Vulcan-Hart 12, 24S, 36C, 48C, 36S User Manual
...
SERVICE MANUAL
ENDURANCE / CHALLENGER
MODULAR SERIES GAS
RANGES
VULCAN
WOLF
This Manual is prepared for the use of trained Vulcan Service
Technicians and should not be used by those not properly
qualified.
12
24S
36S, 36C
48C, 48S, 48SS
60SS, 60SC, 60CS
72SS, 72SC, 72CC, 72CS
C12,
C24S
C36S, C36C
C48S, C48SS, C48C
C60SS, C60SC, C60CS
C72SS, C72SC, C72CC, C72CS
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.
The reproduction, transfer, sale or other use of this Manual,
without the express written consent of Vulcan, is prohibited.
This manual has been provided to you by ITW Food Equipment
Group LLC (“ITW FEG”) without charge and remains the property
of ITW FEG, and by accepting this manual you agree that you will
return it to ITW FEG promptly upon its request for such return
at any time in the future.
For additional information on Vulcan-Hart Company or to locate an authorized
parts and service provider in your area, visit our website at www.vulcanequipment.com
VULCAN-HART
DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC
www.vulcanequipment.com
BALTIMORE, MD 21222
F454A (0615)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES
TABLE OF CONTENTS
SERVICE UPDATES ....................................................................................... 4
SERVICE UPDATES ................................................................................... 4
GENERAL .................................................................................................. 5
INTRODUCTION ....................................................................................... 5
INSTALLATION, OPERATION AND CLEANING ......................................................... 5
LUBRICATION ......................................................................................... 5
TOOLS ................................................................................................. 5
SPECIFICATIONS ...................................................................................... 5
REMOVAL AND REPLACEMENT OF PARTS ............................................................... 6
MANIFOLD COVER .................................................................................... 6
CONTROL BRACKET COVER .......................................................................... 6
CONTROL PANEL (30" OVENS) ........................................................................ 6
KICK PANEL (24" & 30" OVENS) ....................................................................... 6
BULL NOSE ............................................................................................ 7
CONTROL BRACKET .................................................................................. 7
STANDARD OVEN PILOT ASSEMBLY AND THERMOCOUPLE ......................................... 8
STANDARD OVEN BURNER ........................................................................... 8
STANDARD OVEN THERMOSTAT (24" OVEN) ......................................................... 9
STANDARD OVEN THERMOSTAT (30" OVEN) ........................................................ 10
CONVECTION OVEN PILOT ASSEMBLY AND THERMOCOUPLE ..................................... 11
CONVECTION OVEN BURNER ....................................................................... 12
CONVECTION OVEN THERMOSTAT-COMBO VALVE ................................................ 12
CONVECTION OVEN BLOWER AND MOTOR ......................................................... 13
BURNER ORIFICE HOOD (STANDARD AND CONVECTION OVENS) ................................. 14
GAS SAFETY VALVE (STANDARD AND CONVECTION OVENS) ...................................... 14
TOP BURNER PILOT VALVE .......................................................................... 15
TOP BURNER ASSEMBLY ............................................................................ 16
TOP BURNER CONTROL VALVE ..................................................................... 16
TOP BURNER ORIFICE HOOD ....................................................................... 17
OVEN DOOR ......................................................................................... 17
GAS PRESSURE REGULATOR ....................................................................... 18
CONVECTION OVEN DOOR SWITCH ................................................................. 19
CONVECTION OVEN SOLENOID ..................................................................... 19
GRIDDLE THERMOSTAT-COMBO VALVE ............................................................ 20
GRIDDLE GAS SAFETY VALVE ....................................................................... 22
GRIDDLE PILOT ASSEMBLY AND THERMOCOUPLE ................................................. 22
GRIDDLE BURNER ORIFICE HOOD .................................................................. 23
CHARBROILER BURNER ............................................................................. 23
CHARBROILER PILOT ................................................................................ 25
SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 27
OVEN PILOT FLAME HEIGHT ......................................................................... 27
OVEN PILOT ADJUSTMENT ...................................................................... 27
OPEN TOP PILOT ADJUSTMENT ................................................................. 27
BURNER AIR SHUTTER ADJUSTMENT ............................................................... 27
REGULATOR ADJUSTMENT .......................................................................... 28
BURNER NOZZLE CHECK ............................................................................ 29
STANDARD OVEN THERMOSTAT BY-PASS FLAME ADJUSTMENT .................................. 29
STANDARD OVEN THERMOSTAT TEMPERATURE ADJUSTMENT ................................... 30
CONVECTION OVEN THERMOSTAT-COMBO VALVE ADJUSTMENT ................................. 30
OPERATION ...................................................................................... 30
ADJUSTMENT .................................................................................... 30
GRIDDLE THERMOSTAT-COMBO VALVE ADJUSTMENT ............................................. 31
OPERATION ...................................................................................... 31
ADJUSTMENT .................................................................................... 31
F45471 Rev. A (0615) Page 2 of 38
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES
THERMOCOUPLE TEST .............................................................................. 32
OPERATION ...................................................................................... 32
PILOT CHECKS ................................................................................... 32
THERMOCOUPLE CHECKS ...................................................................... 32
CHARBROILER PILOT ADJUSTMENT ................................................................ 33
ELECTRICAL OPERATION ................................................................................ 34
COMPONENT FUNCTION ............................................................................ 34
SEQUENCE OF OPERATION - CONVECTION OVEN ................................................. 34
SCHEMATIC DIAGRAM - CONVECTION OVENS ...................................................... 35
WIRING DIAGRAM - CONVECTION OVENS .......................................................... 36
TROUBLESHOOTING ..................................................................................... 37
TROUBLESHOOTING ................................................................................. 37
© HOBART SERVICE 2015
Page 3 of 38 F45471 Rev. A (0615)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE UPDATES
SERVICE UPDATES
SERVICE UPDATES
This section lists the service updates to the
information in the manual.
June 2015
Added
• CHARBROILER BURNER removal.
• CHARBROILER PILOT removal.
• CHARBROILER PILOT ADJUSTMENT .
• CHARBROILER BURNER AIR SHUTTER
picture under BURNER AIR SHUTTER
ADJUSTMENT.
F45471 Rev. A (0615) Page 4 of 38
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - GENERAL
GENERAL
INTRODUCTION
This manual is for the Endurance / Challenger
XL™ Modular Series Gas Ranges. Procedures in this
manual will apply to all models unless specified.
Pictures and illustrations will be of model 60SC unless
otherwise noted.
All of the information, illustrations and specifications
contained in this manual are based on the latest
product information available at the time of printing.
INSTALLATION, OPERATION AND
CLEANING
Refer to F38201 VULCAN ENDURANCE / WOLF
CHALLENGER Modular Series Gas Restaurant
Ranges I/O Manual for detailed installation, operation
and cleaning instructions.
LUBRICATION
Anderson and Forrester (or comparable) valve grease
for top burner gas valves, top burner pilot valves, and
pressure tap plugs. Apply light coat to valve/plug
threads. Valve grease must be insoluble in propane
and natural gas.
• A non perminate type sealer (preferably fast
drying) such as nail polish or equivelant for
sealing thermostat adjustment screw. If using
Loctite 242, it begins to set in approximately 10
minutes and fully cures in 24 hours according to
manufacturer.
• 3/4" pipe tee and hose barb assembly for
temporarily checking manifold pressure when a
pressure tap is not available in the gas manifold
on some models.
• Adaptor to test thermocouple closed circuit DC
voltages (purchase locally). Adaptors vary
between manufacturers. An example of one
adaptor type is pictured below.
Fig. 1
SPECIFICATIONS
TOOLS
Standard
• Standard set of hand tools.
• VOM with A.C. current tester (Any quality VOM
with a sensitivity of at least 20,000 ohms per volt
can be used).
Special
• Temperature tester (K type thermocouple
preferred).
• Manometer.
• Long reach phillips screwdriver #2 for installing
or removing motor assembly through the
convection oven cavity.
• Two standard 1/4"- 20 x 1" bolts (allen head
recommended). The bolts are used to relieve
spring tension on the door hinge during door
removal and installation.
• Loctite® 246™ for use on the door handle
mounting screws.
Gas Pressures
• Manifold/Operating Pressure
Natural: 5 in. W.C.
Propane: 10 in. W.C.
• Inlet Supply Pressure
Natural - Recomended 7 in. W.C. ; Minimum
5 in. W.C.
Propane - Recomended 11 in. W.C. ;
Minimum 11 in. W.C.
Maximum 14 in. W.C. (0.5 PSI) (Natural or
Propane)
Orifice Size Requirements
• See Orifice Chart in Parts Catalog F43260
ENDURANCE/CHALLENGER MODULAR
SERIES GAS RANGES.
Page 5 of 38 F45471 Rev. A (0615)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
REMOVAL AND REPLACEMENT OF PARTS
MANIFOLD COVER
Shut off the gas before servicing the
unit.
1. Pull crumb tray out.
2. Loosen set screw in the open top burner control
knobs and remove knobs.
3. Remove screws that secure manifold cover and
remove cover.
4. Reverse procedure to install.
Fig. 2
CONTROL PANEL (30" OVENS)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
NOTE: Electrical power disconnect warning applies
to convection ovens.
NOTE: Removal procedure applies to standard and
convection 30" ovens.
1. Pull knob from thermostat.
2. Remove hole plug at top of control panel.
3. Remove screw and lift off control panel.
4. On convection ovens only, note lead wire
locations and disconnect from power switch.
5. Reverse procedure to install.
CONTROL BRACKET COVER
Shut off the gas before servicing the
unit.
1. Pull grease can out.
2. Pull knobs from thermostats.
3. If removing control bracket cover from oven with
a 12" open top burner module and 24" griddle top
module:
A. Pull crumb tray out of 12" section if installed.
B. Loosen set screw in the open top burner
control knobs and remove knobs.
4. Remove screws that secure control bracket
cover and remove the bracket.
5. Reverse procedure to install.
Convection Oven Panel Shown
KICK PANEL (24" & 30" OVENS)
Shut off the gas before servicing the
unit.
1. Lift up on kick panel and rotate down 90°.
Fig. 3
F45471 Rev. A (0615) Page 6 of 38
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
2. Remove screws securing kick panel mounting
brackets (2) to the oven and remove kick panel.
3. Reverse procedure to install.
Fig. 5
BULL NOSE
CONTROL BRACKET
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Remove BULL NOSE.
2. Remove CONTROL BRACKET COVER.
3. If installed, remove compression nut on the
flexible tubing gas line that supplies gas to the
manifold on the adjacent open top burner
section.
1. Turn top burners and griddle off.
2. Remove front row of top burner grates on ranges
with open top burners.
3. Remove all screws securing bull nose to range.
The total number of screws depend on the width
of the range.
4. Lift bull nose off range.
Fig. 6
5. Reverse procedure to install.
Fig. 7
4. Loosen the recessed screws (4) through the
access holes on the two manifold cover brackets
(L & R) that secure the control bracket to the
oven. The bracket mounting holes are keyed for
removal of the control bracket.
Page 7 of 38 F45471 Rev. A (0615)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
2. Remove cavity bottom by lifting up and sliding
out.
3. Remove screws securing oven pilot assembly to
burner carrier.
Fig. 8
5. Lift the control bracket up and tilt forward to
remove bracket from mounting screws.
6. Partially install the grease drawer leaving enough
of the drawer extended to support the control
bracket while servicing.
4. Lower the KICK PANEL (24" & 30" OVENS).
Fig. 10
Fig. 9
7. Griddle controls are now accessible for removal.
A. If replacing control bracket, remove screws
securing griddle controls to bracket.
B. Remove manifold cover brackets (L & R)
from each end of the control bracket as
necessary (2 screws for each bracket).
8. Reverse procedure to install and check for proper
operation.
STANDARD OVEN PILOT
ASSEMBLY AND THERMOCOUPLE
5. Pull oven pilot assembly out through opening in
lower oven frame.
6. If replacing thermocouple only, remove
thermocouple from oven pilot assembly and gas
safety valve. Continue to last step.
When installing, do not bend and kink the
capillary tube or damage to the component may occur.
7. If replacing oven pilot assembly, remove pilot
tubing and thermocouple from oven pilot
assembly.
8. Reverse procedure to install and check for proper
operation.
STANDARD OVEN BURNER
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Remove bottom oven rack(s) and rack guides.
F45471 Rev. A (0615) Page 8 of 38
1. Lower the KICK PANEL (24" & 30" OVENS).
2. Hold the tab on burner carrier with plyers to
3. Remove screws securing burner carrier to oven
support it then remove compression nut from
burner elbow fitting to disconnect gas supply
tubing.
frame.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
STANDARD OVEN THERMOSTAT
(24" OVEN)
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
Fig. 11
4. Pull burner carrier out through opening in lower
oven frame enough to access the oven pilot
assembly.
5. Remove screws securring oven pilot assembly to
burner carrier. Move oven pilot assembly away
from burner.
Do not bend and kink the capillary tube or
damage to the control may occur.
6. Pull burner carrier with burner attached out from
oven.
soap and water solution (bubbles). Do not use an open
flame.
1. Pull out crumb tray.
2. Remove MANIFOLD COVER.
3. Remove oven thermostat knob.
4. Remove screw securing thermostat cover to
oven frame.
7. Remove screws securring burner to the burner
carrier.
Fig. 12
8. Slide oven burner off the burner nozzle to
remove.
9. Reverse procedure to install.
10. Perform BURNER AIR SHUTTER
ADJUSTMENT.
Fig. 13
5. Remove compression nut from elbow fitting at
the rear of thermostat.
6. Remove screws securing thermostat to mounting
flange.
Fig. 14
A. Inspect mounting flange and gasket. If okay,
they may be used during installation. If not
okay, remove and install replacement
flange.
Page 9 of 38 F45471 Rev. A (0615)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
7. Open oven door and remove oven racks.
8. Remove screws securing capillary tube mounting
clips (5) inside the oven cavity.
Fig. 15
NOTE: Capillary tube is permanently attached to
thermostat-combo valve.
9. Remove all mounting clips from capillary tube
and retain for reuse.
10. Pull capillary tube through the hole in oven
sidewall and remove thermostat from oven.
A. Remove insulation sleeve from capillary
tube for installation on replacement
thermostat capillary tube.
2. Remove screws securing capillary tube mounting
clips (5) inside the oven cavity.
Standard 30" oven
NOTE: Capillary tube is permanently attached to
thermostat.
3. Remove all mounting clips from capillary tube
and retain for reuse.
4. Remove CONTROL PANEL (30" OVENS).
5. Remove compression nuts from thermostat
fittings (front & rear).
6. Remove screws securing thermostat to mounting
bracket.
B. Note orientation of compression fitting
elbow on valve body and remove for
installation on replacement valve body.
Clean pipe threads and apply thread
sealant that is suitable for use with propane gases.
When installing, do not bend and kink the
capillary tube or damage to the control may occur.
11. Reverse procedure to install and check for proper
operation.
STANDARD OVEN THERMOSTAT
(30" OVEN)
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Open oven door and remove oven racks.
Fig. 17
F45471 Rev. A (0615) Page 10 of 38
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
2. Remove screws securing burner carrier to oven
frame.
Fig. 19
3. Pull burner carrier out through opening in lower
Fig. 18
7. Remove gas line tubing from thermostat.
8. Pull capillary tube through the hole in oven
sidewall and remove thermostat from oven.
A. Note orientation of compression fittings on
thermostat body and remove for installation
on replacement valve body.
oven frame enough to access the oven pilot
assembly.
Clean pipe threads and apply thread
sealant that is suitable for use with propane gases.
When installing, do not bend and kink the
capillary tube or damage to the control may occur.
NOTE: When installing thermostat capillary tube,
push any insulation back through grommet and
remove loose insulation from oven cavity.
9. Reverse procedure to install and check for proper
operation.
CONVECTION OVEN PILOT
ASSEMBLY AND THERMOCOUPLE
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
Fig. 20
4. If replacing thermocouple only, remove
thermocouple from oven pilot assembly.
When installing, do not bend and kink the
capillary tube or damage to the component may occur.
A. Remove CONTROL PANEL (30" OVENS).
B. Remove thermocouple from gas safety
valve and remove thermocouple from oven.
Continue to last step.
5. If replacing oven pilot assembly, remove pilot
tubing and thermocouple from oven pilot
assembly.
6. Remove screws securing oven pilot assembly to
burner carrier.
7. Reverse procedure to install and check for proper
operation.
1. Lower the KICK PANEL (24" & 30" OVENS).
Page 11 of 38 F45471 Rev. A (0615)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
CONVECTION OVEN BURNER
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Lower the KICK PANEL (24" & 30" OVENS).
2. Remove screws securing burner carrier to oven
frame.
8. Slide oven burner off the burner nozzle to
remove.
9. Reverse procedure to install.
10. Perform
ADJUSTMENT.
BURNER AIR SHUTTER
Fig. 22
CONVECTION OVEN
THERMOSTAT-COMBO VALVE
Fig. 21
3. Pull burner carrier out through opening in lower
oven frame enough to access the oven pilot
assembly and burner elbow fitting.
4. Hold the tab on burner carrier with plyers to
support then remove compression nut from
burner elbow fitting.
5. Remove screws securing oven pilot assembly to
burner carrier. Move pilot assembly away from
burner.
Do not bend and kink the capillary tube or
damage to the control may occur.
6. Pull burner carrier with burner attached out from
oven.
7. Remove screws securing burner to the burner
carrier.
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Remove CONTROL PANEL (30" OVENS).
2. Remove compression nuts from thermostatcombo valve fittings.
3. Remove screws securing thermostat-combo
valve to mounting bracket.
F45471 Rev. A (0615) Page 12 of 38
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