Bosch Evolution 300 Series, Service Manual

Page 1: ...life or physical condition may arise BSH Home Appliances Corporation is not liable for damages caused by improper repairs performed by unauthorized parties Local codes and standards apply and must be observed Contact the Technical Support Team for further assistance SERVICE MANUAL for Bosch YROXWLRQ DQG Series Free standing Gas Ranges Models HGS3023UC HGS3053UC HGS3063UC and HGS5053UC 583000001460...

Page 2: ...ces 2 5 Cooktop Removal 2 7 Surface Burner Igniters 2 8 Surface Burner ontrol Valves 2 11 urface Igniter Spark Module 2 12 Oven Bake Burner 2 14 Bake Burner Igniter 2 14 Bake Burner Orifice 2 15 Oven Broil Burner 2 16 Broil Burner Igniter 2 17 Pressure Regulator 2 18 Surface Burner Flame Adjustment 2 19 Oven Burner Flame Adjustment 2 20 Conversion from Natural Gas to LP Gas 2 24 Oven ontrol Module ...

Page 3: ...ounds prior to completion of service Failure to do so will create a hazard 6 Prior to returning the product to service ensure that All electrical connections are correct and secure All electrical leads are properly dressed and secured away from sharp edges high temperature components and moving parts All non insulated electrical terminals connectors heaters etc are adequately spaced away from all ...

Page 4: ...rior oven light and a removeable storage drawer 500 Series HGS5053UC 500 series gas ranges feature an oval center surface burner while 300 series ranges have a round center surface burner The oven functions are controlled by the ES337 lectronic ven control module Current finish options available are hite lack and lack with tainless teel All 300 and 500 series gas ranges operate on 120 volt 60 hz AC...

Page 5: ... features listed for the 300 series range except for Oven Lockout In place ot the Lock keypad found on the 300 series ranges the Convection keypad is found on these models SHULHV PRGHOV ZLWK FRQYHFWLRQ EDNH Both lectronic ven control styles also feature silent control panel option temperature conversion between C Celsius or F Farenheit and user adjustable temperature calibration More detail on how...

Page 6: ...t of the data tags used on the following FSRs has changed since the beginning of production for the following models HGS3023UC Product designator H Range Fuel Type designator E Electric G Natural Gas D Dual Fuel Model Type designator S Solo Freestanding Color Designator 2 White 5 Stainless Steel 6 Black Counter Designator For visible model changes Series designator 30 300 50 500 80 800 H G S 5 0 5...

Page 7: ...ing of each surface burner location 300 Series Cooktop 500 Series Cooktop 500 Series gas ranges are equipped with five sealed type surface burners with electronic spark ignition Surface burner sizes on the 500 series are 12 000 9500 2 5000 16 000 BTU The center burner of the 500 series range is an elongated oval burner ideal for using griddles or other oblong cookware The illustration at right show...

Page 8: ...wn in the illustration at right If the knob is rotated beyond the LITE position no spark is generated and the burner will not ignite0 however gas will continue to flow to the surface burner Whenever any surface burner control knob is rotated to the LITE position the spark module will generate a spark at all surface burners simultaneously even if other burners have already been lighted Activation of...

Page 9: ...ping excessive noise or lifting away from the burner head Photo B at right illustrates a typical flame at high setting Yellow flames indicate improper fuel to air ratio and can be caused by improper gas pressure improper conversion for use with LP gas or contaminated fuel supply 6XUIDFH XUQHU ODPH GMXVWPHQW Photo 2 B ...

Page 10: ...rammed to bake at any temperature from 170 F to 550 F 77 C to 287 C When broiling the oven control has two selectable preset ranges HI and LO When broiling on the HI setting the maximum oven temperature is 550 F When broiling on the LO setting the maximum oven temperature is 350 F In self clean mode the oven target temperature average is 825 F The actual oven temperatures will fluctuate between 81...

Page 11: ...t six minutes of preheat in order to allow proper venting of oven exhaust gases After the oven has heated for six minutes and the fan has begun to operate it will remain on during the entire convection bake cycle unless the oven door is opened When the door is closed the fan will resume running Calibrating Oven Temperature Offsets Oven performance can be customized to suit the preferences of the i...

Page 12: ...ven sensor to the control This mode may be useful when using a thermometer to test oven temperature since it will allow the technician to monitor the temperature recorded by the thermometer and compare it to the temperature reported by the sensor probe To enter ervice ode unplug or turn off the power to the range While holding the C1 67 keypad down restore power to the range The control will now s...

Page 13: ... increase in oven temperature If the wires or harness connections between the control and the sensor are loose or otherwise defective the resistance detected by the control may be much higher than the actual sensor resistance In some cases this can cause a false error message to be displayed on the control such as F10 or F30 Before assuming that a sensor is defective test the sensor resistance thr...

Page 14: ...ed and burner caps in place Photo C Photo A Photo B Photo D To remove and replace any of the burners first lift off the burner caps as seen in photo B Using a 3 16 nut driver turn the screws counter clockwise to remove as shown in photo C The burner can then be lifted away from the cooktop providing access to the mounting screws for the rifice older ssembly igniter tip and burner orifice as seen in p...

Page 15: ...burner has a decorative cap that can be removed but is not a serviceable item The cap and burner are replaced as an assembly Photo A Photo B The oval burner can be lifted off to access the orifice holder and orifice without removing any screws Once the burner is removed the orifice holder and igniter tip are visible The orifice can be service through the hole in the orifice holder assembly hoto B ...

Page 16: ...ate on the burner can be removed by taking out the two screws seen in photo D from the underside of the burner With the top plate sep rated from the burner the interior of the burner and plate are accessible for cleaning in the event they should become clogged from boil overs or other types of food spills hoto E Photo E ...

Page 17: ...the orifice removed the size stamp is visible The size stamp can be used to determine if the proper orifice size is being used for a specific burner Orifice Size Stamp Retaining Ring The following chart can be used as a guide to identify the proper orifices for the various burner sizes and styles that are currently used on the 300 and 500 series ranges Future models may change so you should always refe...

Page 18: ...dicate the screw locations for the left front orifice holder assembly Remove all screws at all burner locations before attempting to remove the cooktop After the screws are removed insert a putty knife or similar tool between the bottom edge of the cooktop and the manifold panel shown in photo B Push in on the putty knife to release the lock clip that holds the cooktop down The corner of the cookto...

Page 19: ... the cooktop forward to disengage the rear edge from the tab of the chassis support bracket and lift it away from the range Chassis Support Bracket Tab Right Side Photo A Photo B When reinstalling the cooktop engage the rear edge under the chassis support bracket tabs seen in photo B then press the front edge down to engage the front locking clips ...

Page 20: ...e cooktop disconnect the gas line the surface burner control valve to the orifice holder assembly being replaced by first disconnecting the wire from the spark module to the igniter The wire terminal is a locking type terminal as seen in photo D To disconnect the wire ILUVW GHSUHVV WKH ORFNLQJ WDE then pull the wire off the spade terminal on the igniter Note Failure to depress the locking tab before...

Page 21: ...t remove the LP orifice from the original assembly and install it into the replacement orifice holder Surface Burner ontrol Valves To replace a surface burner control valve remove the surface burners and cooktop as described in the previous sections Disconnect the orifice holder assembly from the valve being replaced Remove the surface burner control valve knobs by pulling the knob forward off the va...

Page 22: ...ons Igniter Switches From the top side of the manifold panel remove the screws which secure the two cooktop lock clips and remove the clips photo E The manifold panel can now be removed by pulling forward With the panel removed the surface burner igniter switches are accessible photo F The switches are connected together in a harness and must be replaced as a complete assembly ...

Page 23: ... downward away from the underside of the pipe hoto C Washer Photo D The switches slide over the burner valve shaft and are secured by sockets on the back side of the switch that snap onto studs on the front side of the valve Pull forward to unsnap the switch housing from the valve hoto A When replacing the switches make sure that the switches snap securely and lock to the studs in the valve body T...

Page 24: ...he two screws that fasten the bracket to the left hand body side then roll the bracket and spark module over hoto F Photo F The spark module can also be accessed without removing the bracket by depressing the locking tabs that hold it onto the bracket When reinstalling the module that the red wire is connected to terminal L and the white neutral wire is connected to terminal N on the module The gr...

Page 25: ...tom up about 3 inches and slide it toward the rear oven wall hoto B the oven bottom to release from the front cross brace of the chassis The oven bott m can then be removed from the oven Photo B After removing the oven bottom remove the two screws that secure the flame spreader oven baffle to the chassis hoto C Lift the front edge of the baffle up slightly and pull forward to remove the baffle from th...

Page 26: ...nector remove the lower drawer Photo D Photo E Igniter Harness Connector Plug The igniter harness connector is located on the left side as seen in photo E Unplug the connector then lift the bake burner and igniter assembly out of the oven while guiding the connector plug and wire harness through the cut out Care should be taken to avoid damaging the bake igniter Follow this procedure for replacing...

Page 27: ...an be adjusted for LP gas by turning the orifice hood clockwise until it is snug RQYHUVLRQ IURP 1DWXUDO DV 1 WR LTXLILHG 3HWUROHXP 3 3 2YHQ DNH XUQHU 3 the two screws indicated in photo A Photo A Bake Burner Igniter Bake Burner Orifice Hood Gas Safety Valve Assembly Photo C A close up view of the bake burner igniter and harness can be seen in photo B 1RWH The replacement field service igniter may hav...

Page 28: ...take out the five screws slide the assembly to the left to disengage the burner tube from the orifice spud and pull it forward out of the oven 5 Photo D Orifice Hood Photo E Mounting Nut The broil burner tube is secured to the flame spreader by a threaded stud and nut by the arrow in photo E Remove the nut to separate the burner tube from the flame spreader for service or replacement of either part ...

Page 29: ...Photo C Photo B Remove the two screws indicated by the arrows in photo B Carefully pull the igniter and attached harness forward out of the oven cavity A close up view of the broil burner igniter and harness can be seen in photo C 1RWH The replacement field service igniter may have bare wire ends that must be connected by splicing into the original connector plug harness ...

Page 30: ... only hoto E When this lever is in the off position no gas is supplied to the bake or broil burner gas safety valves and these burners cannot light If the oven burners will not light but the igniters appear to be working check to see if this lever has been turned to the position When converting the range for use with LP gas or making other adjustments the pressure regulator can be accessed from th...

Page 31: ...into the hollow valve stem and engage the slotted screw inside hoto B A properly operating burner will have clean blue flames with no yellow tipping excessive noise or lifting away from the burner head Photo A illustrates a typical flame at high setting Yellow flames indicate improper fuel to air ratio and can be caused by improper gas pressure improper conversion for use with LP gas or contaminated ...

Page 32: ...lustratio 2 the flame is yellow in color increase air shutter opening size If the flame is a distinct blue but too short noisy or lifting away from the burner tube reduce the air shutter opening size 3 2 3 After all adjustments are complete reinstall the burner baffle and oven bottom URLO XUQHU Flame adjus ments for the broil burner are done from inside the oven require removal of any panels or compo...

Page 33: ...TING ALUMINUM REGULATOR If the regulator has an aluminum top as pictured in ig 3 convert the regulator in the following manner A Remove the regulator access cover if equipped Do not remove the Sressure Uegulator or allow it to turn B Unscrew the hex shaped cap and turn it over to access the conversion plug inside the cap ig A Do not remove the spring from the regulator C Rotate the plug 90 degrees...

Page 34: ... types of caps LP Gas Set Up Fig 7 Natural Gas Set Up Fig 6 LP Gas Set Up Fig 8 Natural Gas Set Up Fig 5 Dust Protector 219 57 1 S85 851 56 Photo B Photo C 6 Using a 3 16 nut driver turn the burner mounting screws counter clockwise to remove as shown photo B 2 The burner can then be lifted away from the cooktop providing access to the burner orifice as seen in photo C Use a 7mm nut driver to remove...

Page 35: ...1RWH RU RSHUDWLRQ DW HOHYDWLRQV DERYH IW DSSOLDQFH UDWLQJ VKDOO EH UHGXFHG DW WKH UDWH RI SHUFHQW IRU HDFK IW DERYH VHD OHYHO 6 T 67 1 685 851 56 72 9 5 LOW 6 77 1 0867 867 6 Push in and turn control to LITE until burner ignites 2 ush in and quickly turn knob to LOWEST POSITION f burner goes out reset control to OFF 9 Remove the surface burner control knob Insert a thin bladed screwdriver into the...

Page 36: ... adjusting air shutter To adjust loosen lock screw 3 reposition air shutter 2 and tighten lock screw 3 23 Retest the burner by repeating step 9 above When the burner flame is a distinct blue color burning steady the air shutter is adjusted correctly Replace burner baffle and oven bottom FigXUH 22 8 A 867 1 7 52 851 5 5 6 877 5 6 Observe the flame to determine if the broiler burner flame is properly ad...

Page 37: ...s of the connector and pulling away from the control hoto B Avoid excessive twisting or flexing of the connector plug to prevent damage to the harness or connector socket on the control module Take out the four mounting screws and remove the control module from the control panel 8 5 5 5 5 5 Convection Fan Motor and Blade Photo Some models feature a convection fan to circulate air throughout the ove...

Page 38: ... nut and blade from the motor shaft 5 remov the lower wire cover With the cover removed the fan motor connections can be accessed to check voltage or test continuity of the motor windings To replace the motor first remove the fan blade then take out the three motor mounting screws indicated by the red arrows in photo E Photo E Fan Motor Mounting Screws ...

Page 39: ... 2237 18 5 900 13 6 2697 24 4 1 at right shows the RTD scale found in the tech sheet that is provided with the range Use this scale to compare the resistance measurement to the known oven temperature If the resistance is within the tolerance levels listed then the sensor and connecting harness are not defective and need not be replaced If the resistance is significantly higher or lower than the RTD...

Page 40: ... to disengage the sensor bracket from the slot on the range back panel The sensor can now be pulled out of the oven chassis Oven Door Latch The oven door latch hook is operated by a latch motor that is mounted on the rear of the range chassis just above the oven light socket as seen in photo B above The latch motor has a connecting rod that travels beneath the cooktop below the orifice holder assem...

Page 41: ...hen the cam on the latch motor depresses the plunger on Microswitch Latch Motor Mounting Screws Photo A To latch motor assembly 5 remove the lower wire shield on the of the range Disconnect the wires to the latch motor and to 7 6 3 5 3 2 The entire assembly can now be removed from the range To reinstall tilt the latch motor assembly upward and guide the end of the rod into the motor cam Secure the...

Page 42: ...iced or replaced The door is not available as a complete assembly Open the door fully and pull both hinge locks down until they stop hotos 6 2 Photo 6 Photo 2 Photo C Gently close the door until it stops against the hinge locks at approximately a 45 degree angle hoto C Removing the Door ...

Page 43: ...he range hoto B reinstall the door reverse the previous steps Use your knee to stabilize and help guide the hinge arms into the receiver slots in the frame Once the door is secure in the frame open it fully and close the hinge locks back to their normal position Refer to the Use and Care Manual for additional information removing the oven door Reinstalling the Door ...

Page 44: ...l remain captive in the door assembly while the handle is lowered from below Photo 6 Remove the four screws located along the bottom edge of the door hoto 2 The porcelain door liner assembly with hinges and inner glass attached can now be lifted away from the outer door panel Photo 2 With the door liner assembly removed the outer door panel and outer glass are accessible hoto When replacing the ou...

Page 45: ... hinge assembly away from the liner assembly hoto To remove the wool shield take off both of the door hinges and the two side trims Remove the door spacers from the handle mounting screws by sliding them off the screws and remove the scews hoto 1RWH When reassembling the door make sure that the spacers are placed on the screws to keep them in place and provide proper spacing between the door liner...

Page 46: ...ted under the upturned edge of the porcelain door liner hoto DOOR LINER WOOL SHIELD Photo Remove the four pieces of insulation which surround the inner door glass and spacer photo I Carefully lift out the four pieces of insulation surrounding the window cut out Note When reinstalling the insulation take care to tuck the insulation under the screw brackets on the porcelain liner CAUTION Wear gloves...

Page 47: ...door glass panels and spacer as seen in hoto Photo Photo This leaves only the porcelain door liner with door gasket still attached hoto Note that the end of the gasket passes through two holes a the bottom of the liner Gasket Ends ...

Page 48: ...ed to the liner by metal spring clips that can be pulled out from the opposite side hoto 1 2 sure to re insert the loose ends of the gasket into the holes at the bottom of the door liner before reinstalling the inner door glass panes or insulation hoto ...

Page 49: ...or each ault code there is a listing of the likely failure condition or cause as well as suggested corrective actions to be taken Perform the steps one at a time LQ WKH RUGHU OLVWHG to correct the specific failure condition The tech sheet found on the back of each range provides detailed information for checking component circuits and wiring as well as a listing of the failure fault codes that may ...

Page 50: ...ensor Resistance chart If resistance does not match the RTD chart replace RTD ensor robe Check ensor wiring harness between control module ensor robe connector 2 F30 or F31 Check resistance at room temperature0 if less than 500 ohms replace RTD ensor robe Check for shorted ensor robe harness between control module robe connector F90 F91 F92 F93 F94 Maximum oven door unlock time exceeded Maximum ov...

Page 51: ...by intentionally holding down any control keypad for more than 30 seconds F11 can sometimes be displayed if the temperature sensor circuit develops a bleed or short to chassis ground of the range To check for this condition disconnect the harness connector at the control module that has the two purple wires Using an ohmmeter measure the resistance between each of these violet wires to a ground scr...

Page 52: ...e circuit is shorted zero resistance go to the oven temperature sensor and disconnect it from the range wiring harness connector Test the resistance of the sensor as described above If a normal resistance range of 1080 1110 ohms is present then the sensor is good and the failure is caused by a shorted wiring harness between the sensor and the control module F30 F90 F91 F92 F93 F94 displayed to ind...

Page 53: ... If proper amperage is detected but safety valve does not open replace safety valve If amperage is below 3 1 replace igniter If igniter does not glow test for 120 volts output from control module P5 harness connector pin 1 yellow wire to pin 5 white wire Verify that gas supply to range is turned on with proper pressure C that the service lever on gas regulator is not turned off Test continuity res...

Page 54: ...t for 120 volts output from control module P5 harness connector pin 6 rown ire pin 5 hite ire Surface Burner Igniters Do Not Spark Verify proper power supply to range Test for 120 volts at spark module L1 red wire N white wire when surface burner switch is in LITE position Test wiring harness connections between spark module and surface burner igniter switches ...

Page 55: ...L1 to Convection Fan L1 to Oven Light s Door Switch COM NO Bake Time Bake X X Convection Bake X X Broil X Clean X Oven Light s X Locking X Unlocking X Door Open X Door Closed X Gas Range Circuit Test Matrix ES337 The control module relay circuits can be tested by following the circuit test matrix Always verify the incoming power supply when performing diagnosis Rear View f ontrol odule P5 Harness ...

Page 56: ...e first If the component and wiring connections are good test the output voltage from the control module to the component part NOTE Resistance measurments are approximate Variations due to temperature changes and other factors are normal COMPONENT VOLTAGE RATING RESISTANCE Ω OHMS CONVECTION FAN MOTOR WINDINGS 108 232 15 Ω LOCK MOTOR WINDINGS 108 232 2000 Ω GAS SAFETY VALVE 1 5 Ω BAKE IGNITER 108 23...

Page 57: ...n Avenue Huntington Beach CA 5830000014 ARA EN A For additional assistance please contact the Bosch Technical Support Team 800 444 9091 Visit QuickFinder at http portal mch bshg com portal Service videos are available at www bsh digitaltoolbox com ...