SERVICE MANUAL ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES VULCAN WOLF 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 prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. This manual is not intended to be all encompassing.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES TABLE OF CONTENTS SERVICE UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES THERMOCOUPLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PILOT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS MANIFOLD COVER CONTROL PANEL (30" OVENS) Shut off the gas before servicing the Disconnect the electrical power to the machine and follow lockout / tagout procedures. 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. unit. 4. Reverse procedure to install.
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. 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.
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. Fig. 10 4. Lower the KICK PANEL (24" & 30" OVENS). 5.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS STANDARD OVEN THERMOSTAT (24" OVEN) Shut off the gas before servicing the unit. Fig. 11 4. 5. Pull burner carrier out through opening in lower oven frame enough to access the oven pilot assembly. Remove screws securring oven pilot assembly to burner carrier. Move oven pilot assembly away from burner. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles).
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. 2. Remove screws securing capillary tube mounting clips (5) inside the oven cavity. Standard 30" oven NOTE: Capillary tube is permanently attached to thermostat. Fig. 15 3. NOTE: Capillary tube is permanently attached to thermostat-combo valve.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 2. Remove screws securing burner carrier to oven frame. Fig. 19 3. 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. Pull burner carrier out through opening in lower oven frame enough to access the oven pilot assembly.
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. Fig. 22 8.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 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.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS BURNER ORIFICE HOOD (STANDARD AND CONVECTION OVENS) Fig. 26 8. Loosen bolts (2) securing blower to motor shaft then remove blower. 9. If replacing blower only, proceed to last step. If replacing motor, continue with procedure. 1. Access burner for the type of oven being serviced as outlined under STANDARD OVEN BURNER or CONVECTION OVEN BURNER. 2. Remove the orifice hood from fitting. 3.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS TOP BURNER PILOT VALVE 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. Gas Safety Valve on Standard 24" Oven 1.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS TOP BURNER ASSEMBLY 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. 6. Check for proper operation. 1. Remove top burner grates (front and rear) from the module section being serviced. 7.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 5. Inspect the top control valve for wear and damage, replace as necessary. 6. Reverse procedure to install. Clean pipe threads and apply thread sealant that is suitable for use with propane gases. 5. Close door leaving enough space to clear the oven gas manifold cover during removal. As the door approaches this position, you should notice a decrease in the spring tension on the door. 6.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS GAS PRESSURE REGULATOR 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. 35 3. Fully open door to check operation.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS CONVECTION OVEN DOOR SWITCH Disconnect the electrical power to the machine and follow lockout / tagout procedures. NOTE: Door switch is installed on Convection Ovens only. 1. Remove CONTROL PANEL (30" OVENS). 2. Remove single mounting nut securing door switch bracket to safety valve mounting bracket. 3. Remove screws securing door switch bracket to oven frame and remove bracket from control area. Fig. 38 7.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS GRIDDLE THERMOSTAT-COMBO VALVE 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. 39 3. 4. 5. Remove compression nuts on the inlet and outlet of solenoid.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 9. Remove compression nuts from thermostatcombo valve fittings for the thermostat being replaced. Fig. 42 6. 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. Fig. 45 10.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 11. Reverse procedure to install and check for proper operation. GRIDDLE GAS SAFETY VALVE 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 BRACKET. 2.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS NOTE: When installing, ensure orifice hood is aligned and centered in the burner assembly opening. CHARBROILER BURNER Shut off the gas before servicing the unit. Disconnect the electrical power to the machine and follow lockout / tagout procedures. Fig. 49 4. Remove screws (2) securing pilot assembly to mounting bracket. 5. Reverse procedure to install and check for proper operation.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS Fig. 52 2. Remove radiant [1] to access burner. Fig. 53 3. F45471 Rev. A (0615) Page 24 of 38 Remove burner [1] and deflector [2] by lifting at the rear of burner.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS Fig. 55 5. To Install: A. Install deflector onto replacement burner. 6. Verify BURNER AIR SHUTTER ADJUSTMENT. 7. Install radiant above the burner. 8. Install grate. 9. Check for proper operation. CHARBROILER PILOT Shut off the gas before servicing the unit. Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove CHARBROILER BURNER to access pilot. 2. Remove crumb trays.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS Fig. 57 4. Remove manifold cover. Fig. 58 5. Remove compression nut from pilot valve then remove pilot tube assembly from valve. Fig. 60 7. Reverse procedure to install. NOTE: If replacing pilot and tubing, ensure a compression nut and ferrule are installed on the end of tubing that connects to pilot valve. Fig. 59 6. Remove pilot tube assembly from pilot bracket. Use pliers to separate as needed. F45471 Rev.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS panel. You may need to remove a knob depending on the orientation of the pilot adjustment screw. OVEN PILOT FLAME HEIGHT 1. Oven Pilot Adjustment 1. Remove CONTROL PANEL (30" OVENS). 2. Lower the KICK PANEL (24" & 30" OVENS) to access gas safety valve on 24" standard ovens and to view pilot flame height on all ovens. 3. Remove pilot adjustment cover screw from gas safety valve.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS adjusted as necessary. Make sure the regulator is mounted in the horizontal position with the arrow pointing in the direction of gas flow. Clean vent cap before adjusting. Fig. 66 shows gas flow direction and vent cap location. See unit data plate, riveted inside the kick panel, for manifold pressure setting information. Fig. 67 shows manifold pressure tap location. Top Burner Air Shutters Fig. 66 1.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS OVEN BURNER NOZZLE SHOWN Fig. 68 B. Insert a flat edge screwdriver into the top of regulator housing to reach the adjusting screw. While watching the manometer, turn the adjusting screw clockwise to increase pressure and counterclockwise to decrease pressure until the proper gas pressure is achieved. See data plate. C. Install the regulator closing nut. D. Remove manometer from pressure tap. E.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS 6. 7. Replace thermostat knob. 8. Tighten screws and replace knob. A. 9. Verify temperature setting at 400°F and 450°F. Wait 15 minutes for oven to heat up at each setting. If actual oven temperature is not within 15°F, readjust as outlined in this procedure. If three consecutive adjustments do not produce acceptable results, replace thermostat and verify calibration.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS B. While holding outer shaft in place, turn inner screw using a small flat edge screwdriver 1/8 turn clockwise to decrease and counterclockwise to increase. 1/4 turn = 35°F. See Fig. 72 below. C. Verify temperature at 350°F (or customers preferred setting). Allow oven to cycle 3 times. E.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS B. C. While holding outer shaft in place, turn inner screw using a small flat edge screwdriver 1/8 turn clockwise to decrease and counterclockwise to increase. 1/4 turn = 35°F. See picture Fig. 72 under CONVECTION OVEN THERMOSTATCOMBO VALVE ADJUSTMENT. Verify temperature setting at 350°F (or customers preferred setting). Allow griddle to cycle 3 times.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS • If a VOM is not available, replace the thermocouple with a new one as outlined under STANDARD OVEN PILOT ASSEMBLY AND THERMOCOUPLE or CONVECTION OVEN PILOT ASSEMBLY AND THERMOCOUPLE or and check operation GRIDDLE PILOT ASSEMBLY AND THERMOCOUPLE. Pilot Adjustment • Turn pilot adjustment screws clockwise to decrease the flame. 1. Disconnect thermocouple from gas safety valve. • 2. Select the test to perform.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION Power Cord . . . . . . . . . . . Connects range to power source. On/Off Switch . . . . . . . . . Provides power for the convection oven motor and solenoid valve. Solenoid Valve . . . . . . . Allows gas flow to the convection oven burner assembly when solenoid is energized by the door switch (normally closed valve). Door Switch . . . . . . . . . .
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - ELECTRICAL OPERATION SCHEMATIC DIAGRAM - CONVECTION OVENS Fig. 74 Page 35 of 38 F45471 Rev.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - ELECTRICAL OPERATION WIRING DIAGRAM - CONVECTION OVENS Fig. 75 F45471 Rev.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING GENERAL SYMPTOM Pilot does not remain lit. Burner flame too yellow Slow to heat or not hot enough. Oven temperature too hot. Low burner flame (all burners). Low burner flame (individual burner). Flame floats on burner. POSSIBLE CAUSE 1. Incorrect gas pressure. 2. Pilot burner not adjusted properly. 3. Pilot burner blocked. 4. Thermocouple not positioned correctly or malfunctioning. 5.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - TROUBLESHOOTING CONVECTION OVENS ONLY SYMPTOM POSSIBLE CAUSE 1. Main power supply not on. 2. Incorrect voltage. 3. Oven door switch arm not engaging door hinge arm properely. 4. Oven door switch open or inoperative. 5. Power switch open or inoperative. 6. Convection motor inoperative. 1. Motor mounting bracket or motor mounting plate to the back of the chassis is loose. 2. Fan shroud is loose or fan is rubbing shroud. 3.