and Replacement....................... 49
6.7.14 Control Boards for Large and Small Ovens – Removal and
Replacement........................................................................................ 50
6.7.15 Simmer Control Board Removal and Replacement ............................. 51
6.7.16 LED Indicator Removal and Replacement........................................... 52
6.7.17 Lighting Bar for Control Panel – Removal and Replacement............... 53
6.7.18 Ignition (Spark) Module Removal and Replacement............................ 54
6.7.19 Door Latch Removal and Replacement............................................... 55
6.7.20 Plunger Switch Removal and Replacement......................................... 57
6.7.21 Griddle / Grill Thermostat Removal and Replacement......................... 58
6.7.22 Oven Display Module and Light Switch – Removal and Replacement. 59
6.8 Removal and Replacement of Back-Accessible Components .................... 60
6.8.1 Backguard Removal and Replacement................................................ 61
6.8.2 Back Panel for Small Oven – Removal and Replacement................... 62
6.8.3 Back Panel for Large Oven – Removal and Replacement................... 63
6.8.4 Terminal Block and Power Cord – Removal and Replacement ........... 63
6.8.5 Electrical Wiring Connections at the Terminal Block............................ 64
6.8.6 Cooling Fan Removal and Replacement ............................................. 64
6.9 Removal and Replacement of Front-Accessible Components.................... 65
6.9.1 Oven Temperature Sensor for Large and Small Ovens – Removal and
Replacement........................................................................................ 65
6.9.2 Meat Probe Receptacle Components – Removal and Replacement... 66
6.9.3 Rack Support Removal and Replacement........................................... 67
6.9.3.1 Oven Lamp Assembly and Bulb – Removal and Replacement..... 68
6.9.3.2 Removing the Bulb........................................................................ 69
6.9.3.3 Removing the Lamp Assembly...................................................... 69
6.9.4 Oven Door Removal, Installation, and Alignment................................. 70
6.9.4.1 Removing the Door ....................................................................... 70
6.9.4.2 Installing the Door ......................................................................... 71
6.9.4.3 Aligning the Door........................................................................... 72
6.9.5 Convection Components – Removal and Replacement....................... 72
6.9.6 Broil Burner Components – Removal and Replacement...................... 75
6.9.6.1 Hot Surface Igniter for Broil Burner – Removal and Replacement 75
6.9.6.2 Broil Burner Removal and Replacement....................................... 77
6.9.7 Bake Burner Components (Large Oven) – Removal and Replacement78
6.9.7.1 Bake Burner HSI for Large Oven – Removal and Replacement ... 79
6.9.7.2 Bake Burner for Large Oven – Removal and Replacement .......... 81

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6.9.7.3 Bake Burner Orifice and Elbow Connector for Large Oven –
Removal and Replacement........................................................... 82
6.9.8 Bake Burner Components (Small Oven) – Removal and Replacement84
6.9.8.1 Bake Burner HSI for Small Oven – Removal and Replacement.... 84
6.9.8.2 Bake Burner for Small Oven – Removal and Replacement........... 86
6.9.8.3 Bake Burner Orifice and Elbow Connector for Small Oven –
Removal and Replacement........................................................... 87
6.9.9 Door Interior Cleaning.......................................................................... 88
6.9.10 Oven Door Components – Removal and Replacement....................... 89
6.9.11 Door Gasket Removal and Replacement............................................. 90
6.9.12 Kick Panel Removal and Replacement................................................ 91
7Before Returning Appliance to Service.............................................. 91
8Clean-Up................................................................................................ 92
9Additional Resources........................................................................... 92
9.1 QuickFinder................................................................................................. 92
9.2 Technical Support....................................................................................... 92

Service Manual for the Thermador Pro Grand Next Generation 48-Inch Natural Gas and LP Gas Ranges, Models: PRG486JDG/01, PRL486JDG/01
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1 GENERAL
This manual provides servicing instructions for the following
Thermador Pro Grand Next Generation (PGNG) liquid propane (LP)
ranges.
PRG486JDG/01
PRL486JDG/01
Due to the complexity and the risk of high-voltage electrical shock,
customers should not service their appliances.
The information provided in this document is intended for trained,
qualified personnel only. The proper function and the safety of the
appliance can be affected by an improper repair, and even serious
threats to life or physical condition may arise. BSH Home Appliances
Corporation is not liable for damages caused by improper repairs
performed by unauthorized parties. Local codes and standards apply
and must be observed.
For authorized servicers, additional assistance is available by
contacting our Technical Support Team at [phone].
1.1 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.
1.2 Data Rating Plate
The data rating plate shows the model, serial, and FD number. It is
located at the right side panel (see Figure 1), and is pulled out by the
tab. 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).
Figure 1: Data Rating Plate

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1.3 Wiring Diagram
The wiring diagram is located on the back side of the kick panel
(see Figure 2).
Figure 2: Wiring Diagram Location
1
Kick panel (wiring diagram located on back side)
1.4 Recommended Tools and Supplies
The following are recommended to use when servicing this appliance:
mCaution
Power Drivers
If using a power driver, set the clutch to the lowest setting
üFlat blade screwdrivers: large, small
üPrecision flat-blade screwdriver with a high-strength blade,
1/8 inch (3.0 mm) wide, .020-inch (0.50 mm) thickness tip
üDrivers: T-10, T-20, T-27, T-30
ü2 foot long rachet extension
üRachet with 6 inch long (min.) swivel head extension
ü6 inch long (min.) flex extension
ü5/16 inch deep-well socket
ü1/4 inch nut driver
üAdjustable wrenches (2)
üStrap wrench
üOpen-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
üPipe wrench
üNeedle-nose pliers
üClean putty knife
üProtective gloves
üGas leak test equipment
üPipe sealant
üSmall mirror
üAir lifter / air dolly
üFloor protection
üProtective eye wear (such as glasses, goggles)
üFlashlight
üAmp meter
üThermometer with thermocouple leads
üMultimeter
üClean, non-abrasive cleaning cloth & flexible brush

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1.5 Important Safety Information
Before starting to service an appliance, familiarize yourself with all
safety information and precautions contained in this manual.
1.5.1 Safety Symbols Used In This Manual
Warnings alert you to dangers that may result in bodily injury or death.
mCaution
Cautions alert you to actions that may result in damage to the product,
or property.
1.5.2 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.
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 / Grill Hazard
The griddle / grill plate must always be correctly in place when it’s on.
What to Do If You Smell Gas
■Turn off the electrical power supply (at the circuit breaker), but do
not touch any electrical switch on the appliance
■Shut off gas supply to the appliance
■Do not try to light this or any other appliance
■Do not create or use an open flame or spark
■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.

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■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 (electronic leak detectors are highly
recommended) 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, 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.
In Case of Power Outage
■When there is a removal of electrical power, the XLO / XHI
burners and griddle/grill cannot be used. Do not attempt to light
them manually during a power outage.
■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.
■Ventilate well by opening a door or window, and wait at least 5
minutes for all the gas to dissipate.
■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.
■Never use bleach-containing or chlorinated cleaners, as they act
as oxidizers on metal surfaces

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■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.
Oven Door, Oven Accessories and Oven Gasket
■Use caution when opening the oven door during or immediately
after operation. Stand to the side of the oven when opening an
oven door to allow hot air to escape. Keep face well away from the
open door to avoid injury.
■Before self-cleaning an oven, remove the broiler pan, oven racks,
any utensils, as well as excessive spillage
■Do not clean, rub, damage, move, or remove the door gasket, as it
is essential for providing a tight seal during oven operation. If the
gasket becomes worn or excessively soiled with food particles,
replace the gasket.
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
Backguard Ventilation
■To ensure sufficient airflow for proper oven performance, do not
block or obstruct the vents located on the backguard (high
backguard, lowback, or island trim).
■Backguard vents and surrounding areas are hot. Do not place
plastic, other heat-sensitive items, or flammable / combustible
materials on or near the backguard vents, as these areas could
melt or ignite.
■Don’t touch or clean the backguard vent area while the appliance
is on, nor for several minutes after the appliance is turned off, to
prevent burning yourself.

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mCaution
Code Compliance
Local codes vary. Installation, electrical connections, gas connections,
and grounding must comply with all applicable codes.
2 OPERATION AND CONTROLS
2.1 Knobs and Controls
The control knobs each have an icon to identify the burner location.
2.1.1 Standard Burner Knob
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
the three markers for HI, MED, and SIM.
2.1.2 ExtraLow (XLO) and ExtraHi (XHI) Burner Knobs
XLO and XHI knobs can be set anywhere between the XLO and XHI
markings for a variable range of heat; from 105° F (for XLO) to 185° F
(for XHI).
The burners that have XLO functionality are:
•Left, front
•Left, rear
•Right, front
•Right, rear
The burner at the right, front has XHI functionality (in addition to XLO).
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.
■Press a control knob in, and turn counter-clockwise to HI or XHI.
The igniter for the burner clicks while sparking until flame ignition.
Burner should ignite within 4 seconds.
2.1.3 Griddle / Grill Control Knob
The griddle / grill knob controls the temperature to the griddle or grill,
from 150° F to 500° F.
■Press and turn the knob clockwise to select a setting.
NOTE: The electric griddle preheat time (the time from when the
griddle is turned on until the preheat light goes off) will vary according
to ambient (room) temperature and the level of electrical service. To
preheat the griddle to 350° F may take approximately 10 to 14
minutes.
2.1.4 Temperature / Function Selector Knob for Large Oven
The Temperature/Function Selector Knob for the large oven enables
selecting a temperature from 150° F to 500° F, as well as one of the
oven function modes.
NOTE: Warm setting displays “Warm’” which is about 150° to 175° F.
■Rotate the outer dial to select a cooking mode, and then rotate the
inner knob to select the temperature.
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.

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2.1.5 Temperature / Function Selector Knob for Small Oven
The Temperature/Function Selector Knob for the small oven enables
selecting a temperature from 150° F to 500° F, as well as one of the
oven function modes.
NOTE: Warm setting displays “Warm’” which is about 150° to 175° F.
■Rotate the outer dial to select a cooking mode, and then rotate the
inner knob to select the temperature.
2.1.6 Oven Light and Panel Light Switches
There is a toggle switch for each oven light, and for the panel light.
2.2 LED Indicators
When a burner is lit, its blue LED indicator is illuminated.
2.3 Automatic Re-Ignition
Each rangetop 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
In Case of Power Outage
■When there is a removal of electrical power, the XLO / XHI
burners and griddle/grill cannot be used. Do not attempt to light
them manually during a power outage.
■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.
■Ventilate well by opening a door or window, and wait at least 5
minutes for all the gas to dissipate.
■If you smell gas, refer to the applicable safety precautions stated
in this manual, including the Important Safety Information section
on page 7.
2.5 Rangetop Burner Assembly and Maintop
Components
Figure 3: Rangetop Burner Assembly and Maintop Components
1
Electrode (Igniter)
2
Burner cap
3
Burner base
4
Venturi tube
5
Burner pedestal
6
Jet holder assembly
7
Wire guard clip
8
Burner support rail
9
Heat shield
10
Maintop