Vulcan-Hart HCB1, ML-52201, ML-052213, GHCB40, ML-052208 User Manual

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SERVICE MANUAL

HEAVY DUTY GAS BROILER

MODELS

 

GHCB40

ML-052211

GHCB44

ML-052213

GHMCB44

ML-052214

HCB1

ML-052202

HCB2(B)

ML-052208

IR1

ML-052200

IR2(B)

ML-052201

GHIR44

ML-052210

GHCB40 SHOWN

– NOTICE –

This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified.IfyouhaveattendedaVulcanServiceSchoolforthisproduct,youmaybequalifiedtoperformalltheprocedures described in this manual.

This manual is not intended to be all encompassing. If you have not attended a Vulcan Service School for this product, you should read, in its entirety, the repair procedure you wish to perform to determine if you have the necessary tools, instruments and skills required to perform the procedure. Procedures for which you do not have the necessary tools, instruments and skills should be performed by a trained Vulcan Service Technician.

Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.

For additional information on Vulcan-Hart Company or to locate an authorized parts and service provider in your area, visit our website at www.vulcanhart.com

VULCAN-HART COMPANY, P.O. BOX 696, LOUISVILLE, KY 40201-0696, TEL. (502) 778-2791

FORM 35608 (Aug. 2003)

TABLE OF CONTENTS

 

GENERAL ................................................................................................................................................................

4

Introduction .................................................................................................................................................

4

Installation and Operation ............................................................................................................................

4

Cleaning ......................................................................................................................................................

4

Lighting Pilot ...............................................................................................................................................

4

Data Plate Location .....................................................................................................................................

4

GHCB40 ...............................................................................................................................................

4

HCB1/2(B) ............................................................................................................................................

4

GHIR44 .................................................................................................................................................

4

IR1/2(B) ................................................................................................................................................

4

Specifications .............................................................................................................................................

4

Gas Data ..............................................................................................................................................

4

Tools ...........................................................................................................................................................

4

Standard ...............................................................................................................................................

4

IMPORTANT ............................................................................................................................................................

5

REMOVAL AND REPLACEMENT OF PARTS ..........................................................................................................

6

Covers, Panels and Handles .......................................................................................................................

6

Burner Box Cover (GHCB40, GHCB44, GHIR44) ..................................................................................

6

Burner Shield Cover [HCB2(B), IR1, IR2(B)] .........................................................................................

6

Manifold Cover Assembly (GHCB40 & GHIR44) ...................................................................................

7

Burner Knob Cover Plate [HCB2(B), IR1 and IR2(B)] ............................................................................

7

Control Panel Cover (GHCB40) .............................................................................................................

8

Lower Front Panel (GHCB40) ................................................................................................................

8

Oven Burner Cover (GHCB40) ..............................................................................................................

8

Oven Bottom Assembly (GHCB40) ......................................................................................................

9

Augratin Oven Bottom Assembly (GHCB40) .......................................................................................

10

Oven Door Handle (GHCB40) ..............................................................................................................

10

Broiler Grid Tray (All Models) .....................................................................................................................

11

Grid Carriage Assembly (All Models) .........................................................................................................

11

Burner Ceramics (GHCB40) .....................................................................................................................

12

Burner Assembly ......................................................................................................................................

13

GHCB40 & HCB2(B) ...........................................................................................................................

13

GHIR44 ...............................................................................................................................................

13

Heat Shield (GHIR44) ................................................................................................................................

14

Pilot Elbow Nozzle ....................................................................................................................................

14

Sub-Manifold Assembly ............................................................................................................................

14

GHCB40 .............................................................................................................................................

14

GHIR44 ...............................................................................................................................................

15

Burner Sub-Manifold (GHIR44) .................................................................................................................

15

Pilot Manifold (GHIR44) .............................................................................................................................

16

Oven Burner Assembly (GHCB40) ............................................................................................................

17

Pilot Burner Nozzles (GHIR44) .................................................................................................................

17

– 2 –

Gas Valves, Tubing, Thermostats, Regulators and Solenoids ....................................................................

18

Burner Manifold Assembly (GHCB40) .................................................................................................

18

Burner Manifold Assembly (GHIR44) ..................................................................................................

19

Oven Pilot Valve (GHCB40) ..............................................................................................................

19

Oven Burner Valve (GHCB40) ............................................................................................................

19

Pilot Outage Protection Valve (GHCB40) ...........................................................................................

20

Thermostat (GHCB40) .......................................................................................................................

21

Oven Burner Nozzle (GHCB40) ..........................................................................................................

22

Burner Valve [(IR2(B) and HCB2(B)] ....................................................................................................

22

Burner Valve (GHIR44) ........................................................................................................................

23

Regulator (GHIR44) .............................................................................................................................

23

Regulator [HCB2(B)] ...........................................................................................................................

24

Solenoid (GHIR44) ..............................................................................................................................

24

Lever Arm Assembly (All Models) .............................................................................................................

25

Upper ..................................................................................................................................................

25

Lower ..................................................................................................................................................

25

Blower and Motor ......................................................................................................................................

26

GHIR44 ...............................................................................................................................................

26

IR1 and IR2(B) ....................................................................................................................................

27

Blower Switch (GHIR44) .....................................................................................................................

27

Light (GHIR44) ....................................................................................................................................

28

SERVICE PROCEDURES AND ADJUSTMENTS ..................................................................................................

28

Gas Supply Checks ..................................................................................................................................

28

Regulator Adjustment (All Models) ............................................................................................................

28

Pilot Adjustment (All Models) ....................................................................................................................

29

Burner Venturi Air Shutter Adjustment [GHCB40 and HCB2(B)] .................................................................

29

Burner Service (All Models) .......................................................................................................................

30

Burner Orifice Service (All Models) ...........................................................................................................

30

TROUBLESHOOTING ............................................................................................................................................

31

– 3 –

GENERAL

INTRODUCTION

This service manual was specially written for the Heavy Duty Gas Broilers.

INSTALLATION AND OPERATION

Detailed installation and operation instructions are included in the Installation and Operation Manual which is sent with each Broiler.

CLEANING

Detailed cleaning instructions are included in the Installation and Operation Manual for the appropriate model.

LIGHTING PILOT

Detailed lighting pilot instruction are included in the Installation and Operation Manual for the appropriate model.

DATA PLATE LOCATION

GHCB40

Behind the oven kick panel riveted to left corner of the oven burner box. (Removal of the kick panel is necessary to access plate.)

HCB1/2(B)

Riveted to front right-hand corner of the lower shelf.

GHIR44

Riveted to the door liner behind the left hand door panel.

IR1/2(B)

Riveted to lower cabinet bottom shelf.

SPECIFICATIONS

Gas Data

 

Dimensions

No. of

Total

Model

 

 

 

Burners

BTU

Width

Depth

Height

per

/hr

 

 

Section

 

 

 

 

 

 

 

GHCB40

34”

391/8

79”

4

100,000

GHCB44

34”

391/8

79”

4

100,000

GHMCB44

34”

391/8

57”

4

100,000

HCB1

36”

383/8

68”

4

50,000

HCB2(B)

36”

383/8

801/2

4

100,000

IR1

36”

383/8

69”

4

80,000

IR2(B)

36”

383/8

801/2

4

160,000

GHIR44

34”

381/4

82”

4

80,000

TOOLS

Standard

Hand tools (standard set)

Volt-Ohmmeter (VOM) with AC current tester (any quality VOM with a sensitivity of at least 20,000 ohms per volt can be used).

Gas test kit

Temperature tester (thermocouple or digital pyrometer)

Temperature tester (thermocouple type).

Manometer

– 4 –

IMPORTANT

STOP BOLTS MUST BE IN POSITION FOR SAFE OPERATION OF GRID. IF DAMAGED OR MISSING, REPLACE AT ONCE. DO NOT OPERATE GRID WITHOUT BOLTS.

Two (2) broiler grid 1/4-20 stop bolts and nuts are supplied with each broiler grid to ensure that the grid is not accidentally pulled completely from the broil section while hot. One (1) stop bolt and nut are mounted to the grid carriage RT. and LT. HD. side member through a 0.281 diameter hole directly in front of the grid stop tab. The stop nuts and bolts are screwed tightly against the side members and are properly adjusted extending approximately 1/2” below the stop tab as shown in the above photo.

– 5 –

REMOVAL AND REPLACEMENT OF PARTS

COVERS, PANELS AND HANDLES

Burner Box Cover (GHCB40, GHCB44,

GHIR44)

WARNING: SHUT OFF THE GAS BEFORE SERVICING.

5.Lift and remove the burner box cover from the broiler.

6.Reverse the procedure to install.

Burner Shield Cover [HCB2(B), IR1,

IR2(B)]

WARNING: SHUT OFF THE GAS BEFORE SERVICING.

NOTE: The models HCB2(B) and IR2(B) have two burner shield covers.

1.Open the augratin oven door.

2.Remove the oven rack.

1.Remove the two screws from the burner shield cover and the broiler.

2.Lift and remove the burner shield cover from the broiler.

3.Reverse the procedure to install.

3.Remove the four screws and bushings from the oven.

4.Remove the augratin oven bottom assembly as outlined in Augratin Oven Bottom Assembly.

– 6 –

Manifold Cover Assembly

(GHCB40 & GHIR44)

WARNING: SHUT OFF THE GAS BEFORE SERVICING.

1.Remove the grease tray from the broiler (GHCB40 only).

NOTE: The GHIR44 manifold cover assembly has a chain to protect switch wiring.

2.Loosen the mounting screw in each burner knob.

3.Remove the two burner knobs from the broiler.

4.Remove the two screws from the manifold cover assembly.

5.Remove the manifold cover assembly from the broiler.

6.Reverse the procedure to install.

Burner Knob Cover Plate [

HCB2(B), IR1 and IR2(B)]

WARNING: SHUT OFF THE GAS BEFORE SERVICING.

1.Loosen the mounting screw in each burner knob.

2.Remove the burner knob.

3.Remove two screws from the burner knob cover plate and the broiler.

4.Slide the burner knob cover plate out and remove it from the broiler.

5.Reverse the procedure to install.

– 7 –

Control Panel Cover (GHCB40)

1.Remove the manifold cover assembly as outlined in Manifold Cover Assembly.

2.Loosen the retaining screw and remove the burner knob from the broiler.

3.Pull the thermostat knob to remove it from the broiler.

4.Remove the bolt and the control panel cover from the broiler.

5.Reverse the procedure to install.

Lower Front Panel (GHCB40)

1.Grasp the bottom of the lower front panel.

2.Pull the lower front panel out to remove it from the broiler.

3.Reverse the procedure to install.

Oven Burner Cover (GHCB40)

1.Remove the lower front panel as outlined in Covers, Panels and Handles.

2.Remove the screw from the oven burner cover.

3.Remove the oven burner cover from the broiler.

4.Reverse the procedure to install.

– 8 –

Vulcan-Hart HCB1, ML-52201, ML-052213, GHCB40, ML-052208 User Manual

Oven Bottom Assembly (GHCB40)

WARNING: SHUT OFF THE GAS BEFORE SERVICING.

WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

1.Remove the lower front panel as outlined in Covers, Panels and Handles.

2.Open oven door.

3.Remove rack if necessary.

4.Remove the two screws and brass bushings from the broiler.

5.Loosen the two bolts on the retainer brackets.

6.Remove the oven bottom assembly from the broiler.

7.Remove the oven bottom baffle from the broiler.

8. Remove the oven insulation sheet.

9.Remove the oven bottom tray.

10.Reverse the procedure to install.

– 9 –

Augratin Oven Bottom Assembly (GHCB40)

WARNING: ALL GAS JOINTS DISTURED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME.

1.Remove the four screws and brass bushings from the broiler.

2.Slide the augratin oven bottom assembly from the broiler.

3.Remove the augratin oven bottom baffle from the broiler.

4.Reverse the procedure to install.

NOTE: When installing bottom assembly, angle metal should be at the rear of the oven.

Oven Door Handle (GHCB40)

1. Remove the caps from the oven door.

– 10 –

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