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1. 71 CJ Oven Service Manual Lit No 94 30 007A Digital DAC appliance control The digital appliance control DAC control is a microproccessor based control What this means is that the dac control uses signal voltage to detect switch function The switches used with the DAC control to detect signal voltage are Door switches activated by door movement Air switches activated by air movement from the blowers Latch lock unlock switches activated by the latch cam movement Door switch function is critical in the CM oven The oven door must physically close before the oven can proceed into self clean or microwave modes Latch lock unlock switches must physically open close before the oven can proceed into self clean or microwave mode The air switches must also physically close by air movement from the cooling blowers before the oven proceeds into a bake or broil mode If the cooling motor does not function and the oven goes into a bake or broil mode the oven will overheat and could damage components Heres how it works The board sends out signal voltage 24 V A C to specific switches If the switch is functioning properly the signal returns to the board and the microprocessor chip reads the signal voltage and the function continues Example Signal voltage flows to the air switch When the air switch closes the signal returns to the dac control The oven continues If the air switch does not close the
2. 11049 21 OcL SJoJsueJ EIN UOIJ nUJ jal 21 won OZ SJoJsueJ 401 19 w0 UOIj99AuO9 do C 021 SJoJsueJ 69 Page 70 CJ Oven Service Manual Lit No 94 30 007A pieog SAPMOJDIIN ul 2811 Sal p eog ui Ly s nd no Uld yoyums 3207 7 USAC JOMOT yonms J9MO yoyms 1000 JOMOT jeu is s nd no Gd Uld YIUMS 4907 5 Jaddn YSUMS Jaddn jeubis s nd no 6d Uld 02 91 s nd no G d Uld 102 870 Jaddn s nd no Vid Uld 51677 JAMO O WAZcL SJ9JSUPEJ 193 fd 51617 Jaddn 5 1030 J 42127 Jaddn O O VA Cl 2 0 JV S H OVAZL 595061 0x Aejoy 42127 JOMOT C 021 SJoJsuej Ly
3. 102 FAUT Codes anne 103 Schematic amp Wiring Diagrams 104 106 CJ302 Electronic Oven Control Wiring 104 CJ302 Wiring 105 CJ302 Schematic Diagram 106 Lit No 94 30 007A CJ Oven Service Manual CJ Oven Service Manual THE CJ OVEN SERVICE MANUAL CONTAINS INFORMATION THAT IS NECES FOR SERVICING THE THERMADOR BUILT IN OVEN MODELS CJ302B CJ302W CJ302S THIS MANUAL IS DESIGNED TO BE USED ONLY BY QUALIFIED SERVICE PER SONNEL THERMADOR RECOMMENDS THAT CUSTOMERS DO NOT SERVICE THEIR OWN UNITS DUE TO THE COMPLEXITY AND THE RISK OF HIGH VOLTAGE ELECTRICAL SHOCK THE INFORMATION IS ORGANIZED TO HELP THE SERVICER EASILY FIND WHAT IS NEEDED TO REPAIR THE UNIT GENERAL DATA PLATE LOCATION Data Plate behind oven cooling vent right side Page 1 CJ Oven Service Manual Lit No 94 30 007A SYMBOLS YOU WILL SEE IN THE MANUAL The following symbols are provided through and proper operation and servicing of the oven out this manual For reasons of personal safety follow the instructions carefully each time you 44 WARNIN This symbol alerts you to such dangers as personal injury burns fire and electrical shock Tech Tip This symbol alerts you to a service tip ora special procedure see one of the symbols 44 CAUTION This alerts you to actions that could cause product damage scratches
4. Bracket Screws i CONVECTION FAN Y ASSEMBLY NOT SHOWN Bottom Support Support Screw CJ Oven Service Manual Lit No 94 30 007A REMOVING A CONVECTION FAN MOTOR 44 WARNING Turn off the electrical power circuit to the oven at the main junction box before ser vicing this unit 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Refer to illustration for the following steps 1 2 Turn off the electrical power to the oven To make servicing easier remove the oven door see Page 94 g Remove the racks from the oven Remove the front screws from the left and 9 right oven rack supports and remove the supports from the oven liner Remove the screws from the convection 10 baffle and remove the baffle from the back of the oven liner 11 12 Page 94 Remove the hex nut from the front of the convection blade NOTE The nut has left rotating threads TECH The convection blade hex nut has left rotat ing threads Remove the flat washer and e ring from the convection blade and remove the blade from the motor shaft Remove the screws from the pan and re move the pan Remove the motor screws from the bracket and remove the motor from the bracket Disconnect the two wires from the fan motor terminals Connect the brown wire 45 to the right te
5. 4 Remove the four black screws that are holding the upper latch plate to the front of the upper door latch assembly Upper Latch Plate Mounting Page 25 WH 03 Pull the upper latch plate forward and push the oven door switch out of the mounting hole Disconnect the wires from the oven door switch WH 04 Oven Door Switch CJ Oven Service Manual Lit No 94 30 007A REMOVING THE DOOR LATCH ASSEMBLY HIGH TEMP CUTOUT AND THE MONITOR amp SECONDARY SWITCH ASSEMBLY 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven 2 Openthe microwave oven door 3 Remove the four black screws that are holding the upper latch plate to the front of the upper door latch assembly 2 Black Control Panel Screws 4 Remove the two black screws from the bottom of the control panel assembly Upper Latch Plate 4 Black Screws 5 Pull the upper latch plate forward and position it off to the side 6 Pullthe top of the control panel forward and unhook the two ball studs at the top right and left corners from the catches 7 Disconnect the five cables from the touch glass filter board connectors at P2 P4 P6 P10 and P11 and remove the control panel assembly
6. J Concealed ae element dd SN ff concealed SS JS Shield Enclosure Page 34 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE TOP OVEN THERMAL SENSOR A W A R N G 5 Pull the oven thermal sensor forward un til the wire splices are inside the oven Turn off the electrical power going to the oven before servicing CAUTION gut wres Here When you work on the oven be careful Wire when handling the sheet metal parts There Splices are sharp edges present and you can cut yourself if you are not careful 1 Turn off the electrical power going to the oven 2 Open the microwave oven door 3 Remove the two screws from the oven thermal sensor Oven Thermal Sensor 6 Using the instructions in the Thermal Sensor Kit 35 00 919 splice the wires from the new oven thermal sensor to the main wires Cut the wires from the old sensor at the location shown above Thermal Sensor Halogen Light Page 35 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE UPPER OVEN DOOR GASKET 1 Fully open the oven door 2 Pull the ends of the oven door gasket out of the hole in the door liner 3 the gasket from the door liner and remove it Upper or Single Pull Clips Out Pull Ends Out Oven Door Gasket Of Holes In Liner Of Hole In Liner Service Tech Tip Alert Use a small screwdriver to insert the ends of the ga
7. 20 21 Removing Magnetron amp Magnetron Thermal Cutout 22 23 Removing Control Panel Assembly Display Board amp Touch Panel Glass 24 Removing Upper Or Single Oven Door Switch 25 Hemoving Door Latch Assembly High Temp Cutout amp Monitor amp Secondary Switch Assembly 26 27 Servicing the CJ Upper Oven 28 Removing A Halogen Light Assembly 29 30 Removing the Jet Plate Top Element 31 Stirrer Blade Assembly 32 Removing Meat Probe Jack 33 Removing Jet Plate 34 Removing Oven Thermal Sensor 35 Removing Upper Oven Door Gasket 36 Removing Reinstalling Microwave Oven Door 37 39 Removing Upper Or Single Oven Door Handle amp Outer Glass Assembly Rai 40 Removing An Oven Door Hinge Actuator Arm Center Glass RF Screen 4 Inner Glass 41 43 Removing Upper Door Gasket 43 TLOUDIESNOOUNG cL 44 Testing Components 20A Time Delay Fuse 44 Light Transformer Double Line Break Relay 45 Stirrer Motor High Voltage Diode 46 High Voltag
8. 94 30 007A 2001 BSH Home Appliances Corp Litho U S A 10 01
9. Lower door stuck locked Lower oven door position error locked and open RB o Lower door stuck locked Lower latch input shorted Page 113 Lit No 94 30 007A CJ Oven Service Manual TWNOILdO SM349S ONILNNOW NI H3M0d AV349 3NI13 18000 99 AV1dSI0 N HO IIMS a om td x HOLV1 3 YOOd 7 ES TVNOLLdO M349S ONILNNOW HOSN3S Ec 3univd3dW3L SS W d o 8 Id d32VdS SIHLNI M349S ONILNNOW LON LSNW YAWOLSNOD Ly fa AN S aA NP TS Nue ONPIIM TOMLNOD NJAO DINOMLOATA TOED TWNOILdO MAYIS SNILNNOW Page 114 Lit No 94 30 007A CJ Oven Service Manual See 11x 17 Page CJ302 Wiring Diagram Page 115 0 0 AIR SWITCH 102 TUBE CUTOUT 130 MICRO 132 TRANSFORMER 0 0 UPPER CAPACITOR JET BLOWER BR BR BK OR U O LOWER CAPACITOR BR BR BK OR MICROWAVE BOARD 130 Fr L O MEAT OBE SOCKET MEAT PROBE 112 ps 4 TP Pe P En PAGE NO 2 OF 2 J L O BAKE ELEMENT BEA z2 NE eye Tm STO OVEN RELAY BOARD P9 BOND FR D gt MATERIAL No 5020008360 0 0 LATCH 9 NEUTRAL 153 2 Nos 9 LOCK SW POWER SUPPLY 2 u RIGHT TOUCH LEFT TOUCH CONTROL BOARD CONTROL BOARD P2 P2 18 Iz up Pf
10. There are 2 display heads one for the single oven one for the double oven Page 85 CJ Oven Service Manual Lit No 94 30 007A Glass touch panel The glass touch panel is comprised of a piece of curved glass with 2 control boards glued onto it Left side touch control board The large touch control board is glued on the left side of the curved glass The large touch control board controls the following 12 modes MICROWAVE PROBE JETDIRECT BAKE UPPER CONVECTION LOWER COOKSMART SELF CLEAN BROIL ROAST UPPER 1 2 3 4 OFF PAUSE PROOF STOP LOWER RESUME DEHYDRATE TIME TIME OFF This control board has 3 pin headers and are identified as P1 P2 P3 P1 pin header has 21pins only 20 are used 2 is missing and connects to the display head using 3 harnesses One harness has 10 wires one harness has 8 wires and one harness to 2 wires P2 pin header has 8 pins only 7 are used 2 is missing and connects to the small right side touch control board pin header on the large left side touch control board is not used Right side touch control board The small touch control board is glued on the right side of the curved glass and controls the following 11 modes Thermador LIGHT PANEL LOCK CLOCK TIMER 1 TIMER OFF TIMER 2 CS 1 BREAD DESSERT CS 3 MEAT CASSEROLES CS 2 VEGETABLES CS 4 FROZEN FOOD This control board has 1 pin header and is identified as P2 P2 pin header has 8 pins only 7
11. Will accept all modes except self clean When set in self clean dor will flash and self clean will erase Sends display signals to display head Glass control panel is completely dead No display circuit Must be reset at breaker Sends communication signals to display head Glass control panel is completely dead No display circuit must be reset at breaker Upper lower door latch motors No fail code will accept all modes except self clean When either oven is set to self clean the display will be on constantly doors will not lock It will not go into self clean Page 81 CJ Oven Service Manual Lit No 94 30 007A P18 Relay board transformer No fail code no display at all Board is dead P1 Both cooling motors and halogen lights Will accept modes In about 45 seconds F 34 will appear in the upper oven or F 64 will appear in the lower oven because the Coolingmotors did not come on to close the air switches and signalthe board Additionally the halogen lights in both ovens will not work All relays will close but the lights and motors will not work PS Lower oven convection motor No fail code The lower oven convection motor will not work The relay will snap closed P7 Upper oven convection motor No fail code The upper oven convection motor will not work The relay will snap closed P14 Upper oven double line break relay coil No fail code If double line break relay does not close 11 120
12. pp U O CONNECTOR HALOGEN LIGHT MAGNETRON GND 86 1 o 5 J Frc Ci CONNECTOR 0 0 CONVECTION 155 ELEMENT 1 TUBE MOTOR 156 29 MAG TUBE ie EISEN HALOGEN LIGHTS CUTOUT 34 25 124 TRANSFORMER H ech 0 0 DOUBLE ELEMENT 2 ERI 34 LINE BREAK is d 21 28 1 I 65 86 23 nie 8 En N 85184 94 Im 72 I U O LOWER PLATE ELEMENT Ep E ts L O DOUBLE 0 0 MULLION ELEMENT LINE BREAK RELAY SENSOR LI l BE BE ___ ie o HH EG 79 er Ta a ME i gt J MONITOR SECONDARY SWITCH INTERLOCK 0 0 DOOR SW P3 H SUMMIT U O DOOR LATCH 0 0 BOLT SW 1 M BL E D a SEE WRING DETAIL FOR STANLEY DOOR LATCH 1 iM _ _ __UPPER_OVEN Ht LOWER OVEN npe E L O BROIL ELEMENT CONNECTOR 64 EIE __ E 8 0 79 7 RICHT ae HALOGEN ELEMENT LICHT L o THERMAL SENSOR 4 D UNLOCK 62 59 BSH Home Appliances g C UO BOLT SN E eer WIRE DIAGRAM CJ302 50200000000246 rev CJ Oven Service Manual Lit No 94 30 007A See 11x 17 Page CJ302 Schematic Drawing Page 116 L2 EARTH om RELAY BOARD K9 P10 P11 P14 21 P18 6 P18 1 P18
13. 75 Glass TOUCh Patel ucc ie engel 76 Display Feat 77 Troubleshooting Chart for Display Head Pin Failures 78 CJ Lower Oven Illustration 79 Removing Hidden Bake Element 80 81 Removing Oven Temperature Sensor 82 Removing Convection Bake Element 83 Removing Convection Fan Motor 84 85 Removing Halogen Lamp Holder 86 Removing Lamp Transformer amp Lower Oven Double Line Break Relay 87 Removing Oven Light Switch Oven Door Latch Assembly and High Temp Cut out 88 89 Removing Air Switches 90 91 REMOVING a Blower nennen 92 93 Removing Lower Oven Door 94 Removing Oven Door Gasket 95 Removing Oven Door Components 96 Removing Oven Module 97 Troubleshooting ecke 98 Blower Motor Air Switch 98 Convection Fan Motor Lamp Transformer 99 Oven Door Latrch Assembly 100 Hidden Bake Element Broil Element 101 Convection Bake Element Hi Temp Cutout
14. Ball Stud 2 Screws Tech Tip If necessary refer to Page 104 for the wire connection callouts for single and double electronic oven control boards Control Panel Mounting Bracket 5 Disconnect the wires from the electronic oven control board connectors Page 11 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE FUSEBLOCK amp MICROWAVE PCB CONTRO 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 u 1 E d Hor TER n in N Turn off the electrical power going to the oven Pullthe oven out of its mounting location so that you can access the trim and ple num covers Remove the trim and top plenum covers from the oven see Page 10 Remove the control panel mounting bracket see Step 4 on Page 11 To remove the fuseblock a Pull the fuse out of the clips b Remove the mounting screw from the center of the fuseblock Microwave Control Fuse amp Fuseblock j M 1 12 APPLIBUCE CONTROLS m DIVISION OF EMERSON ELECTRIC LEN EC teen Screw
15. Lit No 94 30 007A CJ Oven Service Manual SERVICING THE COMPONENTS COMPONENT LOCATIONS The serviceable components for the upper Refer to the pages that show the components oven and plenum are in this section of the you wish to service manual Components are shown below TOP PLENUM COMPONENTS Magnetron Thermal Cutoff Stirrer Motor Crossflow Top Cooling Blower Magnetron amp Waveguide HV M W Transformer Magnetron Fan Assembly HV M W Capacitor P Light HV Diode Transformer Microwave J N Y Electronic PCB uh y Oven Control Gis Control UN Fuse amp Fuseblock Double Line Break Relay FRONT COMPONENTS Bl lt Control Panel N Monitor amp Secondary Door Latch Assembly High Temp Cutout Switch Assembly Page 9 CJ Oven Service Manual Lit No 94 30 007A UPPER OVEN COMPONENTS Support Stirrer Motor Stirrer Assembly Element Jet Concealed Enclosure Jetplate Top Light Assembly REMOVING THE TRIM AND TOP PLENUM COVERS W R N G 4 remove the top front plenum cover a Remove the seven 7 screws JUI Ol Me Bore to Cie b Pull the cover forward and remove it oven before servicing 5 To remove the top rear plenum cover re vw CAUTION move the eight screws and lift it off the When you work on the oven be careful oven when handling the sheet metal parts
16. NOTE The door latch assembly and the moni tor and secondary switch assembly must each be replaced as an assembly Individual parts are not available 8 To remove the door latch assembly a Use an angled 1 4 socket and remove the two hex head screws from the front of the door latch assembly Pull the as sembly forward as far as the wires will allow b Disconnect the wires from the latch motor and switches Latch Motor 2 Switches lt High Temp i Se Cutout Door Latch E Assembly pE 2 Hex Head Screws NOTE The M W oven door latch motor is ac tivated by 12 volts D C through a series of di odes on the electronic oven control board see page 3 12 This motor locks the microwave oven door faster than the lower oven motor Page 26 Lit No 94 30 007A 9 To remove the high temp cutout 10 a Use an angled 1 4 socket and remove the two hex head screws from the high temp cutout bracket Pull the cut out forward as far as the wires will al low b Disconnect the wires from the termi nals ia BK 33 High Temp Cutout gt Hex Head Screws Page 27 CJ Oven Service Manual To remove the monitor and secondary switch assembly Note We have placed 2 access holes on the relay board partition to remove the 2 left side latch screws a Remove the four screws and lockwashers from the switch assembly Pull the assembly forward as far as the wires wil
17. To remove the microwave PCB control a Disconnect the wires from the termi nals b Remove the four mounting screws from the bracket Screws Base YOCOORZER DR 14 2 F THERMADOR bet a at n Screws Lit No 94 30 007A CJ Oven Service Manual REMOVING THE LIGHT TRANSFORMER amp DOUBLE LINE BREAK RELAY 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turn off the electrical power going to the oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers from the oven see Page 10 4 remove the light transformer a Disconnect the wires from the termi nals b Remove the two mounting screws from the bracket 15 BE HOOULIH3HL EH _ Transformer Page 13 Screw THERMADOR 4 38 517 4 06 7619 UL CLASS 2 2699 tren 3 YL 84 _ YL 85 WH 19 YL 18 RD 81 To remove the upper or single oven double line break relay a Disconnect the wires from the relay ter minals b Remove the two screws POS up o Double Line Break Helay Screw YL 20 BU 21 BK YL OR 22 34 10 YL 09 CJ Oven Service Manual Lit No 94 30 007A Stirrer
18. 3 _ M UH Wires The wire harness is shown in the illustration above PIN Header PIN Header The wire harness slide onto the pin headers of the relay board display head and touch control boards The illustration above shows the pin headers on the relay board Page 79 CJ Oven Service Manual Lit No 94 30 007A Wire Harnesses Continued The CJ oven uses 5 wire harnesses to transfer signal voltage between the DAC control relay board display head and touch control boards glued on the glass The 5 wire harness connect to the corresponding pin headers on the corresponding components relay board display head touch control board These 5 wire harness are identified as follows 2 Wire White Power Harness This wire harness has 2 wires and connects from pin header P8 on the display head to pin header P2 1 on the left touch control board The center hole of the connector is plugged so it cannot be mis wired This harness sends 24 volts AC To the touch control boards 7 Wire White Bridge Harness This 7 wire harness connects from pin header P2 on the left side TCB to pin header P2 on the right side tcb The 2 hole on the connector housing is plugged there is no wire This harness sends commands between the left tcb and the right tcb 8 Wire Yellow Display Harness This 8 wire yellow harness connects from pin header P10 on the display head to pin header P10 on the relay board right re
19. CJ Oven Service Manual To reinstall the magnetron thermal cut out a Connect the wires BK 130 amp BK131 to the terminals b Install the two screws d Make sure the reset button is properly set Reset it Button lt bs T ad Thermal Cutout Reset Button Magnetron 2 Screws CJ Oven Service Manual Lit No 94 30 007A REMOVING THE CONTROL PANEL ASSEMBLY DISPLAY BOARD amp TOUCH PANEL GLASS 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 2 3 Turn off the electrical power going to the oven Open the microwave oven door To remove the control panel assembly a Remove the four black screws from the grill Remove the 2 back control panel screws and remove panel 4 2 Black Control Panel Screws b Pull the top of the control panel for ward and unhook the two ball studs at the top right and left corners from the catches c Disconnect the five cables from the con trol panel board connectors at P2 P4 P6 P10 and P11 and remove the assem bly To remove the display board and touch panel glass a If not already done remove the con trol panel assembly from the oven see Step 3 b Place the control panel assembly face down a padded work surface to pre vent
20. Cut Leads Here Halogen Bulb Light Assembly Cut the leads that are coming from the light socket near the socket body Cut the leads of the new light assembly approximately 3 from the body Remove 3 8 of insulation from the cut lead ends and the wiring harness Twist two small wire nuts over the ends of the leads CJ Oven Service Manual Lit No 94 30 007A Tech Tips When you reassemble the halogen light as sembly 1 Position the wiring neatly inside the oven liner cutout for the halogen light and press the assembly into place so its edges are flush with the outside of the liner Keep Edges Flush With Liner Install Halogen Bulb Install the bulb in the socket When you reinstall the metal screen do not install screws at the four corners see Step 6 on the previous page When you reinstall the rack support make sure you position it with the stop towards the back see Step 4 on the pre vious page Page 30 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE TOP PLATE 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven 2 To make servicing inside the oven easier remove the microwave oven door see Page 37 for the procedure 3 R
21. PONENTS BE VERY CAREFUL NOT TO TOUCH THE BARE RESISTOR LEADS WHEN YOU DISCHARGE THE CAPACITOR 5 Disconnect the three high voltage micro wave transformer leads from the termi Tan Secondar nals of the high voltage capacitor and the Capacitor Lead magnetron 6 Remove the four mounting screws from Screws Heat Sink Bracket Screw the heat sink bracket and remove the bracket from the top of the transformer Lit No 94 30 007A 8 Remove the four mounting screws from 9 the high voltage microwave transformer and remove the transformer from the OVEN Screw 1014 10 Oven Service Manual Remove the heat sink plate from the top of the high voltage microwave trans former Apply a liberal amount of heat sink paste over the top of the new transformer then place the heat sink plate in the center of the transformer and press it down so it adheres firmly Heat Sink Paste Page 21 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE amp MAGNETRON THERMAL CUTOUT 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 2 Turn off the electrical power going to the oven Pull the oven out of its mounting location so that you can access the trim and ple
22. There Too Erorii Trim are sharp edges present and you can cut Plenum 2 Screws yourself if you are not careful 7 screws Top Rear Plenum Cover 574 9 screws 2 Pulltheoven out ofits mounting location i T p so that you can access the trim and ple T 5 num covers 1 Turn off the electrical power going to the oven 3 To remove the trim remove the two end Screws e Page 10 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE ELECIRONIC OVEN CONTROL BOARD A W A R N G 6 Remove the six screws from the electronic oven control board Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 3 Screws 1 Turn off the electrical power going to the oven 3 Screws 7 Lift the front of the electronic oven con trol board and slide the three wire ties off the front spacers then remove the board from the oven Tie Tie Tie 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers from the oven see Page 10 4 Remove the four screws from the control panel mounting bracket pull the catches out of the ball studs at each end of the bracket see the small inset and remove the bracket from the oven
23. careful not to chip or scratch the oven liner when you pry the lamp holder out of the cutout 6 Cutthe plug off the new lamp holder Connect the cut wires to the new lamp holder with two red inline splices After you connect the wires pull on them to make sure that the inline splices are se cure 8 Gently pull the lamp holder wires up into the plenum area until you can see the red wire splices in the plenum area Make sure that the two red inline splices are in the top plenum area and not in the oven 9 Reassemble the oven heat zone Page 96 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE LAMP TRANSFORMER amp LOWER OVEN DOUBLE LINE BREAK RELAY 44 WARNING Turn off the electrical power circuit to the oven at the main junction box before ser vicing this unit 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Turn off the electrical power to the oven 2 Open the upper oven door 3 Remove the control panel and display head see Page 11 for the procedure 4 Remove the front subpanel see Page 10 5 To remove the lamp transformer see il lustration below a Remove the screws and disconnect the wires from the terminals b Install the new lamp transformer and reconnect the wiring Secondary Winding Primary Winding 6 To remove an old oven relay s
24. defective switch or any other factor causing an overload on the microwave circuit will blow the fuse and stop the operation of the microwave section ofthe oven The fuse is located in a fuse holder in the upper plenum Microwave Fuse Failure The purpose of the fuse system is to prevent operation of the unit in the event of a safety switch failure The safety switches prevent the unit from emitting microwave energy if the door is not completely closed The following is an explanation of the safety switches and an explanation of the fuse protection system The safety switches are the monitor switch and the latch interlock switch primary switch and the right side door interlock switch secondary switch The latch interlock switch primary switch is mounted on the latch assembly The latch interlock switch is closed by the latching of the motorized oven door latch The monitor switch and the right side door interlock switch secondary switch are activated by the door strike movement Fuse Failure Modes The fuse can open due to any of the following failure modes 1 Ashortin the microwave circuit or a component failure that causes the microwave circuit to draw more than 20 amps 2 The monitor switch is closed when the latch s interlock switch is also closed DO NOT ATTEMPT TO REPAIR A SAFETY SWITCH REPLACE A FAILED SAFETY SWIICH Page 65 CJ Oven Service Manual Lit No 94 30 007A DIODE The diode is a device used to c
25. indicate 18 Q If the reading is not correct remove and re place the convection bake element Lit No 94 30 007 THE HI TEMP CUTOUT The hi temp cutout contacts open at or above 350 F 8 and are manually reset by pressing the reset button Refer to Page 88 to access the hi temp cutout 1l With no power applied remove the wires from the terminals of the hi temp cutout 2 Set the ohmmeter to the R x 1 scale 3 Touch the ohmmeter leads to the terminals The meter should indicate continuity 4 If the reading is not correct remove and re place the hi temp cutout Reset Button Terminals Page 112 Lit No 94 30 007A CJ Oven Service Manual Fault Codes Power board not calibrated F14 Display board EEPROM error Lower oven cancel key shorted high Upper oven cancel key shorted low Lower oven cancel key shorted low Key stuck ____ ____ ___ ____ ____ ____ REN o ES ___ Keystuck Upper oven sensor shorted Upper oven sensor open Upper oven over temperature while cleaning OO OB Upper oven over temperature while cooking FA o Upper oven cooling fan not operating BEP E Upper meat probe shorted Upper door signal shorted low Upper door stuck locked 2 F52 58 Upperdoorstucklocked oo o A Upperlatchinputshorted 27576 F Lowerovensenorshorted O Lower meat probe shorted RO ee Lower door signal shorted low F8 o
26. num covers Remove the trim and top plenum covers from the oven see Page 10 CAUTION DISCHARGE THE HIGH VOLTAGE MICROWAVE CAPACITOR WITH A 20 000 OHM 1 OR 2 WATT RESISTOR TO CHASSIS GROUND SEE PAGE 17 BEFORE WORKING ON ANY OF THE HIGH VOLTAGE COM PONENTS BE VERY CAREFUL NOT TO TOUCH THE BARE RESISTOR LEADS WHEN YOU DISCHARGE THE CAPACITOR Remove the two screws from the magne tron fan duct and remove the duct Fan Duct 2 Screws Magnetron Remove the two screws from the vent cover and remove the piece insulation in side 2 Screws Vent Cover To remove the magnetron a Disconnect the magnetron wires OR filament from the two terminals b Disconnect the two wires from the magnetron thermal cutout c Remove the four nuts from the waveguide left right sides and pull apart to remove d Lift up the magnetron to remove Thermal Cutout Wires Wires OR Filament Waveguide Lit No 94 30 007A To reinstall the magnetron on the waveguide use the cross tightening method to tighten the four screws as fol lows a Loosely install Nut 1 b Loosely install screw 2 in an alternate across the transformer mounting hole c Repeat steps aand b for Nuts 3 and 4 so that all four screws are loosely installed d Alternately tighten Nuts 1 through 4 until they are snug The base of the magnetron should be perfectly paral lel with the waveguide to operate prop erly Page 23
27. stallation date For a Service Agency nearest you please call 1 800 735 4328 Teach you how to use the appliance Correct the installation You are responsible for providing electrical wir ing and or gas installa tion and other connect ing facilities Reset circuit breakers or replace home fuses Damage caused from acci dent abuse alteration mis use incorrect installation or installation not in accor dance with local codes or improper storage of the ap pliance Repairs due to other than normal home use This warranty applies to appliances used in normal family households it does not cover their use in commercial situations This warranty is for products purchased and retained in the 50 states of the U S A the District of Columbia and Canada The warranty applies even if you should move during the warranty period Should the appliance be sold by the original purchaser during the warranty period the new owner continues to be protected until the expiration of the original purchaser s warranty period THERMADOR DOES NOT ASSUME ANY RESPONSIBILITY FOR INCIDENTAL OR CONSE QUENTIAL DAMAGES Some states do not allow the exclusions or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This war ranty gives you specific legal rights You may also have other rights which vary from state to state or province to province Page 8
28. volts will not reach upper oven bake broil convection ele ments P15 Lower oven double line break relay coil No fail code If double line break relay does not close 11 120 volts will not reach upper oven bake broil convection elements Page 82 Lit No 94 30 007A CJ Oven Service Manual Thermadar MICROWAVE PROBE JETDIRECT BAKE LIGHT PANEL LOCK CLOCK CONVECTION COOKSMART SELF CLEAN BROIL ROAST TIMER 1 TIMER OFF TIMER 2 1 2 3 4 PAUSE PROOF STOP COOK CS 1 BREAD DESSERT CS 3 MEAT CASSEROLES RESUME DEHYDRATE TIME TIME CS 2 VEGETABLES CS 4 FROZEN FOOD CJ OVEN CONTROL PANEL e Touch Control Glass e Touch Control Boards Display Head Page 83 CJ Oven Service Manual Lit No 94 30 007A ELECTRONIC OVEN CONTROLS HANDLING THE BOARDS The Touch Control Board and the Display Head are subject to failure if static electricity is transferred to the components during han dling When handling these parts usea ground ing strap if available If not touch any grounded metal surface e g the appliance chassis prior to handling these components Thereplacement Touch Control Board and the Display Head are packaged in antistatic bags When removing the boards from their bags handle them as follows 44 CAUTION Power to Oven must be truned OFF before disconnecting or reconnecting wire harnesses to relay board control panel or display board Touch Control Board Handle the T
29. 5 0 MEAT d i Be vs NR SWITCH DISPLAY E M gt 1 0 SWITCH NO NO 0 0 DLB LEFT SIDE RIGHT SIDE TOUCH CONTROL BOARD TOUCH CONTROL BOARD P2 L1 1 SWITCH POSITIONS SHOW OVEN IN IDLE STATE WTH DOOR CLOSED NOTES NO NO K10B u o MULLION ELEMENT 1300W 240V u o HTC ABBREVIATIONS NO NORMALLY OPEN NC NORMALLY CLOSED HTC HICH TEMPERATURE CUT OUT 0 0 UPPER OVEN L O LOWER OVEN DLB DOUBLE LINE BREAK L o DLB K13 NO K14B HTC NO NO NO K12 K8 L O BAKE ELEMENT 2300W 240V K15A K4 K5 NO NO NO NO 1 0 0 0N L O ER CONV COOLING COOLING OTOR MOTOR MOTOR 0 0 LATCH UNLOCK SW NO U O LATCH OCK SW NO U O BOLT SWITCH SECONDARY INTERLOCK SWITCH NO KO K6 K7 P5 P3 P2 P6 o 112131415 BRO BRO EBEN P0 2 4131211 L O DOOR TCH NO L o u o L O LATCH TRANSFORMER UNLOCK SW SENSOR SENSOR NO 5 L O LATCH OCK SW L O BOLT SWITCH wae 2137217 HTC P2 2 NC P2 1 OTOR MICROWAVE BOARD NO MONITOR NO PRIMARY SWITCH INTERLOCK SWITCH AUD NTERLOCK SWITCH FUSE MATERIAL No 5020008360 BSH Home Appliances SCHEMATIC DIAGRAM CJ302 30200000000246 rev A NO 1 OF 2 Lit No 94 30 007A CJ Oven Service Manual Notes Page 117 Thermador 5551 McFadden Avenue Huntington Beach 92649 800 735 4328 RO8577CJ
30. Lit No 94 30 007A MAGNETRON FAN MOTOR Terminals Refer to Page 15 to access the magnetron fan motor To test the motor perform the follow ing steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale 3 Disconnect one of the leads from the mag netron fan motor terminals 4 Touch the test leads to the motor termi nals The meter should indicate less than 10 CJ Oven Service Manual CROSSFLOW BLOWER MOTOR Terminals Refer to Page 16 to access the crossflow blower Totest the motor perform the following steps 1 2 3 Page 49 Turn off the electrical power to the oven Set the ohmmeter to the R x 1 scale Disconnectone of theleads from the cross flow blower motor terminals Touch the test leads to the motor termi nals The meter should indicate less than 1 Q CJ Oven Service Manual DOOR LATCH ASSEMBLY Latch Interlock Switch N O Terminals Latch Motor Terminals Door Unlock Switch Door Lock N O Terminals Switch N O Terminals Refer to Page 25 to access the door latch assem bly To test the door latch assembly compo nents perform the following steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale Testing The Latch Motor 3 Disconnect the two orange wires from the latch motor terminals 4 Touch the test leads to the motor termi nals The meter should indicat
31. Switch Remove the two screws from the air switch bracket and pull the air switch bracket assembly through the air diverter so you can remove the switch and disconnect the wires from the termi nals See Figure 2 and Figure 3 Page 91 5 Reassemble the oven Figure 1 Air Switch Switch Body 2 wires 2 Screws Air Switch Upper Page 100 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE AIR SWIICHES Figure 2 Air switch Lower air switch 2 wires 2 Screws Switch Bracket Figure 3 Air switch through the diverter Page 101 CJ Oven Service Manual Lit No 94 30 007A REMOVING A BLOWER 44 WARNING Turn off the electrical power circuit to the oven at the main junction box before ser vicing this unit 44 CAUTION i When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Turn off the electrical power to the oven 2 To make servicing easier remove the oven door see Page 94 3 To remove the upper blower see Figure A Page 5 93 a Remove the oven from the wall b Remove the screws from the front and rear plenum covers and remove the covers see Page 10 for the procedure c Remove the three screws from the blower motor bracket on the back of the plenum and turn the assembly around 5 so that the back faces you d Remove the three screws that mount the motor to the brack
32. Top firmly by the sides approximately 2 3 of the way down then open the door slightly and lift it until the hinges are free of the frame supports Pull the hinges out of the oven slots and remove the door Continued on the next page Lit No 94 30 007A CJ Oven Service Manual 2 Lower the oven door to its fully open po sition 3 Rotate the U clips on the hinges forward Tech Tip to the unlocked position Make sure that the door seal is tight against the front of the oven liner and that the door Rotate U Clip e Forward To Unlock is not crooked If it is push the hinges into S the slots firmly until it is Service Alert After reinstalling the oven door check around the door for microwave radiation 5 Reinstall the two hinge locking screws leakage 4 Close the oven door Locking Screw 6 Reinstall the hinge pocket covers Page 39 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE UPPER OVEN DOOR HANDLE amp OUTER GLASS ASSEMBLY 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Remove the upper or single oven door from the unit see Page 37 and lay it on a padded surface with the glass side down and the bottom edge facing you 2 Remove the two bottom edge screws and the two top screws from the liner This will separate the glass and liner secti
33. are used 2 is missing and connects to the large left side control board Page 86 Lit No 94 30 007A CJ Oven Service Manual Display Head The display head has a total of 8 pin headers Only 7 are used they are identified as P1 P2 P4 P6 P8 P10 and P11 P1 pin header has 18 pins and connects to the left touch control board 1 P2 pin header has 2 pins and connects to the L O meat probe P4 pin header has 2 pins and connects to the lower oven air switch P6 pin header has 2 pins and connects to the upper oven air switch P8 pin header has 2 pins and connects to the left touch control board 1 P10 pin header has 8 pins and connects to the relay board white harness to P10 on relay board P11 pin header has 9 pins and connects to the relay board white harness to P11 on relay board Page 87 CJ Oven Service Manual Lit No 94 30 007A Troubleshooting chart for display head pin header failures Wire harness off at pin header or open circuits 10 P11 P2 P6 4 8 1 Accepts display signals from relay board Glass control panel is completely dead No display circuit must be reset Accepts communication signals from relay board Glass control panel is completely dead No display circuit must be reset Lower oven meat probe No probe display when probe is inserted Wont accept pro gram If probe is shorted the probe display will be on con stantly and the unit will
34. covers from the oven see Page 10 4 CAUTION DISCHARGE THE HIGH VOLTAGE MICROWAVE CAPACITOR WITH A 20 000 OHM 1 OR 2 WATT RESISTOR TO CHASSIS GROUND SEE PAGE 17 BEFORE WORKING ON ANY OF THE HIGH VOLTAGE COM PONENTS BE VERY CAREFUL NOT e Tech TO TOUCH THE RESISTOR LEADS WHEN YOU DISCHARGE THE IMPORTANT Make sure that you position CAPACITOR the high voltage diode with the cathode terminal at the top and the anode termi nal at the bottom The diode symbol is shown below and on the side of the diode body ony Cathode X Anode Page 19 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE HIGH VOLTAGE MICROWAVE TRANSFORMER 44 WARNING Heat Sink Screw Bracket Screw Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turn off the electrical power going to the E Ds 7 oven 2 Pull the oven out of its mounting location ae A so that you can access the trim and ple 7 Sera num covers 3 Remove the trim and top plenum covers OR Filament Lead Magnetron from the oven see Page 10 4 CAUTION DISCHARGE THE HIGH VOLTAGE MICROWAVE CAPACITOR WITH A 20 000 OHM 1 OR 2 WATT RESISTOR TO CHASSIS GROUND SEE PAGE 17 BEFOREWORKING ON ANY OF THE HIGH VOLTAGE COM
35. dents etc and damage to your personal property ay Service Alert This symbol alerts you to check for micro wave radiation leakage and to record the reading on the service repair ticket while in the customers THERMADOR ASSUMES NO RESPONSIBILITY FOR ANY REPAIRS MADE ON OUR PRODUC AUTHORIZED THERMADOR TS BY ANYONE OTHER THAN SERVICE TECHNICIANS Page 2 Lit No 94 30 007A CJ Oven Service Manual TO AVOID EXPOSURE TO EXCESSIVE MICROWAVE ENERGY Observe these precautions before and during servicing 1 2 Do not operate or allow the oven to be operated with the door open Make the following safety checks on allovens to be serviced before activating the magnetron or other microwave source and make repairs as necessary a Interlock Operation b Proper Door Closing c Seal and Sealing Surfaces arcing wear and other damage d Damage To or Loosening of Hinges and Latches e Evidence of Dropping or Abuse Before turning on microwave power for any service test or inspection within the microwave generating compartments check the magnetron waveguide or transmission line and cavity for proper alignment integrity and connections Any defective or misadjusted components in the interlock monitor door seal and micro wave generating and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner 44 WARNING Thi
36. motor wire connectors The meter should read between 700 and 750 Q If the reading is not within this range remove and replace the door latch assembly Door Latch Positions Lock Switch Open UnLock Switch Closed LATCHED POSITION ee Lock Switch Closed UnLock Switch Open UNLATCHED POSITION Lit No 94 30 007A CJ Oven Service Manual THE HIDDEN BAKE THE BROIL ELEMENT ELEMENT Refer to Page 79 to access the broil element Refer to Pages 80 and 81 to access the bake ele 1 ment 1 With no power applied remove the wires from the terminals of the hidden bake ele ment 2 Setthe ohmmeter to the R x 1 scale 3 Touch the ohmmeter leads to the bake ele 4 ment terminals The meter should indicate 24 Q 4 If the reading is not correct remove and re place the bake element Page 111 With no power applied remove the wires from the terminals of the broil element Set the ohmmeter to the R x 1 scale Touch the ohmmeter leads to the broil ele mentterminals The meter should indicate 15 If the reading is not correct remove and replace the broil element CJ Oven Service Manual THE CONVECTION BAKE ELEMENT Refer to Page 83 to access the convection bake element 1 With no power applied remove the wires from the terminals of the convection bake element Set the ohmmeter to the R x 1 scale Touch the ohmmeter leads to the convection bake element terminals The meter should
37. two top screws from the liner This will separate the glass and liner sections of the door see Page 40 3 Lift the door liner assembly off the door glass assembly and lay it liner side down on the padded work surface NOTE Set the oven door glass assembly out of the way so it does not get damaged 4 remove an oven door hinge a Remove the mounting screw at the bot tom edge of the door b Slide a piece of pipe over the end of the hinge and push it against the spring until you can unlock the U clip then allow the hinge to return to its un locked position and remove the pipe c Unhook the hinge at the top and re move the hinge Unhook Hinge 5 remove the actuator arm a Remove the four screws from the baffle and remove the baffle b Remove the four screws from the ac tuator arm bracket and remove the ac tuator arm from the liner Actuator Arm Bracket Screw 1 of 4 Bottom Screws 6 To remove the center glass a Remove the four screws from the insu lation cover and remove the cover Top Screws Bottom Screws Page 41 CJ Oven Service Manual Lit No 94 30 007A b Remove the insulation strip from 7 To remove the RF screen and the inner around the center glass assembly glass Center Glass Assembly a Remove the bottom insulation from the door b Remove the forty eight screws from the mo screen and remove the screen from over E M ae 1 the inner glass
38. 1 Transfers 120 volts AC to the high voltage transformer to activate the microwave circuitry Kl is activated by 24 volts DC from the relay board Header P1 Receives 24 volts and 5 volts DC from the relay board using wire harness con nector P6 The 18 volts DC activates the relay coil and the 6 volts DC activates the triac on the Microwave PCB Control Terminal P2 1 Inputs 120 volts AC from the latch interlock switches Terminal P2 2 Outputs 120 volts AC to the high voltage transformer when relay K1 closes Header P1 CJ Oven Service Manual Header P3 Receives 12 volts AC from the halogen light transformer at pins 1 amp 2 and Pins 3 amp 4 output 12 volts DC to activate the upper or single oven latch motor The 12 volts DC is produced by passing the 12 volts AC through a bridge rectifier see the follow ing circuits Positive AC Cycle 12 Volts Pulsating DC 12 Volts Pulsating DC Terminal P2 2 Terminal P2 1 Bridge Page 55 CJ Oven Service Manual Lit No 94 30 007A MICROWAVE COMPONENTS DESCRIPTION e 6 aft ENTER gt gt 9 d Fo e 2 I De d 0 e ee Ead D e I 2 Fr w ff Fuse Diode Capacitor High Voltage Transformer High Temp Cutout mag tube Magnetron Tube Page 56 Lit No 94 30 007A CJ Oven Service Manual
39. ECTION ELEMENT Terminals Y Refer to Page 83 to access the convection ele ment To test the element perform the follow ing steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale 3 Disconnect one of the wires from the con vection element 4 Touch the test leads to the convection elementterminals The meter should indi cate between 15 and 25 Lit No 94 30 007A LOWER OVEN BAKE ELEMENT Terminals Refer to Page 81 to access the bake element To test the element perform the following steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale 3 Disconnect one of the wires from the bake element 4 Touch the test leads to the bake element terminals The meter should indicate be tween 20 and 30 Q LOWER OVEN CONVECTION MOTOR Refer to Pages 84 85 to access the convection motor To test the motor perform the follow ing steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale 3 Disconnect one of the wires from the con vection motor 4 Touch the test leads to the convection motor terminals The meter should indi cate between 10 and 20 Page 52 Lit No 94 30 007A UPPER OVEN JET CONCEALED ELEMENT Refer to Page 34 to access the jet concealed element To test the element perform the fol lo
40. Motor Assembly Do Not Dissassemble Stirrer Motor Assembly Proper alignment of these components is critical This assembly is aligned and assembled at the factory Replace Entire Assembly Important The stirrer motor assembly is comprised of the folloing parts 1 Stirrer Motor 1 Stirrer Shaft 1 Stirrer Motor 1 Stirrer Shield Bracket 4 Stirrer Bushing 1 Stirrer Motor San Insulation 28 Bracket Screws 1 Mounting Bracket 1 Stirrer Screw 1 Stirrer Bushing 1 Stirrer Screw Washer Stirrer Motor Stirrer Motor Bracket Stirrer Motor Insulation T mt 22 E Mounting Bracket Stirrer Motor Stirrer Shield Inside underneath 1 Stirrer Screw Washer 1 Stirrer Screw M Page 14 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE STIRRER MOTOR ASSEMBLY 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum covers from the oven 4 Disconnect the stirrer motor wires from the terminal block and the in line connec tor 5 Remove the fische paper over the stirrer motor cove
41. NING To Avoid Electrical Shock e Disconnect the power to the appliance before servicing For those checks requiring the use of elec trical power exercise extreme care Do not attempt high voltage tests RESPECT HIGH VOLTAGE Page 5 CJ Oven Service Manual Lit No 94 30 007A PROCEDURE FOR MEASURING MICROWAV E RADIATION LEAKAGE A WARNING Check for microwave radiation leakage before and after every servicing Should the leakage be more than 5 mw cm inform Thermador immediately After repairing or replacing any radiation safety device keep a written record for future reference as required by D H H S regulations This requirement must be strictly observed In addition the leakage reading must be recorded on the service repair ticket while in the customer s home NOTE The maximum allowable leakage according to U S Government standard is 5 mw while in the customer s home Using 4mw cm as the highest acceptable meter reading allows for meter and probe accuracy tolerances Equipment Holaday model 1501 or equivalent meter Glass thermometer 212 or 100 600 cc glass beaker Page 6 Before performing any tests be sure to observe the following precautions Do not exceed the meter s full scale deflection Leakage monitor should initially be set to the highest scale To prevent false readings hold the test probe by the grip portion of the handle only and m
42. POST FROM CATCH OVEN DOO Lit No 94 30 007A To remove the oven door latch assembly see Inset 2 Page 89 1 4 ratchet and a 1 4 thin wall socket and remove the two front hex head screws from the latch bracket b Pull the latch assembly to the right so that the flange on the left side clears the bracket and then pull it forward as far as the wires will allow c Remove the wires from the switch con nectors and the motor wires from the main harness d To replace a door lock or door unlock switch on the latch assembly remove the two screws from the switch body and remove the switch To remove the hi temp cutout see Inset 3 Page 89 a Remove the two 1 4 hex head screws from the bracket b Remove the hi temp cutout and discon nect the wires Install the replacement component Reassemble the oven PULL TOP OF VENT GRILLE FORWARD TO REMOVE POST FROM CATCH H LATCH SCREWS M A LOWER AIR VENT GRILLE Swe Page 98 oia OVEN CHASSIS Post CATCH Lit No 94 30 007A CJ Oven Service Manual REMOVING the OVEN LIGHT SWITCH the OVEN DOOR LATCH ASSEMBLY and the HI TEMP CUTOUT Inset 1 NORMALLY OPEN GOLD CONTACTS DOOR OPEN SWITCH OPEN NORMALLY CLOSED DOOR OPEN SWITCH CLOSED You will need the following tools to remove the components 1 4 rat
43. Page 16 Lit No 94 30 007A 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turn off the electrical power going to the oven Pull the oven out of its mounting location so that you can access the trim and ple num covers Remove the trim and top plenum covers from the oven see Page 10 Rear Vi 3 Screws Page 17 WH75 SH162 BU 161 WH 164 BU 163 CJ Oven Service Manual REMOVING THE CROSSFLOW TOP COOLING BLOWER 4 Disconnect the wires from the terminals of the crossflow top cooling blower Remove the three screws from the blower mounting bracket and remove the blower from the oven Top View gt E hw Crossflow Cooling Blower BU 74 Cooling Blower CJ Oven Service Manual Lit No 94 30 007A REMOVING THE HIGH VOLTAGE MICROWAVE 44 WARNING 5 Turn off the electrical power going to the oven before servicing 6 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven 2 Pulltheovenoutofits mounting location so that you can access the trim and ple num covers 3 Re
44. REASSEMBLY NOTE Insulation Strip Make sure that you position the screen EN p Y L 3 T with the best side showing through the we inner glass c Remove the screws from the four insu lation cover brackets and the four glass assembly clamps and remove the brackets and clamps Insulation c Lift the inner glass off the oven door CAUTION The inner glass is not heat treated like the center glass Be sure to install the untreated glass in the in ner glass position A F a cH 4 rackets Inner Glass Insulation Rope d Lift the center glass and frame out of the liner CAUTION The center glass is heat treated on both sides If you re move both the center and inner glass d If you need to replace the insulation be sure to install the heat treated glass l rope that is under the inner glass in the center glass position pull it out of the track and install the new one in its place REASSEMBLY NOTE Make sure that the end strands of the insulation do not show through the inner glass when you reinstall the glass es Continued on the next page Page 42 Lit No 94 30 007A Ca Service Alert After reinstalling the oven door check around the door for microwave radiation leakage CJ Oven Service Manual Tech Tip The center glass is heat treated and has the letters HB stamped in two places near one of the edges If you a
45. RMADOR 19 40 517 Secondary Terminals Primary Terminals Refer to Page 13 to access the light transformer To test the light transformer perform the fol lowing steps 1 2 o Turn off the electrical power to the oven Set the ohmmeter to the R x 1 scale Disconnect one of the wires from the bot tom primary terminals Touch the test leads to the bottom termi nals The meter should indicate less than 1 Q Disconnect the wires from the top three terminals Touch the test leads to the following num bered terminals The meter should indi cate less than 1 Q at each location a Terminals 8 and 6 b Terminals 8 amp 10 c Terminals 6 and 10 Page 45 CJ Oven Service Manual DOUBLE LINE BREAK RELAY Switch N O Solenoid Refer to Page 13 to access the double line break relay To test the double line break relay per form the following steps 1 2 3 Turn off the electrical power to the oven Set the ohmmeter to the R x 1 scale Disconnectthe two yellow solenoid wires from the relay Touch the test leads to the relay terminals The meter should indicate less than 1 Q Disconnect the other two switch wires from the relay Touch the test leads to the relay terminals The meter should indicate an open circuit infinite resistance CJ Oven Service Manual STIRRER MOTOR Stirrer Motor Refer to Page 14 to access the stirrer motor To test the stirrer mo
46. SERVICE MANUAL for THERMADOR BUILT IN OVENS MODELS CJ302B CJ302W CJ302S Thermador Lit No 94 30 007A OAOE OnE APPEN October 2001 CJ Oven Service Manual Lit No 94 30 007A Table of Contents General 1 8 Data Plate LOCAUOM ash 1 Symbols You Will See In The 2 Avoid Exposure To Excessive Microwave Energy 3 Cautions To Observe When Troubleshooting 4 Avoid Electrical Shock 5 Measuring For Microwave Radiation Leakage 6 7 Thermador Waranty eresie 8 Servicing Components 9 Component Locations 9 Removing Trim amp Top Plenum 5 10 Removing Electronic Oven Control Board 11 Removing Fuseblock Microwave PCB Control 12 Removing Light Transformer amp Double Line Break Relay 13 The Stirrer Motor 5 5 14 Removing Stirrer Motor Assembly 15 Removing Magnetron Fan Assembly 16 Removing Crossflow Top Cooling Blower 17 Removing High Voltage Microwave Capacitor 18 Removing High Voltage Diode 19 Removing High Voltage Microwave Transformer
47. accept no programs at all Upper oven air switch F 34 will appear if upper oven air switch does not close If air switch does not close the mode is cancelled after about 45 seconds Lower oven air switch F64 will appear if lower oven air switch does not close If air switch does not close the mode is cancelled after about 45 seconds Power supply to touch control board No fail code time of day on clock control panel is dead no reaction Display communication signals to tcb No fail code Time of day on clock control panel is dead no reaction Troubleshooting chart for right side touch control board header pin failures Wire harness off at pin header or circuits open P2 Sends commands to display head No fail code Will not send commands from right side of tcb to display head Such as numbers 0 through 9 and start Page 88 Lit No 94 30 007A CJ Oven Service Manual CJ LOWER OVEN SAME AS C AND Bracket Broil Element Brackets Hidden Bake Element Under Oven Liner 2 Top Front Mounting Screws i S Wires Access xz Panel Hex Nut Meat Probe Jack Page 89 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE HIDDEN BAKE ELEMENT LOWER OVENS ONLY 44 WARNING Turn off the electrical power circuit to the oven at the main junction box be fore servicing this unit 44 CAUTION When you work on the oven be carefu
48. al voltage for door switch latch switch and air switch function 120 V A C is rectified to 24 V D C to energize the DAC control relay coils double line break relay coils microwave relay coil and to fire the triac in the microwave board These switches are mounted on a bracket located on the right side of the plenum behind the control panel see front view below Page 73 CJ Oven Service Manual Lit No 94 30 007A Voltages When troubleshooting testing and repairing the ovens you will observe these voltages 1 4000 volts half wave doubler for microwave section 120 240 volts for elements and jet blowers 24 volts D C relay coils and microwave board triac 24 volts A C for signal voltage 12 volts A C for halogen lights 12 volts rectified D C for the upper oven latch motor een The following parts are high voltage parts of the microwave circuit magnetron tube diode capacitors high voltage transformer The following parts require 240 volts to function bake elements broil elements convection elements The following parts require 120 volts A C to function Dac control step down transformer 120 volts to 24 volts and D C High voltage transformer steps down 120 V A C volts to 3 2 V A C filament voltage for magnetron tube Steps up 120 V A C to approximately 2000 V D C for magnetron excitation Halogen light center tap transformer 120 V A C to 12 V A C convection mo
49. ar corner of relay board This harness sends display sig nals from the relay board back to the display head 9 Wire Orange Communication Harness This 9 wire harness connects from pin header P11 on the display head to pin header P11 on the relay board right front comer of board Ihis harness sends communication signals from the display head to the relay board 18 Pin White Communication Harness This split wire harness has 18 wires and con nects from pin header P1 on the large left side tcb to pin header P1 on the display head The side with the single connector goes to the dis play head the side with the split 2 connector housings goes to the left side TCB This harness sends communication from both the left and right TCBs to the display head Page 80 Lit No 94 30 007A CJ Oven Service Manual Troubleshooting chart for relay board header pin failures Wire harness off at pin header or circuits open P2 P3 P5 P9 P10 P11 PO Lower oven sensor Control functions normal When sensor opens f 61 code will appear If sensor shorts f 60 will appear Cooling fan is on constantly Upper oven sensor Controls function normal When sensor opens f 31 code will appear If sensor shorts f 30 will appear Cooling fan is on constantly Lower oven door latch Will accept all modes except self clean When set in self clean DOR will flash and self clean will erase Upper oven door latch
50. both K9 Transfers 120 volts from L2 to upper oven convection elements K10 Transfers 120 volts from L2 to upper oven Jet Plate and mullion elements K11 Transfers 120 volts from L2 to upper oven tube fan and stirrer motor K12 Transfers 120 volts from L2 to lower oven bake element K13 Transfers 120 volts from L2 to lower oven broil element K14 Transfers 120 volts from L2 to lower oven convection element K15 Transfers 120 volts from L2 to lower oven convection motor These relays have normally open contacts that transfer voltage when the are snapped closed These relays have a coil that is snapped closed by 24 VDC from the eeprom memory chip on the relay board CJ Oven Service Manual Lit No 94 30 007A DAC RELAY BOARD continued The relay board has 8 small pin headers They are identified as P2 P3 P5 P6 P9 P10 P11 P14 P15 These small pin headers carry signal voltage to specific components The pin numbers are identified on the schematic The illustration below shows that the arrow will always point to Pin 1 Oo OF Li 8 Small Pin Header Identification P2 P3 P5 P6 P9 P10 P11 Pl4 P15 Sends current to the lower oven sensor It is a 3 pin header only l and 2 are used 3 is missing on the pin header and 3 is plugged on the harness so it cannot be miswired Sends current to the upper oven sensor It is a 3 pin header only 2 and 3 are used 1 is missing o
51. ch one of the test leads to the chassis and the other lead to the tan wire connec tor The meter should indicate less than 1 Q Page 47 CJ Oven Service Manual MAGNETRON Z lt Filament lt Terminals CAUTION DISCHARGE THE HIGH VOLT AGE CAPACITOR BEFORE TESTING THE MAGNETRON REFER TO PAGE 17 FOR THE PROCEDURE Refer to Page 21 to access the magnetron To test the magnetron perform the following steps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to the R x 1 scale 3 Disconnect the leads from the filament terminals of the magnetron 4 Touch the test leads to the primary termi nals The meter should indicate less than 10 Lit No 94 30 007A MAGNETRON THERMAL CUTOUT TCO Terminals Reset Button CAUTION DISCHARGETHE HIGH VOLT AGE CAPACITOR BEFORE TESTING THE MAGNETRON THERMAL CUTOUT RE FER TO PAGE 17 FOR THE PROCEDURE Refer to Page 22 to access the magnetron ther mal cutout TCO To test the TCO perform the following steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale 3 Disconnect one of the leads from the mag netron TCO terminals 4 Touchthe test leads to the normally closed terminals The meter should indicate a short circuit 0 Q NOTE If the meter indicates an open circuit infinite resis tance press the reset button on the TCO and check it again If it remains open replace the TCO Page 48
52. chet 1 4 thin wall socket 2 Phillips Offset Screwdriver OVEN DOOR LATCH SCREWS ZN AIR VENT GRILLE lt screws gt E AIR VENT GRILLE Inset 2 Hi Temp Upper Oven Cutout Wht 05 Lower Oven Wht 55 Reset Button Hex Head Upper Oven Wht 01 amp 02 Lower Oven Wht 51 amp 52 Upper Oven Motor 07 amp 08 Lower Motor 57 amp 58 Wht Upper Oven Wire Wht 06 Connector Lower Oven Wht 56 Upper Oven Wht 02 amp 03 Lower Oven Wht 52 amp 53 Bracket SI Y bas Hex Head Screw Hex Head Screw Slide Latch Flange From Under Bracket Page 99 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE AIR SWIICHES Refer to illustrations below and on Page 91 for W PB N the following steps Turn off the electrical power circuit to the 1 Turn off the electrical power to the oven oven at the main junction box before ser vicing this unit 2 Pulltheovenoutof its mounting location so that you can access the back cover and A C A UTI both air switches When you work on the oven be careful 3 Upper Air Switch Remove the two screws when handling the sheet metal parts There from the switch body and disconnect the are sharp edges present and you can cut wires from the terminals See Figure 1 yourself if you are not careful below 4 Lower Air
53. closes the latch interlock switch and completes the circuit to the microwave board see illustration below Door Unlatched Latch interlock switch is open current stops to microwave NC P2 1 Microwave Board board NO Monitor Primary Switch Interlock Switch Secondary U O Latch Interlock Interlock Switch Switch FUSE Door Latched Latch interlock switch is closed current flows to microwave board P2 1 Microwave Board Monitor NO Primary Switch Interlock Switch Secondary U O Latch Interlock Interlock Switch FUSE Switch Page 62 Lit No 94 30 007A CJ Oven Service Manual Latch Unlock Switch The N O latch unlock switch is closed with the door latch unlatched The unlock switch in the closed position sends a signal to the board that the door is not latched This prevents the board from proceeding into self clean or microwave Latch Lock Switch The N O latch lock switch is open with the door latch unlatched There is no completed signal voltage circuit to the board DAC Control Board 5 4 3 2 1 Door unlatched Door Switch N O Lock Switch N O Lock switch open Unlock Switch Unlock switch closed Latch Lock Unlock Switch Circuit In Microwave When microwave is selected the latch motor runs The cam on the latch assembly opens the unlock switch and closes the lock switch The completed circuit through
54. ds of the old gasket out of the that it is flush and even with the surface holes in the door see Inset 1 on the illus of the door tration 8 Close the oven door and check to make 3 Working from one end of the gasket to sure that the gasket fits firmly and evenly the other carefully pull the clips that are with the front of the oven INSET 1 rg EA G GA gt Pull End Of Gasket Out Of Hole 2 Push End Gasket Into Hole With Eraser End Of Pencil OVEN DOOR S Gasket Pull Clips Out Of Holes In Oven Door U NEW GASKET Y iy Push Clips Into Holes INSET 2 Page 105 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE OVEN DOOR COMPONENTS 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut To remove any of the oven door compo nents remove the oven door from the oven see Page 94 Refer to illustration below as you remove the door components The illustration yourself if you are not careful shows the order of removal Gasket Door Liner Inner Glass 2 W Spacer Insulation Cover Door Door Baffle Trim 9 9 9 Glass Support Bracket Y Door Glass W Curved Panel Page 106 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE OVEN MODULE 30 Convection Kit 35 00 687 W A R N G 1 Turn off the electrical power to
55. e 66 Lit No 94 30 007A CJ Oven Service Manual MICROWAVE BOARD The Microwave Board has one snap relay K1 Two Pin Headers P1 and P3 and two 1 4 terminals P2 1 and P2 2 K1 Relay This relay transfers 120 Volts AC to the high voltage transformer to activate the micro wave circuit The K1 Relay Coil is activated by 24 Volts DC from the relay board P1 Pin Header This is a 3 pin header that receives 24 Volt DC from the Relay Board using a wire har ness from PIN Header P6 on the relay board P3 Pin Header Pins 1 and 2 inputs 12 Volts AC from the halogen light transformer circuit Pins 3 and 4 output 12 volts DC Rectified through a series of diodes to activate the upper oven or single oven latch motor P2 1 Terminal This terminal inputs 120 Volts AC from the latch interlock switches P2 2 Terminal This terminal outputs 120 Volts AC to the transformer when relay K1 closes STIRRER MOTOR The stirrer motor is a 120 volt AC motor The purpose of the stirrer motor is to run the stirrer blades at the output of the wave guide The stirrer rotates at about 60 rpm As the microwave energy enters the oven cavity through the wave guide it bounces off the rotating stirrer blades and is reflected throughout the oven cavity at constantly changing angles providing a more even microwave distribution In the jet impinged oven the stirrer blade also mixes the air flow into the top of the oven Tech Tip The stirrer motor tu
56. e Capacitor High Voltage Transformer 47 Magnetron Magnetron Thermal Cutout TCO 48 Magnetron Fan Motor Crossflow Blower Motor 49 Door Latch Assembly Monitor amp Secondary Switches 50 Door Switch Oven Thermal Sensor 51 Broil Element Bake 52 Convection Element Convection Motor 53 M W Transformer Air Switch Meat Probe Jack 54 Microwave Control eene 55 Microwave Components Description 56 62 Interlock eoi b mr oto e e ed 57 atch Mounted ten 57 Oven Mounted switches 58 Switches Activated by Hook 59 20 Ampere Fuse Fuse Failure 60 Diode High Voltage Transformer Magnetron Tube 61 Microwave Board Stirrer Motor Microwave Transformer Cooling Fan amp Air Switch 62 CJ Lower Oven 63 CJ Relay Board Matrix eese 64 CJ DAC Relay Board 65 68 Wire Harnesses 69 70 Troubleshooting Chart for Relay Board Headers Pin Failures 71 72 CJ Oven Control ee 73 Electronic Oven Controls 74 Control Panel Assembly
57. e high voltage capacitor perform the following steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 10K scale 3 Disconnect the wires from the capacitor terminals 4 Touch the test leads to the capacitor termi nals The meter should indicate a high resistance and then gradually begin to fall back toward infinity 5 Switch the test leads and the meter should again indicate a high resistance and gradu ally fall back toward infinity CJ Oven Service Manual HIGH VOLTAGE TRANSFORMER Tan Lead secondary Primary Orange Leads Terminals secondary CAUTION DISCHARGETHE HIGH VOLT AGE CAPACITOR BEFORE TESTING THE TRANSFORMER REFER TO PAGE 17 FOR THE PROCEDURE Refer to Page 19 to access the high voltage transformer To test the high voltage trans former perform the following steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale Testing The Primary Winding 3 Disconnectthe black and white wires from the primary terminals of the transformer 4 Touch the test leads to the primary termi nals The meter should indicate less than 1 Q Testing The Secondary Windings 5 Disconnect the two orange transformer wires from the magnetron terminals 6 Touch the test leads to the orange wire connectors The meter should indicate less than 1 Q 7 Disconnect the light tan transformer wire from the high voltage capacitor 8 Tou
58. e less than 1 Q Testing The Door Lock Door Unlock amp Latch Interlock Switches All Normally Open N O 5 Disconnect one of the wires from the ter minal of the switch under test 6 Touch the test leads to the switch termi nals The meter should indicate an open circuit infinite resistance 7 Press the switch button to close the con tacts The meter should indicate a short circuit 0 Q Lit No 94 30 007A MONITOR amp SECONDARY SWITCHES Common Monitor Switch N C Terminals Common Secondary Switch N O Terminals Refer to Page 25 26 to access the monitor and secondary switches To test the switches per form the following steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale Testing The Secondary Switch Normally Open N O 3 Disconnect one of the wires from the sec ondary switch 4 Touch the test leads to the switch termi nals The meter should indicate an open circuit infinite resistance 5 Press the switch button to close the con tacts The meter should indicate a short circuit 0 Q Testing The Monitor Switch Normally Closed N C 6 Disconnect one of the wires from the monitor switch 7 Touch the test leads to the switch termi nals The meter should indicate a short circuit 0 Q 8 Press the switch button to close the con tacts The meter should indicate an open circuit infinite resistance Page 50 Li
59. e wave when handling the sheet metal parts guide as illustrated Failure to place these two There are sharp edges present and you 2 screws in the proper place will cause mi can cut yourself if you are not careful crowave arching in the cavity when the stirrer rotates past these two 2 screws Page 32 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE MEAT PROBE JACK 44 WARNING Turn off the electrical power going to the oven before servicing Meat Probe ES Jack Access Panel 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven 2 Pull the oven out of its mounting location just far enough so that you can access the meat probe jack access panel on the right side of the oven Positive Wire Open the microwave oven door Raise the cover on the meat probe jack then use 17 mm 11 16 socket and re move the hex nut Tech Tips 1 Connect the wire with the GND tag on it 5 Remove the screw from the meat probe to the ground terminal on the meat probe jack access panel on the right side of the jack This terminal is part of the jack s oven frame Be sure to reinstall the flat washer on the jack 6 Removethe piece of insulation that is cov ering the meat probe jack To make it easier when reinstalling
60. ee Illustration below a Remove the screws and disconnect the wires from the relay terminals b Install the new oven stalled fan relay with the terminals positioned as shown and reconnect the wiring Upper Yel 102 Lower Org 112 Upper Wht 103 Lower Wht 113 Upper Blk 104 Lower Blk 114 Upper Blk 12 Lower Blk 92 Douible Line Break Relay Front Of Oven Reassemble the oven Page 97 CJ Oven Service Manual REMOVING the OVEN LIGHT SWITCH the OVEN DOOR ASSEMBLY and the HI TEMP CUTOUT in LOWER OVEN 44 WARNING Turn the electrical power circuit to the oven at the main junction box before ser vicing this unit 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Refer to illustration on Page 89 for the follow ing steps 1 Turn off the electrical power to the oven 2 Open the oven door for the component you wish to remove 3 remove the lower air vent grille re B move the two front oven door latch screws see illustration below then pull the posts on the ends of the air vent grille out of the catches in the chassis 4 To remove the oven light switch discon nect the wires from the terminals press in on the locking arms and push the 8 switch out of the vent see Inset 1 Page 89 PULL TOP OF VENT GRILLE FORWARD TO REMOVE
61. emove the oven racks Front Tabs Page 31 Jetplate Top 2 Front Screws Clip To remove the top jet plate a Remove the two front screws from the jet plate top b Carefully lower the jet plate down c To remove bottom jet plate lift jet plate up from front tabs and pull forward Jet plate can be removed without re moving side rails JetPlate Bottom CJ Oven Service Manual Lit No 94 30 007A 9 REMOVING THE STIRRER BLADE ASSEMBLY Stirrer Stirrer JetPlate washer Assembly Top Clip 4 tasa Access hole for mounting screw JetPlate Top Light Assembly WAVE GUIDE Ld M 7 Ad WARNING 2 flat head 1 8 Allen Turn off the electrical power going to the oven before servicing To remove the stirrer blade assembly a If not already done remove the top jet plate See Page 30 a lt A c 7 lt Phillips head b Through the mounting screw access Wave wide screws hole in the stirrer blade remove the screw and washer from the stirrer blade The wave guide is attached to the can with assembly and remove the assembly eleven 11 Phillips head thruss head screws six 6 locknuts and two 2 flat head socket screws A 1 8 inch Allen wrench will be needed to remove the two 2 flat head socket screws Ad CAUTION The two 2 flat head socket screws must be When you work on the oven be careful installed in the top left corner of th
62. es Be sure the oven temperature sensor connec II tors are pushed back into the rear of the oven N and out of the oven heat zone 2 gt d Slide Fiber Sleeving Over N 7 CHR a Wires amp Against Collar Of Oven Temperature Sensor Collar Page 92 MOUNTING SCREW q OVEN TEMPERATURE SENSOR Lit No 94 30 007A CJ Oven Service Manual REMOVING THE CONVECTION BAKE ELEMENT 44 WARNING Turn off the electrical power circuit to the oven at the main junction box before ser vicing this unit 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Refer to illustration below for the following steps 1 Turn off the electrical power to the oven 2 make servicing easier remove the oven door see Page 94 Remove the racks from the oven Remove the front screws from the left and right oven rack supports and remove the supports from the oven liner Remove the screws from the convection baffle and remove the baffle from the back of the oven liner Remove the screws from the convection bake element bracket and the screw from the bottom support and pull the element forward then disconnect the wires from the terminals Install the new convection bake element and connect the wires to the terminals Reassemble the oven BACK OF LINER ge Bracket CONVECTION ELEMENT
63. et Page 102 e Disconnect the four wires from the mo tor terminals f Install the new blower in the mounting bracket and mount the assembly to the plenum To remove the lower blower see Figure B Page 5 93 a Remove the oven from the wall b Remove the rear panel from the oven c Remove the four bracket screws 1 2 6 amp 7 from the back of the oven d Remove the three blower screws 3 4 amp 5 from the bracket and remove the motor e Loosen the wire ties and remove the two motor wires from the rest of the wire harness f Install the new blower in the mounting bracket mount the assembly to the back of the oven and connect the wires g Install the motor wires in the wire har ness ties with the rest of the wires and dress them neatly Reassemble the oven Lit No 94 30 007A CJ Oven Service Manual REMOVING A BLOWER BACK OF PLENUM Mounting Bracket White BY SS I os Screw Jeo Upper Blower Upper Blower Figure A Lower Blower Figure B Blower Wire 24 To gt Blower Wire 23 Upper Blower Motor Upper Blower Motor 1 _ LT Blower Bracket 9 Page 103 CJ Oven Service Manual Lit No 94 30 007A REMOVING AN OVEN DOOR Refer to the illustration below for the follow 3 remove the door DSDS a Grasp the door by the sides toward the 1 Open the door to its fully open position back and raise the fr
64. ge 109 With no power applied remove the wires from the terminals of the lamp transformer Set the ohmmeter to the R x 1 scale Touch the ohmmeter leads to the primary terminals The meter should indicate 9 Q Touch the ohmmeter leads to the secondary terminals The meter should indicate 2 Q If the readings are not correct remove and replace the lamp transformer Secondary Winding Primary Winding CJ Oven Service Manual THE OVEN DOOR LATCH ASSEMBLY The oven door latch locks the oven door during the 5 CLEAN cycle see the illustration at the bottom of the next column for the various latch positions Refer to Page 88 to access the oven door latch assembly 1 To test one of the latch switches 1 With no power applied remove the wire connectors from the switch terminals Set ohmmeter to the Rx 1 scale 3 Connect one of the ohmmeter leads to the common C terminal of the switch 4 4 Touch the other ohmmeter lead to the N O normally open switch terminal The meter should indicate no continuity with the switch inits normal position and continuity when it is activated Page 110 Lit No 94 30 007A If the reading is not correct remove and re place the switch To test the door latch motor windings With no power applied disconnect the motor wires from the terminal block and main har ness connector Set the ohmmeter to the R x 100 scale Touch the ohmmeter leads to the
65. l when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Turn off the electrical power to the oven 2 Pull the oven out of its mounting location so that you can access the back 3 Remove the screws from the rear panel and remove the panel see Figure A Page 86 Refer to Figure B Page 86 for the following steps 4 Unwrap and remove the indicated wire tie from the support bracket Remove the three screws from the support bracket and rotate it to the right so you can access the flange at the bottom of the oven Remove the six screws from the flange Remove the two wires from the bake ele ment Refer to Figure C Page 86 and bend the bottom flange down as far as possible so that you can pull the bake element out from under the unit Refer to Figure D Page 86 for the following steps 9 10 Page 90 Remove the screws from the hidden ele ment cover and remove the cover Remove the two screws from the hidden bake element and pull the element out from the unit NOTE Be careful not to tear the insulation under the element Lit No 94 30 007A CJ Oven Service Manual REMOVING THE HIDDEN BAKE ELEMENT LOWER OVENS ONLY J U Support Bracket Remove Screws Rear Panel Bake Element Remove Screws Wires Remove 5 3 Screws Wire Tie Flange Remove 6 Screws Figure B m Bend Flange Bend Fla
66. l allow b Disconnect the wires from the switch terminals Secondary Switch Monitor Switch b Screw amp Lockwasher 1 of 4 Lit No 94 30 007A CJ Oven Service Manual REMOVING A HALOGEN LIGHT ASSEMBLY 44 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven 2 To make servicing inside the oven easier remove the microwave oven door see Page 37 for the procedure 3 Remove the oven racks 4 Removethe screws from the rack support that is over the halogen light you wish to service CAUTION When you remove the halogen lens holder and lens in the next step be care ful that the lens does not fall out and break 5 Remove the four screws from the halogen lens holder and remove the holder and lens from the oven liner 6 Remove the screws from the metal screen that is over the halogen light and remove the screen Page 29 8 Screw 1 of 4 9 Lens Holder amp Lens 10 11 T cae ret Det T T 1 1 5 T e rese 10120 Metal Screen A EI EN L1 T o m Pull the light assembly out of the oven liner cutout and remove the halogen bulb from the socket
67. losed This switch provides a current path to the microwave plate transformer With the door open or if the switch fails there is no current to the microwave transformer The oven mounted switches are mounted as shown in the illustration above facing the oven See Top View above Page 60 Lit No 94 30 007A CJ Oven Service Manual Door Latch Assembly Switches The door latch assembly has 3 mounted switches The n o latch interlock switch primary the n o lock switch and the n o unlock switch These switches are positioned as follows in the idle state unlatched Normally Open Latch Interlock Switch Open Normally Open Latch Unlock Switch Closed Normally Open Latch Lock Switch Open These switches are activated by cam movement when the latch motor runs see illustration below DOUBLE SWITCH d Com LATCH INTERLOCK SWITCH PRIMARY MOUNTED ON TOP SWITCH MOUNTED Motor Terminals LOCK SS gt pr di ON BOTTOM NOT VISIBLE SS ess sur n pee Late anum mee Interlock am D gt d WITCH s g N O wee anna WR gt on Latch Hook Page 61 CJ Oven Service Manual Lit No 94 30 007A Latch Interlock Switch Primary Circuit In Microwave The N O latch interlock switch is open with the door unlatched When microwave mode is selected the latch motor runs The cam on the latch assembly
68. motors on or off See illustrations below DAC Control Board 5 4 2 1 Door Switch N O Lock Switch N O Unlock Switch N O Closed Door Switch Page 58 Lit No 94 30 007A CJ Oven Service Manual Switches Activated by Hook Monitor switch secondary switch These switches are activated by a spring action hook on the microwave oven door When the door is opened and closed these switches are activated see illustration below Hook Page 59 CJ Oven Service Manual Lit No 94 30 007A Oven Mounted Switches These switches are mounted on a bracket located on the right side of the plenum behind the control panel see Front View below Front View Monitor Switch Secondary Switch Top View Monitor Switch Circuit The monitor switch is mounted on the left side of the bracket It is normally closed The switch is opened by the forward motion of the hook when the door is closed The purpose of this switch is to cause the fuse to blow if the latch switch is not open when the microwave door is opened The switch is wired across the neutral and positive side of the line The fuse will blow if the monitor switch and the primary switch are closed at the same time Secondary Switch Circuit he right side door interlock switch secondary is mounted on the right side of the oven bracket It is normally open The switch is closed by side ways motion of the hook when the oven door is c
69. move the trim and top plenum covers from the oven see Page 10 4 CAUTION DISCHARGE THE HIGH VOLTAGE MICROWAVE CAPACITOR WITH A 20 000 OHM 1 OR 2 WATT RESISTOR TO CHASSIS GROUND BEFORE WORKING ON ANY OF THE HIGH VOLTAGE COMPONENTS BE VERY CAREFUL NOT TO TOUCH THE BARE RESISTOR LEADS WHEN YOU DISCHARGE THE CAPACITOR Touch Resistor ouch Resistor Lead To Chassis Lead To Capacitor Terminal ee as Y Page 18 Disconnect the wires from the terminals of the high voltage microwave capacitor Remove the capacitor mounting bracket screw and remove the bracket and capaci tor from the transformer side shield High Voltage Bracket OR 135 Microwave Capacitor Screw OR 136 Transformer TAN Transformer Side Shield Secondary Lead Lit No 94 30 007A CJ Oven Service Manual REMOVING THE HIGH VOLTAGE DIODE W ARN 5 Disconnect the wires from the terminals of the high voltage diode Turn off the electrical power going to the oven before servicing 6 Remove the mounting screw from the di ode and remove the diode from the shield vq CAUTION Screw When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turn off the electrical power going to the oven 2 Pull the oven out of its mounting location so that you can access the trim and ple num covers 3 Remove the trim and top plenum
70. n the pin header ano fil is plugged on the harness so it cannot be miswired Sends current to the lower oven latch switches It is a 5 pin header Only 1 2 3 and 5 are used 4 is missing on the pin header and is plugged on the harness to prevent miswiring Send 18 VDC to the Microwave board to snap K1 relay closed and 5 VDC to the microwave board to activate the triac Sends current to the upper oven latch switches It is a 4 pin header All 4 pins are used Sends current to p10 header on the display head It is an 8 pin header All 8 pins are used Sends current to Pl 1 header on the display head It is a 9 pin header All 9 pins are used Sends current to the upper oven double line break relay coil it is a 2 pin header Both pins are used Sends current to the lower oven double line break relay coil it is a 3 pin header Only and 3 are used 2 is missing on the pin header and is plugged on the harness to prevent miswiring Page 76 Lit No 94 30 007A CJ Oven Service Manual DAC RELAY BOARD continued The relay board has 5 large pin headers They are identified as PO P1 P7 P8 P18 These large pin headers carry current to specific components The pin numberts are identified on the schematic P0 large pin header has 8 pins and are identified as follows PO 1 P0 2 P0 3 P0 4 P0 5 P0 6 P0 7 0 8 Receives current from center tap of light transformer Sends current to microwave board to activate m w o
71. nge Down Down Flange SER 5 4 ____ X E o i i 5 gy Hidden Screw Bake Element 1 of 2 Figure 7 Hidden Screw Element Cover 1 of 4 Figure D Page 91 CJ Oven Service Manual REMOVING THE OVEN TEMPERATURE SENSOR 44 WARNING Turn off the electrical power circuit to the oven at the main junction box before ser vicing this unit 44 CAUTION When you work on the oven be careful 6 when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Refer to illustration below for the following 7 steps 1 Turn off the electrical power to the oven 2 To make servicing easier remove the oven door see Page 94 3 Remove the racks from the oven 9i Oven Liner Lit No 94 30 007A Remove the screws from the bracket and pull the oven temperature sensor forward until the wire connectors are through the opening Cut the inline splices from the oven tem perature sensor and main harness wires Connect the wires from the new oven tem perature sensor to the main harness wires with two red inline splices After you con nect the wires pull on them to make sure that the inline splices are secure Use a screwdriver or stiff wire and push the wires into the back of the oven as far as they will go then install the oven tem perature sensor in the oven liner with its two screws Reassemble the oven SAL Splic
72. o Page 92 to access the blower motor 1 With no power applied disconnect the mo 1 tor wire connectors from their terminals Set the ohmmeter to the R x 1 scale 3 Touch the ohmmeter leads to the motor ter 3 minals The meter should indicate 13 THE AIR SWITCH Refer to Page 90 to access the air switch 4 f the reading is not correct remove and replace the blower motor Motor Terminals Page 108 With no power applied remove the wire connectors from the terminals Set the ohmmeter to the R x 1 scale Connect one of the ohmmeter leads to the common C terminal of the switch the termi nal callouts are stamped on the switch Touch the free ohmmeter lead to the N O normally open switch terminal The meter should show no continuity with the switch in its normal position and continuity when it is activated If the readings are not correct remove and replace the switch Lit No 94 30 007A CJ Oven Service Manual THE CONVECTION FAN MOTOR THE LAMP TRANSFORMER Refer to Page 84 to access the convection fan Refer to Page 87 to access the lamp transformer motor 1 1 With no power applied disconnect the mo tor wire connectors from their terminals Set the ohmmeter to the R x 1 scale Touch the ohmmeter leads to the motor termi nals The meter should indicate 12 0 4 4 If the reading is not correct remove and replace the convection fan motor Di Convection Fan Motor Pa
73. ons of the door RN Top Screws O Bottom Screws 3 Lift the door liner assembly off the door glass assembly and set the liner aside 4 To remove the oven door handle remove the hex head screws see the small inset from the left and right handle brackets and remove the brackets and handle from the glass Handle Brackets 5 remove the outer oven door glass a Remove the four screws from the left and right glass support brackets and remove the brackets Top Screws gt Glass Support u Brackets a A j N ER _ Bottom Screws b Rotate the top door trim w end caps back and remove it from the top of the door Door Trim With End Caps 6 If not already done remove the handle from the outer door glass see Step 4 a Service Alert After reinstalling the oven door check around the door for microwave radiation leakage Page 40 Lit No 94 30 007A CJ Oven Service Manual REMOVING AN OVEN DOOR HINGE ACTUATOR ARM CENTER GLASS RF SCREEN amp INNER GLASS 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Remove the upper or single oven door from the unit see Page 37 and lay it on a padded surface with the glass side down and the bottom edge facing you 2 Removethe two bottom edge screws and the
74. ont of the door sev 2 Raise the hinge latch over the hook on each eral inches there will be some resis of the hinges tance in the spring mechanism because the hinge is locked b When the door is high enough lift it until the hinges clear the indents and pull it out of the slots in the front frame Position Down To Close Door Position Up To Hinge Latch Remove Door Page 104 Lit No 94 30 007A CJ Oven Service Manual REMOVING THE OVEN DOOR GASKET 44 CAUTION When you work on the oven be careful attached to the gasket out of the holes in the oven door see Inset 2 on the illustra tion when handling the sheet metal parts 4 Position the new fiberglass gasket around There are sharp edges present and you the oven door so that the clips are near can cut yourself if you are not careful the holes 5 Working from one end of the gasket to the CAUTION Before you replace the fiberglass other insert the gasket clips into the holes gasket on the oven door make sure that the NOTE Onee m red control is turned OFE and thatthe oven gently pull the clip to make sure that it is cool is locked into place Refer to illustration below for the following apend pon ends of the gasket fully into the holes in steps the oven door 1 Open the oven door to its fully open po 7 Check the entire gasket to make sure that sition all of the clips are properly inserted and 2 Pull the en
75. onvert alternating current AC into pulsating direct current DC allowing it to pass forward in one direction while blocking the current flow in the opposite direction There is no charge stored in this part HIGH VOLTAGE TRANSFORMER The high voltage transformer has one primary winding and two secondary windings The stepup secondary winding converts 120 volts To 2300 volts across the transformer terminals The other secondary winding steps down 120 volts AC to 3 3 volts AC Which heats the magnetron tubes cathode filament The cathode filament preheats approximately 1 second before the high voltage circuit is energized MAGNETRON TUBE The magnetron tube is a vacuum tube in which the flow of electrons from the heated cathode to the anode is controlled by a magnetic field to produce an electromagnetic wave 2450 mhz These electromagnetic waves are called microwaves To operate the magnetron tube requires both a minimum power input of 3800 to 4000 volts DC From the transformer Diode and capacitor and 3 8 volts from the filament transformer lead The tube has a 650 watt rating Note Wire mesh gasket rf between the magnetron tube and the wave guide must be in place when reinstalling the tube When reinstalling the tube tighten the four tube nuts diagonally Do not tighten the two nuts on one side then the two nuts on the other side Removing and replacing the magnetron tube requires a microwave leakage test Pag
76. ort between the oven chassis and the terminal of the high voltage capacitor terminals of lead wire from magnetron filament high voltage transformer filament lead wire and diode lead wire with an insulated screwdriver to discharge 44 WARNING There is high voltage present with high current capabili ties in the circuits of the high voltage winding and fila ment winding of the high voltage transformer It is ex tremely dangerous to work on or near these circuits with the oven energized Do not measure the voltage in the high voltage circuit including the filament voltage of the magnetron Never touch any circuit wiring with your hand or with an insulated tool during operation 3 When parts must be replaced disconnect the power to the unit 4 Avoid inserting nails wire etc through any holes in the unit during operation Never insert a wire nail or any other metal object through the lamp holes on the cavity or any other holes or gaps because such objects may work as an antenna and cause microwave leakage 5 Confirm after repair After repairing or replacing parts make sure that the screws of the oven etc are neither loose or missing Microwaves might leak if screws are not properly tightened 6 Make sure that all electrical connections are tight Check for microwave energy leakage Refer to Measuring For Microwave Radiation Leak age on Page 6 Page 4 Lit No 94 30 007A CJ Oven Service Manual 44 WAR
77. ouch Control Board only by the edges of the glass and the plastic frame DO NOT TOUCH the connector pins or the micro processor chips Display Head Handle the Display Head only by the edges of the plastic frame DO NOT TOUCH the con nector pins the microprocessor chip orjumper wires IMPORTANT NOTE Repack the old boards in the antistatic bags and original packaging before returning them to a parts distributor Page 84 Lit No 94 30 007A CJ Oven Service Manual Control Panel Assembly The control panel assembly is comprised of the following parts Control panel There area total of 6 control panels 2 black 2 white and 2 stainless The control panels are what determines the color of the unit Curved glass touch panel There are 2 glass touch panels One is for the single oven the other is for the double oven Both are black in color and both are the same size The difference between a 27 inch oven and a 30 inch oven is deter mined by the control panel Mounting brackets There are 6 mounting brackets that hold the glass against the control panel snug 2 of these brackets mount the display head to the back plate Back plate The back plate is used to put pressure against the glass and hold it in place The back plate also serves to mount the display head Wire harnesses There are a total of 5 wire harnesses on the control panel There is 1 orange harness 1 yellow harness and 3 white harness Display head
78. ove it along the shaded area shown in the following illustration Meter reading with the top panel removed should be less than 4mw cm Meter reading for fully assembled oven with the door normally closed should be less than 4mw cm Meter reading for fully assembled oven before the latch switch primary is interrupted while lightly pulling on the door should be less than 4mw cm Abed Ahh ER EEE sf Lit No 94 30 007A CJ Oven Service Manual PROCEDURE FOR MEASURING MICROWAVE RADIATION LEAKAGE continued A WARNING Avoid contacting any high voltage parts Pour 275 15 9 oz 2 OZ of 20 5 C 68 9 F water in a beaker graduated to 600 cc and place the beaker in the center of the oven Setthe radiation monitor to 2450 MHz and follow the manufacturer s recommended test procedure to assure correct results NOTE When measuring the leakage always use the 2 inch 5 cm spacer supplied with the probe Start the magnetron and measure the leakage by holding the probe perpendicular to the surface being measured Measuring With The Top Panel Removed Whenever you replace the magnetron measure for radiation leakage before the top panel is installed and after all necessary components are replaced or adjusted Special care should be taken in measuring around the magnetron 5 Measuring A Fully Assembled Oven After all com
79. oven switches Door activated switches 1 Upper oven door switch 2 Lower oven door switch 3 Monitor switch 4 Secondary switch Door latch assembly switches 1 Latch interlock switch primary 2 Latch lock switch 3 Latch unlock switch Air switches 1 Lower oven air switch 2 Upper oven air switch Page 57 CJ Oven Service Manual Lit No 94 30 007A Door Switch Upper lower oven door switch The normally open oven door switch is mounted on the oven latch plate This switch is used to complete a circuit from the DAC control board through the door switch and back to the DAC control board Closing the oven door closes the switch and completes the circuit The completed circuit signals the board to turn the oven light off and that the oven is ready to go into self clean or microwave Opening the oven door opens the switch contacts and breaks the circuit The broken circuit signals the board to turn the oven light on and to turn the convection motor off in any convection mode DAC Control Board Door Switch Lock Switch N O Unlock Switch N O Open Door Switch Terminals N O Door switch circuit The board sends out signal voltage 24 V A C to the switch If the switch is functioning properly the signal returns to the DAC control board the microprocessor chip in the DAC control reads the signal the DAC control energizes the indicated relays to turn lights and
80. ponents including the top panel are fully assembled measure for radiation leakage around the door periphery and the door viewing window 6 Record keeping and notification after Page 7 measurement Take a leakage reaching after any adjustment or repair to a microwave oven Record this leakage on the repair ticket even if itis zero A copy of this repair ticket and the microwave oven leakage reacting should be kept by the repair facility If the radiation leakage is more than after determining that all parts are in good condition and functioning properly and that genuine replacement parts as listed in this manual have been used immediately notify Thermador and inform the owner that the microwave cannot be used At least once a year have the radiation monitor calibrated by its manufacturer CJ Oven Service Manual Lit No 94 30 007A THERMADOR WARRANTY Length of Warranty Thermador will pay for Thermador will not pay for FULL ONE YEAR All repair labor and replacement 1 Serviceby an unauthorized For one year from date of instal parts found to be defective due to agency Damage repairs lation or date of occupancy for a materials and workmanship Ser by an unauthorized BB new previously unoccupied vice must be provided by a Fac or use of unauthorized dwelling Save all dated receipts tory Authorized Service Agency parts or other evidence of date of in during normal working hours E
81. r 2 screws 6 Remove the stirrer motor cover 4 screws 7 Remove the stirrer blade assembly Stirrer Motor Wires _ In line Connector Terminal Block 8 Remove the stirrer shield 4 screws 9 Remove the 28 mounting screws that at tach the stirrer motor assembly to the can lift the stirrer motor assembly out of the stirrer motor cavity 10 Reassemble and be sure to use all the new mounting screws provided in the kit 28 Screws Fw Uk Y 1 bo 7 44 L q Ax Stirrer Motor 2 Screws Fische Paper 4 Screws Cover Stirrer Motor Page 15 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE MAGNETRON FAN ASSEMBLY WH 124 BU 25 4 WARNING Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turnoffthe electrical power going to the oven Bracket Screws 2 Pulltheovenoutofits mounting location so that you can access the trim and l En 5 Remove the two fan assembly bracket 3 Remove the trim and top plenum covers screws from the plenum and remove the from the oven see Page 10 assembly 4 Disconnect the wires from the terminals 6 Remove the two duct screws and slide it of the magnetron fan assembly off the fan assembly
82. re in doubt as to which glass is heat treated use an ohmmeter to check it To do this set the ohmmeter to the R X 1 scale and touch the test probes to the glass If the glass is heat treated the meter will indicate a short 0 If the meter does not indicate a read ing infinity the glass is untreated Removing the Upper Oven Door Gasket 1 Remove four 2 air vent grille screws 2 Remove two 2 oven door latch screws 3 Remove air vent grille and remove door gasket from grille 4 Reverse removal order to reassemble Upper Air Vent Grill Screws Oven Door Latch Screws Note This gasket is designed to divert heat smoke and grease away from the control panel Page 43 CJ Oven Service Manual Lit No 94 30 007A TROUBLESHOOTING TESTING THE COMPONENTS Resistance Measurements 44 WARNING TO AVOID ELECTRICAL SHOCK DISCONNECT THE POWER TO THE APPLIANCE BEFORE TESTING Refer to Page 12 to access the 20A time delay 20A TIME DELAY FUSE fuse To test the 20A time delay fuse perform the following steps 1 Turn off the electrical power to the oven Touch Metal Caps 2 Setthe ohmmeter to the R x 1 scale 3 Touch the test leads to the metal end caps of the fuse If the fuse is good the meter should indicate a short circuit 0 If the fuse is open the meter will indicate an open circuit infinite resistance 20A Time Delay Fuse Page 44 Lit No 94 30 007A LIGHT TRANSFORMER THE
83. rminal of the new convection fan mo tor and the white wire 44 to the left ter minal then install the motor assembly Reassemble the oven CJ Oven Service Manual Lit No 94 30 007A Oven Liner Brown Wire 45 Fan Motor Bracket with Insulation 9 6 CN Fan Motor I Screws e E Ring Flat Washer e H Hex Nut Left Rotating Thread A amp Top Screw 1 x Top Screw Convection Baffle 43 43 mE Bottom Screws nn gt Page 95 CJ Oven Service Manual Lit No 94 30 007A REMOVING HALOGEN LAMP HOLDER 44 WARNING Turn off the electrical power circuit to the Halogen oven at the main junction box before ser PS vicing this unit 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful Refer to illustration right for the following steps Lamp Cover u 1 Turn off the electrical power to the oven 2 Remove the oven racks 3 Remove the oven rack support for the halogen lamp holder you are removing CAUTION Make sure that the halogen bulb is cool before you remove it in the next step 4 Pull the lamp cover out of the halogen lamp holder and remove the bulb 5 Pry the lamp holder out of the oven liner and cut the wires approximately 2 from the lamp holder body CAUTION Be
84. rns in either direction Page 67 CJ Oven Service Manual Lit No 94 30 007A CJ CONTROLS III IL EEE man ans ER DE DE HE EN U gt SC y Page 68 Lit No 94 30 007A CJ Oven Service Manual RELAY BOARD MATRIX Ko __ UpperOvenLatchMotor __ __ ___ LowerOvenlatchMotor _ __ 2 None S __ Nome KA Upper Oven Cooling Motor K5 Lower Oven Cooling Motor ___ 6 ____ Upper Oven HalogenLamp ______ K12 Lower Oven Bake Element Lower Oven Broil Element Lower Oven Convection Element Lower Oven Convection Motor Page 69 Lit No 94 30 007A CJ Oven Service Manual J0 0W 2 1030UJ 21 2 V A 021 SJoJsueJ J0 0W 1 M07 10 0UJ 21 2 V A OZ SJoJsueJ yy Aejoy 1010 UOI 99AUOO 1907 21 2 V A OZ SJoJsueJ VSL ejau 10101 9AeMOJOI A Ue doi ueuioJo qnL 1 mojg lef oyeq UOI 29AUu09 USAC 1 M07 USAC JOMOT 21 1 VA 8710 V OZ Ssiajsuen 02 S aysuen 00 5 5 OZ 519 5 VLIM Aejay gt Ly ejou uonounJ ejaH
85. s product should be serviced only by trained qualified personnel Although this product has been manufactured in compliance with FDA Radiation Perfor mance Standards 21 CFR Subchapter J itis very important that all repairs should be made in accordance with procedures described in this manual to avoid being exposed to excessive microwave radiation Check for radiation leakage before and after every servicing Refer to Measuring For Microwave Radiation Leakage on Page 6 Certain components used in the microwave oven are important for safety It is essential to replace these critical parts only with manufacturer s specified parts to prevent microwave leakage shock fire or other hazards Do not modify the original design Page 3 CJ Oven Service Manual Lit No 94 30 007A CAUTIONS TO OBSERVE WHEN TROUBLESHOOTING Unlike many other appliances the microwave oven is high voltage high current equipment Although it is free from danger in ordinary use extreme care should be taken during repair 44 CAUTION Remove your wristwatch when working close to or when replacing the magnetron 1 Check the grounding The microwave oven is designed to be used when grounded Make sure it is grounded properly before beginning repair work 2 Discharge the electric charge in the high voltage capacitor For about 30 seconds after the oven stops an electric charge remains in the high voltage capacitor When replacing or checking parts sh
86. scratching the finish Page 24 c Disconnect the cables from the touch panel glass filter board connectors d Remove the nine indicated screws from the control panel plate and lift the plate off the control panel 4 Top Control Panel Plate Screws 5 Bottom Control Panel Plate Screws e Lift the display board off the control panel Display Board Touch Panel Glass f Remove the screws from the mounting brackets and remove the brackets from the display board Bracket Screws Po tm Ej BBBLS gt an Te Mi ig mide 2 o B a x d aller ANI MET 9 ENS ud mo acm TOP UEM Bu ES vanis Y za s 1 Bav Tar TE rae 3 Dd E mum i EL B gt i i zu 2 er Bracket Screws g Lift the touch panel glass with filter boards out of the control panel frame Lit No 94 30 007A CJ Oven Service Manual REMOVING THE UPPER OVEN DOOR SWITCH 44 WARNING 5 Turn off the electrical power going to the oven before servicing 44 CAUTION When you work on the oven be careful when handling the sheet metal parts There are sharp edges present and you can cut yourself if you are not careful 1 Turn off the electrical power going to the oven Open the microwave oven door 3 Remove the four outer black screws from the bottom of the control panel assembly see Step 3a Page 23
87. signal does not return to the board The board will then flash an error code Simply stated the board sends out a signal and the signal must return to the board Page 72 Lit No 94 30 007A CJ Oven Service Manual Digital DAC appliance control ontinued The following switches receive signal voltage from the DAC control board and return the signal voltage to the DAC control board Both door switches closing the oven door closes these switches The completed circuit signals the DAC control that the door is closed and the oven is ready to self clean or microwave Latch lock unlock switches as the latch motor rotates the cam opens or closes these switches The completed circuit signals the DAC control that the door is locked and the oven is ready to self clean or microwave Air switches air movement from the cooling motor closes the air switch and completes the circuit The completed circuit signals the DAC control that the cooling motor is working and it is ready to go into the selected mode DAC control relays output pins The DAC control has 14 relays KO K15 and 7 output pin CONNECTORS P2 P3 P5 P6 P9 P14 P15 The 7 relay coils are snapped shut and transfer current to specified components The 7 output pins output signal voltage or low voltage to specified components The DAC control receives 120 V A C and transforms and rectifies these 120 V A C internally as follows 120 V A C is stepped down to 24 V A C sign
88. sket into the liner hole Fully insert one end at a time Check around the door for microwave radiation leakage Page 36 Lit No 94 30 007A CJ Oven Service Manual REMOVING and REINSTALLING the UPPER MICROWAVE OVEN DOOR REMOVING THE OVEN DOOR 4 Fully open the oven door CAUTION Be careful handling the oven door when removing it as it is very heavy Never lift the door by the handle 1 Pull the oven out of its mounting location so that you can access the left and right hinge pocket covers see the following photo 2 Remove the screws from the left and right hinge pocket covers and remove the cov ers 5 Raise the U clip over the hook on each of the hinges to lock them This will prevent the hinge from snapping closed when the door is removed Hook 3 Remove the locking screw from each of the hinges Locking Screw Page 37 CJ Oven Service Manual Lit No 94 30 007A 6 Grasp the oven door by the sides near the REINSTALLING THE OVEN DOOR top and carefully close it until the hook 1 in the hinge contacts the hinge support approximately 3 4 of the way You will feel some spring resistance while you do this which is normal Hold the oven door by the sides approxi mately 2 3 of the way down and insert the hinges into the oven slots near the top as far as possible 7 Gently lean against the top of the door to Insert Hinge Into hold it in position and grasp the door Slot Near
89. t No 94 30 007A DOOR SWITCH Terminals P Refer to Page 24 to access the door switch To test the switch perform the following steps 1 2 3 Turn off the electrical power to the oven Set the ohmmeter to the R x 1 scale Disconnect one of the wires from the door switch Touch the test leads to the normally open switch terminals The meter should indi cate an open circuit infinite resistance Press the switch button to close the con tacts The meter should indicate a short circuit 0 Q CJ Oven Service Manual OVEN THERMAL SENSOR Refer to Page 35 to access the oven thermal sensor To test the sensor perform the follow ing steps 1 Turn off the electrical power to the oven 2 Setthe ohmmeter to the R x 1 scale 3 Touch the test leads to the in line splice Page 51 connections inside the oven with the sen sor removed or at connector P3 on the electronic oven control board The meter should indicate approximately 1050 Q at room temperature CJ Oven Service Manual LOWER OVEN BROIL ELEMENT Terminals Refer to Page 79 to access the broil element To test the element perform the following steps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to the R x 1 scale 3 Disconnect one of the wires from the broil element 4 Touch the test leads to the broil element terminals The meter should indicate be tween 13 Q and 20 Q LOWER OVEN CONV
90. the hex nut on the jack place the nut inside the spring cover and close the cover Thread the nut onto the jack as far as pos sible by turning the cover and then tighten it firmly using the socket 7 Pullthe meat probe jack and flat washer out of the cutout and disconnect the two wires from the terminals Page 33 CJ Oven Service Manual Lit No 94 30 007A REMOVING THE JET PLATE ELEMENT NOTE The Jet Plate Element is concealed un 4 WARNING der the base of the Upper Oven Module Turn off the electrical power going to the replace this part you willneed to pulltheoven oven before servicing out of the wall and remove the element from the right side of the oven This element is used AUTI in cooking and self clean modes When you work on the oven be careful Refer to illustration below for the following steps when handling the sheet metal parts There to remove the Jet Plate Element are sharp edges present and you can cut 1 Remove the back panel of oven yourself if you are not careful 2 Remove the right side trim 3 Remove the right door hinge pocket 4 Remove the right side cover 5 Cut away the insulation carefully to ex pose the side cover You will need to re use this insulation 6 Remove the concealed element cover 7 Pull out the concealed DI Lc x La E element Pi JL Right side cover Right Door Hinge Pocket Insulation
91. the lock switch signals the board to proceed into microwave mode see illustration below DAC Control Board 5 4 3 2 1 Door latched Door Switch Lock Switch gt Lock switch closed Unlock Switch N O Unlock switch open Page 63 CJ Oven Service Manual Lit No 94 30 007A Air Switches The air switches are used to complete the 24 V A C signal voltage circuit from the DAC control through the air switches and back to the DAC control board The 2 air switches are mounted in the rear of the oven These 2 air switches have paddles that are in the path of the airflow from the cooling motors Air movement from the cooling motors closes the air switches and completes the circuit The completed circuit signals the board that the cooling motors are working and the board allows the oven to proceed into the selected mode If the oven cooling motors do not run do not close the air switches do not complete the signal voltage circuit back to the DAC control within 40 seconds an F34 or F64 error code will appear and the oven will not go into the selected mode see illustration Air switch through the diverter Air switch with paddle Air switch Circuit L O Meat Probe il Air Switch Air Switch ENE Page 64 Lit No 94 30 007A CJ Oven Service Manual 20 AMPERE FUSE The Microwave Oven is protected from interlock switch failure by 20 ampere Fuse A
92. the oven To make servicing easier remove the oven Turn off the electrical power circuit to the door see Page 94 oven at the main junction box before ser 3 Remove the oven from the wall vicing this unit 4 Remove the components from the oven A C AUTI O N shown in illustration below Refer to the sections in this manual for the procedures When you work on the oven be careful on removing the components when handling the sheet metal parts There E are sharp edges present and you can cut yourself if you are not careful With all of the oven components removed remove the six screws three on each side from the front sides of the oven can 6 Pulltheoven can forward and remove it c Convection Mtg g Bracket Cover Convection Element z Oven Can Screws 3 on each side Counter Support Bracket L amp R Counter Support Hinge Convection Motor Assembly Convection Baffle Oven Module Kit Hidden Bake Element P Mea Meat Probe Receptacle s o Meat Probe Hidden Element Meat Probe aco are Receptacle Cover Hole Plug Page 107 CJ Oven Service Manual Lit No 94 30 007A TROUBLESHOOTING TESTING THE COMPONENTS 44 WARNING TO AVOID ELECTRICAL SHOCK e DISCONNECT THE POWER TO THE APPLIANCE BEFORE SERVICING e FOR THOSE CHECKS REQUIRING THE USE OF ELECTRICAL POWER EXERCISE EXTREME CARE e DO NOT PERFORM HIGH VOLTAGE TESTS THE BLOWER MOTOR Refer t
93. tor perform the following steps 1 the electrical power to the oven 2 Set the ohmmeter to the R x 1 scale 3 Disconnect the stirrer motor wire going to the terminal block 4 Touch the test leads to the motor connec tors The meter should indicate approxi mately 1 5 Q Tech Tip The stirrer motor turns in either direction Lit No 94 30 007A HIGH VOLTAGE DIODE Cathode 3 Anode Diode Symbol CAUTION DISCHARGETHE HIGH VOLT AGE CAPACITOR BEFORE TESTING THE DIODE REFER TO PAGE17 FOR THE PRO CEDURE Refer to Page to access the high voltage diode To test the high voltage diode perform the following steps 1 Turn off the electrical power to the oven 2 Set the ohmmeter to the 1 scale 3 Disconnect the wires from the diode IMPORTANT Use the above photo for the proper terminal polarity connections Disre gard any other polarity markings on the diode body 4 Touch the negative meter lead to the cathode terminal and the positive lead to the anode terminal The meter should indicate continuity current flow 5 Switch the test leads and the meter should indicate a very high resistance Page 46 Lit No 94 30 007A HIGH VOLTAGE CAPACITOR Terminals CAUTION DISCHARGETHE HIGH VOLT AGE CAPACITOR BEFORE TESTING IT REFERTOPAGE17FORTHEPROCEDURE Refer to Page 17 to access the high voltage capacitor To test th
94. tors cooling motors tube fan microwave transformer cooling fan stirrer motor lower oven latch motor The following parts require 24 volts D C to function relays KO through K15 on DAC control relay K1 on microwave board both double line break relays The following require 12 volts A C to function halogen lights p3 pin on microwave board The following part requires 12 volts D C rectified to function upper oven latch motor for faster door closure Page 74 Lit No 94 30 007A CJ Oven Service Manual RELAY BOARD Digital Appliance Controls There are 2 relay boards 1 for a single oven and 1 for a double oven You can use the double oven board for a single oven You must use a double oven board for a double oven The relay board has 14 snap relays activated by 24 volts d c 8 small pin headers that carry sienal voltage to components and 5 large pin headers that provide or transfer 120 volts ac to components Relays K0 through K15 Transfers 12 volts from transformer to microwave board K1 Transfers 120 volts from L2 to lower oven latch motor K2 None K3 None K4 Transfers 120volts from L2to both oven cooling motors K5 Transfers 120 volts from L2 to both oven cooling motors K6 Transfers current to complete 12 v a c Upper oven halogen light circuit K7 Transfers current to complete 12 v a c Lower oven halogen light circuit K8 Transfers 120 volts from L2 to upper oven Jet Blowers
95. ven door latch Blank Sends 120VAC to lower oven latch motor Blank Sends 120 VAC to microwave stirrer motor Not used Blank P1 large pin header has 8 pins and are identified as follows P1 1 P1 2 P1 3 P1 4 P1 5 P1 6 P1 7 P1 8 Receives current from center tap of halogen light transformer Sends current to lower oven halogen lights Receives current from center tap of halogen light transformer Sends current to uper oven halogen lights Blank Sends current to both cooling motors tube fan and microwave transformer cooling fan Blank Sends current to both cooling motors tube fan and microwave transformer cooling fan Page 77 CJ Oven Service Manual Lit No 94 30 007A DAC RELAY BOARD continued P7 large pin header has 4 pins and are identified as follows P7 1 P7 2 P7 3 P7 4 Blank Blank Current from L2 to K11 relay Current to upper oven convection motor P8 large pin header has 4 pins and are identified as follows P8 1 P8 2 P8 3 P8 4 Current from L2 to K15 relay Current to lower oven convection motor Blank Blank P18 large pin header has 6 pins and are identified as follows P18 1 Current from L1 to relay board transformer P18 2 Blank P18 3 Neutral from to relay board transformer P18 4 Not used P18 5 Blank P18 6 Chassis ground Page 78 Lit No 94 30 007A CJ Oven Service Manual Explanation of the Wire Harness Connector Housing eee Eee
96. wing steps 1 2 9 Turn off the electrical power to the oven Set the ohmmeter to the R x 1 scale Disconnect one of the orange wires from the element Touch the test leads to the convection element terminals The meter should indi cate 25 9 Page 53 CJ Oven Service Manual UPPER OVEN MULLION ELEMENT Refer to Page 9 to access the mullion element terminals To test the element perform the fol lowing steps 1 2 3 Turn off the electrical power to the oven Set the ohmmeter to the R x 1 scale Disconnect one of the blue wires from the element Touch the test leads to the element termi nals The meter should indicate between 44 3 Q CJ Oven Service Manual Lit No 94 30 007A LOWER OVEN MEAT PROBE JACK aam Om Refer to Page 33 to access the meat probe jack To test the jack perform the following steps 1 Set the ohmmeter to the R x 1 scale 2 Disconnect one of the wires from the meat probe jack 3 Touch the test leads to the meat probe jack terminals The meter should indicate an open circuit infinite resistance 4 Plug the meat probe into the jack The meter should indicate a short circuit 0 Q Page 54 Lit No 94 30 007A MICROWAVE PCB CONTROL Refer to Page 12 to access the microwave PCB control The control has a relay K1 two head ers Pl amp P3 and two 1 4 wire terminals P2 1 amp P2 2 These components perform the following functions Relay K

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