SERVICE MANUAL GAS RESTAURANT RANGE EG24, 36, 48, 60, 160 AND 260 MODEL EG24 EG36 EG48 EG60 EG160 EG260 ML-52486 ML-52487 ML-114956 ML-52488 ML-52489 ML-52490 EG36 VULCAN-HART COMPANY, FORM 31054 Rev. A (5-98) P.O. BOX 696, LOUISVILLE, KY 40201-0696, TEL.
IMPORTANT FOR YOUR SAFETY THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL GAS EQUIPMENT, WHO SHOULD PERFORM THE INITIAL FIELD START-UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL. POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE SMELL OF GAS IS DETECTED. THIS INFORMATION CAN BE OBTAINED FROM THE LOCAL GAS SUPPLIER.
GAS RESTAURANT RANGE MODELS EG60 EG36 EG160 EG260 EG48 EG24 PL-53006 –4–
SERVICE MANUAL GAS RESTAURANT RANGES INDEX PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE DESCRIPTION PAGE SERVICE NOTATIONS 6 UNITS MOUNTED ON CASTERS 7 SERVICING SIMPLE CHECKS AND ADJUSTMENTS 7-10 GAS CONNECTIONS 11, 12 TESTING THE GAS SUPPLY SYSTEM 12 ORIFICE SIZE REQUIREMENTS FOR DIFFERENT ELEVATIONS 12 PILOT LIGHTING AND ADJUSTMENTS 13-17 THERMOSTAT ADJUSTMENTS 18-21 REGULATOR CHECK, ADJUSTMENT, INSTALLATION 22-24 STANDARD OVEN & GRIDDLE THERMOSTAT REPLACEMENT 24-27 OVEN PILOT CHE
DEDICATED TECHNICAL SERVICE HOT LINE(1-502-778-2791) SERVICE NOTATIONS: 1. The procedures outlined in this manual are to be performed only by Vulcan-Hart authorized service representatives. 2. An authorized Vulcan-Hart service representative is one who is familiar with Vulcan equipment and who has been endorsed by Vulcan-Hart Company to service the equipment.
UNITS MOUNTED ON CASTERS Units mounted on casters utilizing a flex hose and quick-disconnect must be installed with a restraining device. The restraining device must be connected at all times. If disconnection of the device is necessary, turn off the gas supply before disconnection. Reconnect the restraint before turning the gas supply on and returning the unit to its original installation position and before beginning unit operation.
SERVICING SIMPLE CHECKS AND ADJUSTMENTS (Cont.) 2. Oven Door Turnbuckle NOTE: For the 24L units, refer to procedure outlined under 2A. If the oven door is not closing properly, the door turnbuckle may require adjustment. To adjust the turnbuckle, flip down the lower front kick panel. The turnbuckle is connected between the right- and left-hand door springs (Fig. 1). With your hand, rotate the cast center piece of the turnbuckle two rotations at a time, then check the door tension.
SERVICING SIMPLE CHECKS AND ADJUSTMENTS (Cont.) 3. Pilot Flame Height TOOLS REQUIRED: Standard flat blade screwdriver. Top Burners: To adjust pilot flame height of the unit top burners, locate the pilot adjustment screws found on the front manifold pipe. It is not necessary to remove the manifold cover, as adjustment access holes have been provided in the panel. With screwdriver, turn the adjustment screw of the pilot valve experiencing the pilot flame height problems (Fig. 3).
SERVICING SIMPLE CHECKS AND ADJUSTMENTS (Cont.) 2. With screwdriver, adjust pilot key (located under pilot adjustment cap) to provide the proper size flame. 3. Replace pilot adjustment cap. NOTE: If unit still is not heating correctly, refer to THERMOSTAT ADJUSTMENTS on Page 18. 4. Air Shutter Adjustment TOOLS REQUIRED: Standard flat blade screwdriver. The efficiency of the oven depends on a delicate balance between the air supply and the volume of gas.
GAS CONNECTIONS CAUTION: All gas supply connections and any pipe joint compound used must be resistant to the action of propane gases. Each unit is factory-equipped with the type gas specified on the rating plate. The installation gas connection is a 3 ⁄4" (19mm) 14 FPT thread ANSI schedule #40 standard pipe. Codes require that a gas shutoff valve be installed in the gas line ahead of the range. Standard units are equipped with fixed burner orifices which coincide with the proper unit operation elevation.
GAS CONNECTIONS (Cont.) NOTE: A leak limiter is supplied with every regulator to allow excess gas pressure to escape. Do not obstruct leak limiter on gas pressure regulator as obstruction may cause regulator to malfunction. WARNING: PRIOR TO LIGHTING, CHECK ALL JOINTS IN THE GAS SUPPLY LINE FOR LEAKS. USE SOAP AND WATER SOLUTION. DO NOT USE AN OPEN FLAME. After piping has been checked for leaks, all piping receiving gas should be fully purged to remove air.
PILOT LIGHTING AND ADJUSTMENTS NOTE: Although pilot lighting procedures are to be performed by both installation and operation personnel, only the installation/service personnel should attempt to make any pilot, burner, or temperature adjustments to this unit. The operation personnel are authorized only to perform the procedures for pilot lighting. All adjustment procedures associated with pilot lighting must be performed by an authorized Vulcan-Hart installation or service person.
PILOT LIGHTING AND ADJUSTMENTS (Cont.) OPEN TOP BURNERS 1. Turn main gas supply “ON”. 2. Wait 30 seconds and, using a taper, light the open top pilot (Fig. 10). Fig. 10 3. If pilot fails to light, turn main gas supply “OFF”. Wait 5 minutes and repeat the above procedures. 4. Turn one open top burner valve “ON” to remove air from the gas line. Turn burner “OFF” when gas begins to flow. OPEN TOP BURNER ADJUSTMENTS TOOLS REQUIRED: Standard flat blade screwdriver. 1.
PILOT LIGHTING AND ADJUSTMENTS (Cont.) BROILER/GRIDDLE 1. Turn main gas supply “ON”. 2. Wait 30 seconds and, using a taper, light broiler/griddle pilot (see Fig. 9). 3. If pilot fails to light, turn main gas supply “OFF”. Wait 5 minutes and repeat Steps 1 and 2. 4. Turn burner valve “ON” to purge air from the lines. Turn burner valve “OFF” when gas begins to flow. BROILER/GRIDDLE ADJUSTMENTS TOOLS REQUIRED: Standard flat blade screwdriver, lighter taper.
PILOT LIGHTING AND ADJUSTMENTS (Cont.) 2. Light pilot by depressing the reset button located behind the kick panel (Fig. 12). Light pilot and continue to hold reset button in for 1 minute. If pilot fails to light, turn main gas supply “OFF” and wait 5 minutes before repeating Step 2. 3. After pilot is lit, turn the temperature dial to the desired setting. Nightly Shutdown: Turn oven burner valve “OFF”. Complete Shutdown 1. Turn oven burner valve “OFF”. 2. Turn main gas supply “OFF”. Fig.
PILOT LIGHTING AND ADJUSTMENTS (Cont.) OVEN BURNER ADJUSTMENTS NOTE: These procedures should be performed only by a qualified Vulcan-Hart service representative. TOOLS REQUIRED: Standard flat blade screwdriver. All Restaurant Range series units equipped with pressure regulator and fixed orifices have been adjusted at the factory and should require no further adjustments. However, the efficiency of the range depends on a delicate balance between the air supply and the volume of gas.
THERMOSTAT ADJUSTMENTS NOTE: These procedures should be performed only by a qualified Vulcan-Hart service representative. STANDARD OVEN Although the unit thermostats are factory positioned to their proper setting, it is not unusual for the thermostat to be knocked out of adjustment during shipment. If the oven or griddle heat response seems to be lacking after burner air shutter adjustments have been checked, perform the following adjustments.
THERMOSTAT ADJUSTMENTS (Cont.) 3. Light the burner. Turn the dial to the highest set temperature. 4. After 10 minutes, turn the dial clockwise to the point slightly beyond the first mark on the dial (shown by an “X”). 5. Remove the dial and sleeve (Fig. 17). Fig. 17 Fig. 18 6. With a screwdriver, turn the left-hand bypass adjustor screw counterclockwise to increase the flame, clockwise to decrease it, until the flame appears to be 1⁄8" (3.175mm) over the entire burner area (Fig. 18). 7.
THERMOSTAT ADJUSTMENTS (Cont.) 3. Allow unit to heat until the burner flame is heard cutting “OFF”. Wait about 10 minutes until the burner flame has cycled “ON” and “OFF” several times. Then compare the test instrument reading with the dial setting. If the reading is within ± 15°F (-9.4°C) of the dial setting, its calibration is correct. If reading is not within this temperature window, then recalibrate by performing Steps 4 through 13. 4. Pull the dial straight off the dial shaft (see Fig. 17). 5.
THERMOSTAT ADJUSTMENTS (Cont.) 10. To recalibrate, hold the thermostat dial in place. Insert screwdriver into dial shaft to engage the calibration stem adjustment screw (Fig. 20). Push inward (do not turn stem). Fig. 20 11. While holding stem calibration screw in place, turn thermostat dial until it is set on the actual temperature shown by the testing device (Fig. 21). Fig. 21 12. Release the calibration screw and reinstall the dial insert. 13. Set the dial to 450°F (232.
REGULATOR CHECK, ADJUSTMENT, INSTALLATION REGULATOR CHECK A regulator is installed on each range. When servicing this equipment for possible gas pressure problems, the following visual checks should be made first. Make sure the regulator has been installed at the rear of the unit with arrow pointing in the horizontal position in the direction of gas flow. The only exception to this rule is if the outlet pressure of the unit has been reset prior to this service call. Then turn on the range top burners.
REGULATOR CHECK, ADJUSTMENT, INSTALLATION (Cont.) 2. With only two open top burners “ON”, note the manometer reading. The reading should be 3.7" Water Column (.92 kPa) for natural gas units and 10.0" Water Column (2.5 kPa) for propane gas units. If readings taken are lower, check the incoming line pressure. NOTE: The line pressure should never drop below 5.0" Water Column (1.25 kPa) for natural gas or 11.0" Water Column (2.7 kPa) for propane gas.
REGULATOR CHECK, ADJUSTMENT, INSTALLATION (Cont.) 1. Connect the manometer to the pressure tap provided on the rear manifold pipe (see Fig. 23). 2. Check the reading. The reading should be 3.7" Water Column (.92 kPa) for natural gas and 10.0" Water Column (2.5 kPa) for propane gas. 3. If reading is incorrect and the proper line pressure has been verified, then the regulator must be adjusted. Using a standard flat blade screwdriver, remove the regulator adjustment cap (Figs. 26 & 27). Fig. 27 Fig.
STANDARD OVEN & GRIDDLE THERMOSTAT REPLACEMENT STANDARD OVEN AND GRIDDLE THERMOSTAT CHECKS AND CALIBRATION Refer to THERMOSTAT ADJUSTMENTS on Page 18 of this manual for the procedures for checking and calibrating the thermostat for the standard oven and griddle. STANDARD OVEN AND GRIDDLE THERMOSTAT REPLACEMENT TOOLS REQUIRED: Pipe wrench, 6" adjustable wrench, 1⁄8" flat blade screwdriver, 5⁄16" socket, and socket wrench. 1. Disconnect unit gas supply and allow unit to cool. 2.
STANDARD OVEN & GRIDDLE THERMOSTAT REPLACEMENT (Cont.) 4. From inside the oven, straighten the capillary lead. From the opening in the oven top section, pull the capillary out of the oven cavity (Fig. 29). Fig. 30 5. Remove the top section burner valve knobs, top grates and aeration plate. (Figs. 30) 6. Remove screws holding the control panel in place. 7. Disconnect the thermostat burner tubing (Fig. 31). Fig. 31 8. Remove top burners, if required, to access the thermostat.
STANDARD OVEN & GRIDDLE THERMOSTAT REPLACEMENT (Cont.) 9. Unscrew the thermostat from the manifold pipe (Figs. 33, 34, & 35). Fig. 34 Fig. 33 Fig. 35 10. Replace thermostat mounting block. Place pipe dope on the threaded end of the new thermostat mounting block to be installed onto the unit. 11. Install the new thermostat by reversing Steps 1 through 9 above. NOTE: Do not kink the new capillary line when feeding it through the oven cavity.
OVEN PILOT CHECK, REPLACEMENT OVEN PILOT CHECK If all other systems have been checked and pilot will not stay lit, replacement of the pilot may be necessary. OVEN PILOT REPLACEMENT TOOLS REQUIRED: 1⁄4" socket, socket driver, 1⁄2" and 7⁄16" open end wrenches. 1. Disconnect unit from main gas supply and allow unit to cool. 2. Remove oven bottom assembly (see Fig. 16). 3. Disconnect pilot from gas tubing (Fig. 41). Fig. 41 4. Remove (2) #8 sheet metal screws holding pilot bracket in place. 5.
STANDARD OVEN PILOT SAFETY VALVE CHECK, REPLACEMENT STANDARD OVEN PILOT SAFETY VALVE CHECK NOTE: A quick check of the following conditions and symptoms will assist in verifying that the pilot safety valve is properly functioning. TOOLS REQUIRED: Flow meter, millivolt tester. If the unit pilot is “ON” but the unit is not heating, check the gas flow from the thermostat to the safety valve, using a flow meter (Fig. 36). (Flow meter kits are available from Vulcan-Hart Service Parts Depots under Part No. 495.
STANDARD OVEN PILOT SAFETY VALVE CHECK, REPLACEMENT (Cont.) Fig. 37 5. If the millivolt reading is below 5 MV, replace the thermocouple. 6. If the MV reading is within tolerance, the safety valve should be replaced. SAFETY VALVE REPLACEMENT PROCEDURES TOOLS REQUIRED: 7⁄16" open end wrench, 11⁄16" open wrench, and 3⁄8" open end wrench. 1. Disconnect unit from main gas supply. 2. Disconnect thermocouple from safety valve (Fig. 38). Fig.
STANDARD OVEN PILOT SAFETY VALVE CHECK, REPLACEMENT (Cont.) 3. Disconnect right- and left-hand pilot gas tubing from the safety valve (Fig. 39). Fig. 39 4. Disconnect right- and left-hand burner gas tubing from the safety valve (Fig. 40). Fig. 40 5. Remove safety valve from unit. 6. Install new valve by reversing Steps 1 through 4.
THERMOCOUPLE CHECK, REPLACEMENT THERMOCOUPLE CHECK 1. Fold lower kick panel down. 2. Perform pilot lighting procedures (see Page 13). 3. If unit will not stay lit, using a volt meter, check the millivolt reading from the valve thermocouple connection while holding pilot button in the “ON” position (see Fig. 37). 4. If millivolt reading is below 5 MV, replace thermocouple. THERMOCOUPLE REPLACEMENT TOOLS REQUIRED: 7⁄16" open end wrench, 3⁄8" open end wrench, 1⁄4" socket and socket driver. 1.
OVEN BURNER NOZZLE AND ORIFICE CHECK, REPLACEMENT OVEN BURNER NOZZLE AND ORIFICE CHECK If burner operation seems poor and all other systems have been verified, remove burner nozzle and orifice to check for blockage or damage. Blockages can often be cleaned using water pressure and a mild soap solution or by running a correct size drill tap through the nozzle opening. OVEN BURNER NOZZLE AND ORIFICE REPLACEMENT TOOLS REQUIRED: 1⁄2" open end wrench. 1. Disconnect unit from gas and allow unit to cool. 2.
OVEN BURNER CHECK, REPLACEMENT OVEN BURNER CHECK If the oven burner is not properly firing and all other systems have been checked, the oven burner may need to be cleaned or replaced. OVEN BURNER REPLACEMENT TOOLS REQUIRED: 1⁄4" socket and socket driver. 1. Disconnect unit from main gas supply and allow unit to cool. 2. Remove burner strap-down tie if applicable. 3. Remove (2) #8 sheet metal screws securing burner to pilot bracket (Fig. 45). Fig. 45 4.
TOP SECTION PILOT CHECK, REPLACEMENT TOP SECTION PILOT CHECK If all other systems have been checked and pilot will not stay lit, cleaning or replacement of pilot may be necessary. TOP SECTION PILOT REPLACEMENT TOOLS REQUIRED: 7⁄16" open end wrench. 1. Disconnect unit from main gas supply and allow unit to cool. 2. Remove defective pilot from pilot tube. 3. Check pilot for blockage. 4. If blockage is found, clean pilot tip and replace or install new pilot tip. 5.
TOP SECTION BURNER VALVE AND NOZZLE CHECK, REPLACEMENT TOP SECTION BURNER VALVE CHECK After a long period of use on the range, the top section burner valve can show signs of wear. Check valve for gas leakage and sloppy valve control. Check also for valve nozzle blockage or damage. TOP SECTION BURNER VALVE AND NOZZLE REPLACEMENT TOOLS REQUIRED: 1⁄2" open end wrench, 6" adjustable wrench or standard pipe wrench, 1⁄4" socket and socket driver. 1. Disconnect main unit gas supply. 2.
