Vulcan GHCB44 Service Manual
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. If you have attended a Vulcan Service School for this product, you may be qualified to perform all the procedures
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.
SPECIFICATIONS
Gas Data
Dimensions No. of Total
Model
Width Depth Height
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
Burners BTU
per
Section
/hr
TOOLS
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.
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.
3. Remove the four screws and bushings from
the oven.
4. Remove the augratin oven bottom assembly
as outlined in Augratin Oven Bottom Assembly.
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.
– 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.
– 7 –
4. Slide the burner knob cover plate out and
remove it from the broiler.
5. Reverse the procedure to install.
Control Panel Cover (GHCB40)
1. Remove the manifold cover assembly as
outlined in Manifold Cover Assembly.
4. Remove the bolt and the control panel cover
from the broiler.
5. Reverse the procedure to install.
Lower Front Panel (GHCB40)
2. Loosen the retaining screw and remove the
burner knob from the broiler.
3. Pull the thermostat knob to remove it from the
broiler.
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.
– 8 –
2. Remove the screw from the oven burner cover.
3. Remove the oven burner cover from the
broiler.
4. Reverse the procedure to install.
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.
7. Remove the oven bottom baffle from the
broiler.
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.
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.
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.
1. Remove the four screws and brass bushings
from the broiler.
2. Slide the augratin oven bottom assembly from
the broiler.
Oven Door Handle (GHCB40)
1. Remove the caps from the oven door.
– 10 –
Loading...