Használati útmutató Vulcan 36C-2B24GT

Vulcan sütő 36C-2B24GT

Olvassa el alább 📖 a magyar nyelvű használati útmutatót Vulcan 36C-2B24GT (56 oldal) a sütő kategóriában. Ezt az útmutatót 5 ember találta hasznosnak és 2 felhasználó értékelte átlagosan 4.5 csillagra

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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 ............................................................... 7
GRIDDLE MANIFOLD COVER (PREVIOUS PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GRIDDLE MANIFOLD COVER (CURRENT PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONTROL BRACKET COVER .......................................................................... 8
CONTROL PANEL (30" OVENS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
KICK PANEL (24" & 30" OVENS) ....................................................................... 9
BULL NOSE ............................................................................................ 9
GRIDDLE CONTROL BRACKET (PREVIOUS PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GRIDDLE CONTROL BRACKET (THERMOSTACTICALLY CONTROLED -
CURRENT PRODUCTION) ........................................................................ 10
STANDARD OVEN PILOT ASSEMBLY AND THERMOCOUPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD OVEN BURNER .......................................................................... 11
STANDARD OVEN THERMOSTAT (24" OVEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD OVEN THERMOSTAT (30" OVEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONVECTION OVEN PILOT ASSEMBLY AND THERMOCOUPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONVECTION OVEN BURNER ....................................................................... 15
CONVECTION OVEN THERMOSTAT VALVE .......................................................... 16
CONVECTION OVEN BLOWER AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BURNER ORIFICE (STANDARD AND CONVECTION OVENS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
GAS SAFETY VALVE (STANDARD AND CONVECTION OVENS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TOP BURNER PILOT VALVE .......................................................................... 19
TOP BURNER ASSEMBLY ............................................................................ 20
TOP BURNER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TOP BURNER ORIFICE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OVEN DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GAS PRESSURE REGULATOR ....................................................................... 22
CONVECTION OVEN DOOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CONVECTION OVEN SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GRIDDLE THERMOSTAT VALVE (PREVIOUS PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GRIDDLE THERMOSTAT VALVE (CURRENT PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GRIDDLE GAS SAFETY VALVE (PREVIOUS PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GRIDDLE SAFETY VALVE (CURRENT PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GRIDDLE PILOT ASSEMBLY AND THERMOCOUPLE (PREVIOUS PRODUCTION) . . . . . . . . . . . . . . . . . . . . 30
GRIDDLE PILOT ASSEMBLY AND THERMOCOUPLE (CURRENT PRODUCTION) . . . . . . . . . . . . . . . . . . . . 30
GRIDDLE BURNER ORIFICE HOOD (PREVIOUS PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
GRIDDLE BURNER ORIFICE HOOD (CURRENT PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHARBROILER PILOT ................................................................................ 32
CHARBROILER BURNER ............................................................................. 33
SAFETY VALVE (FLAME SAFETY OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OVEN SAFETY VALVE (CURRENT PRODUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ROTARY IGNITER (FLAME SAFETY OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TOP BURNER PILOT ASSEMBLY AND THERMOCOUPLE (FLAME SAFETY OPTION) . . . . . . . . . . . . . . . . 39
DOOR STOP .......................................................................................... 41
SERVICE PROCEDURES AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PILOT FLAME HEIGHT ............................................................................... 43
OVEN PILOT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES
F45471 Rev. G (0121) Page 2 of 56
TOP BURNERS PILOT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
BURNER AIR SHUTTER ADJUSTMENT ............................................................... 43
REGULATOR ADJUSTMENT .......................................................................... 44
BURNER NOZZLE CHECK ............................................................................ 45
STANDARD OVEN THERMOSTAT BY-PASS FLAME ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
STANDARD OVEN THERMOSTAT TEMPERATURE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CONVECTION OVEN THERMOSTAT VALVE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION ...................................................................................... 47
CALIBRATION .................................................................................... 47
GRIDDLE THERMOSTAT VALVE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATION ...................................................................................... 48
CALIBRATION .................................................................................... 48
THERMOCOUPLE TEST .............................................................................. 49
OPERATION ...................................................................................... 49
PILOT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
THERMOCOUPLE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CHARBROILER PILOT ADJUSTMENT ................................................................ 50
ELECTRICAL OPERATION ................................................................................ 51
COMPONENT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SEQUENCE OF OPERATION - CONVECTION OVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SCHEMATIC DIAGRAM - CONVECTION OVENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
WIRING DIAGRAM - CONVECTION OVENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TROUBLESHOOTING ..................................................................................... 55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES
© HOBART SERVICE 2021
Page 3 of 56 F45471 Rev. G (0121)
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.
TOOLS
Standard
• Standard set of hand tools.
• VOM with minimum of NFPA-70E CATIII 600V,
UL/CSA/TUV listed. Sensitivity of at least 20,000
ohms per volt and the ability to measure DC
micro amps. Meter leads must also be rated at
CAT III 600V.
• Pipe thread sealant suitable for use with propane
gas.
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 1" long bolts that fit into door hinge slot. (size
varies depending on revision of doors).
The screws 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.
• A non permanent type sealer (preferably fast
drying) such as nail polish or equivalent 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.
• Pipe taps may be needed to clean or repair
internal threads on gas manifolds. Use a wire
brush to clean external pipe threads on fittings.
• 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
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)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - GENERAL
Page 5 of 56 F45471 Rev. G (0121)
Orifice Size Requirements
• See Orifice Chart in Parts Catalog F43260
ENDURANCE/CHALLENGER MODULAR
SERIES GAS RANGES.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - GENERAL
F45471 Rev. G (0121) Page 6 of 56
Fig. 6
5. Reverse procedure to install.
CONTROL BRACKET COVER
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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.
Fig. 7
CONTROL PANEL (30" OVENS)
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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.
Convection Oven Panel Shown
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 8 of 56
KICK PANEL (24" & 30" OVENS)
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Lift up on kick panel and rotate down 90°.
2. Remove screws securing kick panel mounting
brackets (2) to the oven and remove kick panel.
3. Reverse procedure to install.
Fig. 9
BULL NOSE
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. 10
5. Reverse procedure to install.
GRIDDLE CONTROL BRACKET
(PREVIOUS PRODUCTION)
NOTE: The information in this section applies only to
production built up to 5/12/19 for Manual Griddles
models starting at Serial Number 481949646.
Production built up to 2/14/19 for T-stat Griddles
models Serial Number 481938361.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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.
Fig. 11
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 9 of 56 F45471 Rev. G (0121)
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.
Fig. 12
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. 13
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.
GRIDDLE CONTROL BRACKET
(THERMOSTACTICALLY
CONTROLED - CURRENT
PRODUCTION)
NOTE: The information in this section applies only to
current production starting on 5-13-19 for Manual
Griddles models starting at Serial Number
481949647. Starting on 2-15-19 for T-stat Griddles
models Serial Number 481938362.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove GRIDDLE MANIFOLD COVER
(CURRENT PRODUCTION).
2. Remove BULL NOSE.
3. Remove end caps (1, Fig. 14) on both sides.
4. Remove bracket mounting screws. Two screws
in each of the following locations:
• Right side mounting screws (2, Fig. 14).
Fig. 14
• Left side mounting screws (Fig. 15).
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 10 of 56
Fig. 15
5. Pull bracket (1, Fig. 16) forward.
Fig. 16
6. Reverse procedure to install.
STANDARD OVEN PILOT
ASSEMBLY AND THERMOCOUPLE
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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.
2. Remove cavity bottom by lifting up and sliding
out.
3. Remove screws securing oven pilot assembly to
burner carrier.
Fig. 17
4. Lower the KICK PANEL (24" & 30" OVENS).
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 and follow lockout / tagout
procedures.
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).
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 11 of 56 F45471 Rev. G (0121)
2. Hold the tab on burner carrier with plyers to
support it then remove compression nut from
burner elbow fitting to disconnect gas supply
tubing.
3. Remove screws securing burner carrier to oven
frame.
Fig. 18
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.
7. Remove screws securring burner to the burner
carrier.
Fig. 19
8. Slide oven burner off the burner nozzle to
remove.
9. Reverse procedure to install.
10. Perform BURNER AIR SHUTTER
ADJUSTMENT.
STANDARD OVEN THERMOSTAT
(24" OVEN)
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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. Pull out crumb tray.
2. Remove GRIDDLE MANIFOLD COVER
(PREVIOUS PRODUCTION).
3. Remove oven thermostat knob.
4. Remove screw securing thermostat cover to
oven frame.
Fig. 20
5. Remove compression nut from elbow fitting at
the rear of thermostat.
6. Remove screws securing thermostat to mounting
flange.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 12 of 56
Fig. 24
Fig. 25
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.
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 and follow lockout / tagout
procedures.
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. 26
3. Pull burner carrier out through opening in lower
oven frame enough to access the oven pilot
assembly.
Fig. 27
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 14 of 56
CONVECTION OVEN
THERMOSTAT VALVE
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 thermostat valve
fittings.
3. Remove screws securing thermostat valve to
mounting bracket.
Fig. 30
4. Remove thermostat valve from gas line tubing.
5. Remove oven racks.
6. Open oven door and remove screws securing
capillary tube mounting clips (4) at the top of oven
cavity.
Fig. 31
NOTE: Capillary tube is permanently attached to
thermostat valve.
7. Remove all mounting clips from capillary tube
and retain for reuse.
8. Pull capillary tube through the hole in oven
sidewall and remove thermostat valve from oven.
A. Remove insulation sleeve from capillary
tube for installation on replacement
thermostat capillary tube.
B. Note orientation of compression fittings 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.
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 BLOWER AND
MOTOR
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove cover from electrical junction box at the
rear of range.
2. Disconnect motor wiring at junction box.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 16 of 56
3. Loosen screw securing armored cable to junction
box.
4. Remove oven racks and rack guides from oven.
5. Place cardboard over the oven cavity bottom to
protect it during motor removal.
6. Remove screws securing motor mount panel to
the oven. Pull the assembly out from the oven.
Fig. 32
7. Remove screws (4) securing blower cover to
motor mount panel.
Fig. 33
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.
10. Remove mounting nuts and spacers securing
motor mounting brackets (2) to motor mount
panel.
Fig. 34
A. Remove motor mounting brackets from
motor for reuse.
B. Remove cover from motor junction box,
disconnect wires and remove armored
cable from motor junction box.
C. Inspect the motor insulation located
between the motor mounting brackets and
the motor mount panel. Replace if
damaged.
11. Install motor mounting brackets and armored
cable onto replacement motor.
12. Reverse procedure to install and check for proper
operation.
BURNER ORIFICE (STANDARD
AND CONVECTION OVENS)
1. Access burner for the type of oven being serviced
as outlined under STANDARD OVEN BURNER
or CONVECTION OVEN BURNER.
2. Remove the orifice spud (1, Fig. 35) from hood
(2, Fig. 35).
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 17 of 56 F45471 Rev. G (0121)
Fig. 35
NOTE: There are two types of orifices. The orifice
used in the oven has a spud that screws into a
threaded hood (1, Fig. 36). The open top and griddle
uses a pre-drilled orifice hood (2, Fig. 36).
Fig. 36
3. Perform BURNER NOZZLE CHECK.
4. Reverse procedure to install.
5. Check for proper operation.
GAS SAFETY VALVE (STANDARD
AND CONVECTION OVENS)
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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) on
standard and convection ovens or lower the
KICK PANEL (24" & 30" OVENS) on standard
24" ovens.
2. Remove pilot tubing and thermocouple from gas
safety valve.
3. Remove inlet and outlet gas lines from gas safety
valve.
Gas Safety Valve on Standard 24" Oven
Shown inFig. 37
Fig. 37
Gas Safety Valve on 30" Oven Shown in Fig.
38
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 18 of 56
TOP BURNER ASSEMBLY
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 top burner grates (front and rear) from
the module section being serviced.
2. Remove pilot from mounting clip on the top
burner assembly. Move pilot away from burner
assembly.
Fig. 40
3. Lift burner heads off the top burner assembly.
4. Lift the top burner assembly at the rear and pull
away from manual valves.
A. Remove pilot mounting clip and flash tube
from the top burner assembly for resuse on
replacement burner assembly.
5. Reverse procedure to install.
NOTE: When installing, ensure that each end of the
flash tube is aligned with the ignition ports on the
burner “venturi” casting for proper burner ignition.
Fig. 41
6. Check for proper operation.
7. Verify BURNER AIR SHUTTER ADJUSTMENT.
TOP BURNER CONTROL VALVE
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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. 42
1. Remove GRIDDLE MANIFOLD COVER
(PREVIOUS PRODUCTION).
2. Remove TOP BURNER ASSEMBLY.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 20 of 56
3. Remove TOP BURNER PILOT VALVE.
4. Remove top burner control valve from the
manifold.
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.
NOTE: When installing, ensure top burner control
valve is aligned and centered in the burner assembly
opening. The valve must be perpendicular to the
manifold.
7. Check for proper operation.
TOP BURNER ORIFICE HOOD
1. Access top burner orifice hood as outlined under
TOP BURNER ASSEMBLY.
2. Remove the orifice hood from top burner control
valve.
3. Reverse procedure to install.
4. Check for proper operation.
OVEN DOOR
Removal
1. Remove CONTROL PANEL (30" OVENS).
NOTE: Removal of control panel is to provide
additional space on the right side of door to ease door
removal and installation.
2. Lower KICK PANEL (24" & 30" OVENS).
3. Fully open the oven door.
When servicing hinges, use cut resistant glove
with additional padding to compress hinge to
insert bolt into slot or remove bolt after door is
removed.
4. Insert a tight fitting 1" long bolt/screw (size
depends on door revision) into each door hinge
slot at the top of the spring loaded hinge.
Use the tightest fitting bolts / screws to relieve
spring tension on door hinge during removal and
installation.
Fig. 43
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. Remove door as follows:
A. Hold door at bottom corners then lift the door
up and out to disengage the hinges.
B. The notch on swivel hinge must release
from bottom edge of the door hinge stop to
remove door. As needed, lift up on the
swivel hinges using forefinger to aid in
releasing.
C. The spring-loaded hinge must release from
the roller inside the slot on door hinge stop
to remove door.
7. If replacing door or door spring hinge, position the
door face down. Press down on hinge enough to
relieve spring force then remove bolt from door
hinge slot.
Installation
1. Compress each spring-loaded hinge enough to
insert the bolt into the slot at top of hinge.
2. Hold door at bottom corners while facing the oven
cavity. Place knee on the front of door to help
balance it as necessary during installation.
A. Using index fingers, lift swivel hinges until
they touch the spring-loaded hinges and
hold in place.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 21 of 56 F45471 Rev. G (0121)
B. Tilt the top of door toward the oven so that
the swivel hinge is at a slightly downward
angle to pass between the bar and bottom
edge of door hinge stop.
C. Insert hinges into the slots making sure that
the spring-loaded hinges go above the bar
to catch on the roller and the swivel hinges
go underneath the bar to catch on the
bottom edge of door hinge slot.
D. Lower the door and position it as necessary
to engage the swivel hinge slots with the
bottom edge of both door hinge slots.
Fig. 44
3. Fully open door to check operation. If bottom
edge of door rubs the front edge of cavity bottom
then the swivel hinge is not engaged as
described.
A. To seat the swivel hinge, open door
approximately 30° and pull in the same
direction on the door handle. The hinge
should drop into place.
4. Open door and check operation. If okay, remove
bolts and close door. If not okay, remove door
and repeat installation procedure.
5. On convection ovens, verify door switch is
operating properly.
6. Reinstall oven control panel.
7. Raise kick panel.
GAS PRESSURE REGULATOR
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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.
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
1. Thread regulator onto pipe hand tight with arrow
pointing in direction of gas flow to the range.
Fig. 45
2. Tighten regulator securely in horizontal position
with the regulator adjustment upward as
described on regulator.
NOTE: Regulator will not function properly without
adjustment screw pointing upward.
3. Connect supply gas line to gas pressure
regulator inlet.
4. Adjust regulator as outlined in REGULATOR
ADJUSTMENT.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 22 of 56
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. 46
4. Open door to unoperate the switch.
5. Note lead wire locations and disconnect from
door switch.
6. Remove screws and mounting nuts securing
door switch to door switch bracket.
Fig. 47
7. Reverse procedure to install and check door
switch for proper operation.
CONVECTION OVEN SOLENOID
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 door switch bracket as outlined under
CONVECTION OVEN DOOR SWITCH. Allow
bracket to rest at the bottom of control area.
2. Remove screws securing the mounting bracket
that holds the safety valve, oven thermostat and
the oven solenoid to the oven frame.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 23 of 56 F45471 Rev. G (0121)
Fig. 48
3. Remove compression nuts on the inlet and outlet
of solenoid.
4. Remove screws and mounting nuts securing
solenoid to bracket.
5. Disconnect lead wires from solenoid.
Fig. 49
6. Remove fittings from solenoid for reuse on
replacement valve.
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
7. Reverse procedure to install and check for proper
operation.
GRIDDLE THERMOSTAT VALVE
(PREVIOUS PRODUCTION)
NOTE: The information in this section applies only to
production built up to 5/12/19 for Manual Griddles
models starting at Serial Number 481949646.
Production built up to 2/14/19 for T-stat Griddles
models Serial Number 481938361.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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. Raise griddle plate from the front and support
using 4x4 blocks.
3. Pull thermostat bulb out of the holder for the
thermostat valve being replaced.
NOTE: Capillary tube is permanently attached to
thermostat valve.
Fig. 50
4. Remove CONTROL BRACKET COVER.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 24 of 56
5. If installed, remove compression nut on the
flexible tubing gas line that supplies gas to the
manifold on the adjacent open top burner
section.
Fig. 51
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. 52
7. Lift up control bracket and tilt forward to access
griddle thermostat valves.
8. Partially install the grease drawer leaving enough
of the drawer extended to support the control
bracket while servicing.
Fig. 53
9. Remove compression nuts from thermostat valve
fittings for the thermostat being replaced.
Fig. 54
10. Remove screws (3) securing thermostat valve to
the control bracket and remove the thermostat
valve.
Fig. 55
A. Note orientation of compression fittings on
the thermostat valve and remove for
installation on replacement valve.
B. Remove insulation sleeve from capillary
tube for installation on replacement
thermostat capillary tube.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 25 of 56 F45471 Rev. G (0121)
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
When installing, do not bend and kink the capillary
tubes or damage to the controls may occur. Ensure
capillary tubes are routed properely through mounting
slots before lowering the griddle or damage to the
controls may occur.
NOTE: When installing, ensure orifice hood is aligned
and centered in the burner assembly opening. The
griddle orifice bracket must be perpendicular to the
manifold.
11. Reverse procedure to install and check for proper
operation.
GRIDDLE THERMOSTAT VALVE
(CURRENT PRODUCTION)
NOTE: The information in this section applies only to
current production starting on 5-13-19 for Manual
Griddles models starting at Serial Number
481949647. Starting on 2-15-19 for T-stat Griddles
models Serial Number 481938362.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Remove GRIDDLE CONTROL BRACKET
(THERMOSTACTICALLY CONTROLED -
CURRENT PRODUCTION).
2. Remove BULL NOSE.
3. Disconnect inlet and outlet brass fittings.
Fig. 56
4. Disconnect pilot burner flex line.
Fig. 57
5. Remove thermostat mounting screws.
Fig. 58
6. Lift griddle plate and secure with work blocks on
both sides.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 26 of 56
GRIDDLE GAS SAFETY VALVE
(PREVIOUS PRODUCTION)
NOTE: The information in this section applies only to
production built up to 5/12/19 for Manual Griddles
models starting at Serial Number 481949646.
Production built up to 2/14/19 for T-stat Griddles
models Serial Number 481938361.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 GRIDDLE CONTROL BRACKET
(PREVIOUS PRODUCTION).
2. Remove pilot tubing and thermocouple from gas
safety valve.
3. Remove compression nuts from gas safety valve
fittings.
Fig. 64
4. Remove screws (2) securing gas safety valve to
the control bracket and remove the valve.
A. Note orientation of compression fittings on
the valve and remove for installation on
replacement valve.
Fig. 65
When installing, do not bend and kink the capillary
tube or damage to the control may occur.
Clean pipe threads and apply pipe joint compound.
Any pipe joint compound used must be resistant to the
reaction of propane gases.
NOTE: When installing, ensure orifice hood is aligned
and centered in the burner assembly opening.
5. Reverse procedure to install and check for proper
operation.
GRIDDLE SAFETY VALVE
(CURRENT PRODUCTION)
NOTE: The information in this section applies only to
current production starting on 5-13-19 for Manual
Griddles models starting at Serial Number
481949647. Starting on 2-15-19 for T-stat Griddles
models Serial Number 481938362.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Remove GRIDDLE MANIFOLD COVER
(CURRENT PRODUCTION).
2. Remove manifold support bracket if applicable.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 28 of 56
Fig. 66
3. Remove gas supply flex line.
Fig. 67
4. Remove thermocouple.
Fig. 68
5. Unscrew safety valve from gas supply manifold.
Fig. 69
6. Reverse procedure to install.
NOTE: Remove and reuse gray seal, unless also
being replaced
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
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.
7. Verify proper operation.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 29 of 56 F45471 Rev. G (0121)
GRIDDLE PILOT ASSEMBLY AND
THERMOCOUPLE (PREVIOUS
PRODUCTION)
NOTE: The information in this section applies only to
production built up to 5/12/19 for Manual Griddles
models starting at Serial Number 481949646.
Production built up to 2/14/19 for T-stat Griddles
models Serial Number 481938361.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 GRIDDLE CONTROL BRACKET
(PREVIOUS PRODUCTION).
2. Remove screws (2) securing pilot assembly
mounting bracket to griddle burner box.
A. If replacing thermocouple only, remove
thermocouple from pilot assembly and gas
safety valve. Continue to last step.
3. If replacing pilot assembly, remove pilot tubing
and thermocouple from pilot assembly.
Fig. 70
4. Remove screws (2) securing pilot assembly to
mounting bracket.
5. Reverse procedure to install and check for proper
operation.
When installing, do not bend and kink the capillary
tube or damage to the control may occur.
NOTE: When installing, ensure orifice hood is aligned
and centered in the burner assembly opening.
GRIDDLE PILOT ASSEMBLY AND
THERMOCOUPLE (CURRENT
PRODUCTION)
NOTE: The information in this section applies only to
current production starting on 5-13-19 for Manual
Griddles models starting at Serial Number
481949647. Starting on 2-15-19 for T-stat Griddles
models Serial Number 481938362.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Remove GRIDDLE THERMOSTAT VALVE
(CURRENT PRODUCTION).
2. Remove screw between pilot burner gas supply
line and thermocouple.
Fig. 71
3. Remove gas supply flex tube.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 30 of 56
Fig. 72
4. Reverse procedure to install.
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.
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
5. Verify proper operation.
GRIDDLE BURNER ORIFICE HOOD
(PREVIOUS PRODUCTION)
NOTE: The information in this section applies only to
production built up to 5/12/19 for Manual Griddles
models starting at Serial Number 481949646.
Production built up to 2/14/19 for T-stat Griddles
models Serial Number 481938361.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 GRIDDLE CONTROL BRACKET
(PREVIOUS PRODUCTION).
2. Remove the orifice hood from fitting.
Fig. 73
3. Reverse procedure to install and check for proper
operation.
NOTE: When installing, ensure orifice hood is aligned
and centered in the burner assembly opening.
GRIDDLE BURNER ORIFICE HOOD
(CURRENT PRODUCTION)
NOTE: The information in this section applies only to
current production starting on 5-13-19 for Manual
Griddles models starting at Serial Number
481949647. Starting on 2-15-19 for T-stat Griddles
models Serial Number 481938362.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Remove GRIDDLE MANIFOLD COVER
(CURRENT PRODUCTION).
2. Remove control bracket GRIDDLE CONTROL
BRACKET (THERMOSTACTICALLY
CONTROLED - CURRENT PRODUCTION).
3. Remove nut (1, Fig. 74).
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 31 of 56 F45471 Rev. G (0121)
Fig. 74
4. Carefully pull forward for access and remove
orifice.
5. Reverse procedure to install.
6. Verify proper operation.
CHARBROILER PILOT
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove CHARBROILER BURNER to access
pilot.
2. Remove crumb trays.
Fig. 75
3. Remove knobs from front of range.
Fig. 76
4. Remove manifold cover.
Fig. 77
5. Remove compression nut from pilot valve then
remove pilot tube assembly from valve.
Fig. 78
6. Remove pilot tube assembly (1, Fig. 79) from
pilot bracket (2, Fig. 79). Use pliers to separate
as needed.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 32 of 56
Fig. 79
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.
CHARBROILER BURNER
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Fig. 80
Charbroiler Burner Components - Front View
• [1] Grate
• [2] Radiant
• [3] Burner
• [4] Deflector
1. Remove grate (1, Fig. 81) from charbroiler.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 33 of 56 F45471 Rev. G (0121)
Fig. 81
2. Remove radiant (1, Fig. 82) to access burner.
Fig. 82
3. Remove burner (1, Fig. 83) and deflector (2, Fig.
83) by lifting at the rear of burner.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 34 of 56
Fig. 83
4. Remove burner rod (1, Fig. 84) securing deflector
(2, Fig. 84) to burner.
Fig. 84
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.
SAFETY VALVE (FLAME SAFETY
OPTION)
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 GRIDDLE MANIFOLD COVER
(PREVIOUS PRODUCTION).
2. Disconnect pilot flex tube (1, Fig. 85) from gas
manifold.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 35 of 56 F45471 Rev. G (0121)
Fig. 85
3. Remove top burner grates (front and rear) from
the range.
4. Lift grate support (1, Fig. 86) from range top.
5. Remove heat shield (2, Fig. 86).
Fig. 86
6. Disconnect thermocouple (1, Fig. 87) from safety
valve.
Fig. 87
7. Lift the top burner assembly at the rear and slowly
pull away from manual valves. Lower the burner
assembly and allow it to rest inside the burner
box.
8. Remove gas manifold from frame (1, Fig. 88).
9. Disconnect safety valve compression nut (2, Fig.
88) from tube adapter on gas manifold then
remove safety valve from gas manifold.
Fig. 88
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
NOTE: See TOOLS for cleaning of pipe threads.
When installing, do not bend and kink the capillary
tubes or damage to the controls may occur.
10. Reverse procedure to install and check for proper
operation.
OVEN SAFETY VALVE (CURRENT
PRODUCTION)
NOTE: The information in this section applies only to
current production starting on 5-13-19 for Manual
Griddles models starting at Serial Number
481949647. Starting on 2-15-19 for T-stat Griddles
models Serial Number 481938362.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 36 of 56
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Loosen set screw in knob (1, Fig. 89) and
remove.
Fig. 89
2. Remove access cover screw (Fig. 90).
Fig. 90
3. Lift cover up and off retainer screws (Fig. 91).
Fig. 91
4. Disconnect gas connections.
• Main gas supply (1, Fig. 92).
• Gas flex line (2, Fig. 92) out to burner.
• Gas flex line (3, Fig. 92) out to pilot.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 37 of 56 F45471 Rev. G (0121)
Fig. 92
5. Remove fitting (1, Fig. 93), retaining nut (2, Fig.
93) and pull assembly off bracket (3, Fig. 93)
Fig. 93
6. Remove thermocouple (1, Fig. 94).
Fig. 94
7. Remove capillary from inside oven mounting
bracket.
Fig. 95
NOTE: Removing bulb may be easier by removing
bracket. Bracket must be pinched to relieve tension to
remove bulb.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 38 of 56
Fig. 96
8. Remove thermostat/pilot safety valve with
capillary tube.
9. Reverse procedure to install.
Clean pipe threads and apply thread sealant that
is suitable for use with propane gases.
10. Verify proper operation.
ROTARY IGNITER (FLAME SAFETY
OPTION)
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
1. Remove GRIDDLE MANIFOLD COVER
(PREVIOUS PRODUCTION).
2. Disconnect igniter wires (1, Fig. 97) at the rear of
rotary igniter (2, Fig. 97).
3. Remove screws and nuts (3, Fig. 97) securing
rotary igniter (2, Fig. 97) to the mounting bracket
on gas manifold then remove rotary igniter.
4. Remove screws and spacer nuts from rotary
igniter and install them on the replacement rotary
igniter.
Fig. 97
5. Reverse procedure to install and check for proper
operation.
TOP BURNER PILOT ASSEMBLY
AND THERMOCOUPLE (FLAME
SAFETY OPTION)
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Shut off the gas before servicing the
unit and follow lockout / tagout
procedures.
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 GRIDDLE MANIFOLD COVER
(PREVIOUS PRODUCTION).
2. Disconnect pilot flex tube from gas manifold.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 39 of 56 F45471 Rev. G (0121)
Fig. 98
3. Disconnect igniter wires (1, Fig. 99) from rotary
igniter (2, Fig. 99).
Fig. 99
4. Remove top burner grates (front and rear) from
the range.
5. Lift grate support (1, Fig. 100) from range top.
6. Remove heat shield (2, Fig. 100).
Fig. 100
7. Disconnect thermocouple (1, Fig. 101) from
safety valve.
Fig. 101
8. Remove screws (1, Fig. 102) securing pilot
assembly (2, Fig. 102) and flash tube (3, Fig.
102) to the top burner assembly. Slide pilot
assembly out from mounting slot in flash tube.
Fig. 102
NOTE: The pilot assembly picture above is shown
with the pilot shield removed.
9. If replacing thermocouple only, remove
thermocouple (1, Fig. 103) from pilot assembly.
Continue to last step.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 40 of 56
10. If replacing pilot assembly, remove pilot flex (2,
Fig. 103) tube and thermocouple (1, Fig. 103).
A. Remove screw (3, Fig. 103) securing pilot
assembly to mounting bracket.
Fig. 103
11. Remove insulation sleeving from thermocouple
tube and igniter wire. Retain for use on
replacement part.
12. Reverse procedure to install and check for proper
operation.
When installing, do not bend and kink the capillary
tubes or damage to the controls may occur.
NOTE: When installing be sure to route thermocouple
through the insulation sleeving. And, ensure the flash
tube is aligned properly between the burner heads.
Refer to TOP BURNER ASSEMBLY removal
procedure.
DOOR STOP
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove OVEN DOOR.
2. Tie string or flexible wire around pin or roller (1,
Fig. 104).
NOTE: Holding onto string/wire while removing stop
will secure it from failing down into oven cavity.
Fig. 104
3. Unscrew stop bracket from oven frame.
4. Slide stop bracket down cavity channel and out
through opening (3, Fig. 104).
5. Tie string or flexible wire around pin or roller on
new bracket (1, 2, Fig. 105) to assist installation
up through cavity channel.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
Page 41 of 56 F45471 Rev. G (0121)
Fig. 105
6. Align oven frame and stop bracket mounting
holes (2, Fig. 105) and install screws.
7. Install OVEN DOOR.
8. Verify door operation.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS
F45471 Rev. G (0121) Page 42 of 56
SERVICE PROCEDURES AND ADJUSTMENTS
PILOT FLAME HEIGHT
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.
Gas Safety Valve on 30" Ovens Shown
(Convection & Standard)
4. Rotate pilot adjustment screw toclockwise
decrease and to increase pilotcounterclockwise
flame height.
5. Pilot flame is in adjustment when it is
approximately ½" tall and flame surrounds one
third of the thermocouple down from the tip of the
hot junction end.
6. Reverse procedure to install and check for proper
operation.
NOTE: After adjustment, ensure cover screw is re-
installed.
Top Burners Pilot Adjustment
To adjust the pilot flame height of the top burners,
locate the pilot adjustment screws found on the front
manifold pipe between the burner control knobs. It is
not necessary to remove the gas manifold cover as
adjustment access holes have been provided in the
panel. You may need to remove a knob depending on
the orientation of the pilot adjustment screw.
1. Locate the pilot adjustment screw located behind
the adjustment access hole in the panel.
Fig. 107
2. Rotate the screw clockwise to decrease and
counterclockwise to increase flame height.
3. Pilot is in adjustment when it will stay on
continually and lights the burners without
delayed ignition.
4. On range models with a thermocouple, the pilot
burner flame should surround the thermocouple
at the hot tip end and cover an area of at least
3/8" to 1/2" on the thermocouple hot tip end.
BURNER AIR SHUTTER
ADJUSTMENT
The efficiency of the burner depends on a delicate
balance between the air supply and volume of gas.
Whenever this balance is disturbed, poor operating
characteristics and excessive gas consumption may
occur. An air shutter on the front of the burner controls
the gas mixer balance. A yellow streaming flame on
the burner is an indication of insufficient primary air.
To correct this condition, loosen the shutter screw and
rotate the air shutter open until the flame begins to lift
from the burner, then close the shutter slightly and
tighten the shutter screw. A proper flame should be
blue in color, well-defined and seated on the burner
port. A white-blue flame is a result of excessive
primary air.
NOTE: The factory default air shutter positions are
half open natural; full open propane.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND
ADJUSTMENTS
Page 43 of 56 F45471 Rev. G (0121)
Top Burner Air Shutters
Oven Burner Air Shutter
Charbroiler Burner Air Shutter
REGULATOR ADJUSTMENT
NOTE: Regulators come preset, but should be
checked anytime one is installed. Before adjusting
regulator, check incoming gas line pressure. Incoming
pressure must be 6-14" W.C. for natural gas and
11-14" W.C. for propane gas. If incoming pressure is
not correct, have the gas source checked and
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. 111 shows gas flow direction
and vent cap location.
See unit data plate, riveted inside the kick panel, for
manifold pressure setting information. Fig. 112 shows
manifold pressure tap location.
Fig. 111
1. Connect manometer to either of the pressure
taps provided on the range gas piping between
the burner control valve sets. If pressure taps are
not available, install a pipe tee and hose barb
assembly on the outlet of the regulator. See
TOOLS.
Fig. 112
2. Open the valves to turn on approximately half of
the units burners to the full on position and check
manometer reading. The reading should be 5"
W.C. for natural gas and 10" W.C. for propane
gas. Tolerance is ±0.3" W.C.
3. If manifold pressure is not correct, adjust the
regulator as follows:
A. Remove the regulator closing nut.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND
ADJUSTMENTS
F45471 Rev. G (0121) Page 44 of 56
Fig. 113
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. Apply thread sealant to pressure tap plug
and reinstall. Thread sealant must be
insoluble in propane and natural gas.
BURNER NOZZLE CHECK
The burner nozzle is mounted between the oven gas
supply tubing/mounting bracket and the u-burner
assembly. If burner operation seems poor and other
systems have been checked, access the burner for
the range section being serviced and remove the
burner nozzle.
• Check for blockage or damage.
• Verify gas orifice hood is correct for the altitude.
See SPECIFICATIONS for Orifice Size
Requirements.
OVEN BURNER NOZZLE SHOWN
STANDARD OVEN THERMOSTAT
BY-PASS FLAME ADJUSTMENT
NOTE: The bypass flame setting has a direct affect
on calibration, and must be verified prior to checking
or adjusting calibration of any "modulating
thermostat". The by-pass flame can be viewed
through the kick panel for adjustment.
All burners on the device must be on during by-pass
flame adjustment.
1. Turn thermostat knob to 375°F.
2. Wait 15 minutes for oven to heat up.
3. Turn thermostat knob to lowest oven setting. DO
NOT TURN OFF.
4. Observe burner flame. The flame should be
approximately 1/8" and stable on each port as
shown in Fig. 115.
Fig. 115
By-Pass Flame shown in Fig. 115
Item Description
1
Gap in flame, or some
flickering of the flame is
acceptable, only in the U-
shape bend of the burner.
2 By-Pass flame.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND
ADJUSTMENTS
Page 45 of 56 F45471 Rev. G (0121)
3 Oven burner.
5. Remove thermostat knob.
6. With a small flat edge screwdriver, turn by-pass
flame adjustment screw Fig. 116
counterclockwise to increase by-pass flame or
clockwise to decrease flame until both legs of
burner have approximately 1/8" stable flame on
each port. Ports should be set to just above
“flickering”.
Fig. 116
7. Replace thermostat knob.
A. Turn knob to 400°F .
B. Verify increase in flame height on burner
ports.
8. Turn knob back to lowest oven setting. Verify
decrease in by-pass flame height on burner ports
and that burner remains lit.
9. Verify STANDARD OVEN THERMOSTAT
TEMPERATURE CALIBRATION.
STANDARD OVEN THERMOSTAT
TEMPERATURE CALIBRATION
Do not use bi-metal or mercury thermometers
when testing food equipment or products.
Chemicals within these instruments may be toxic
if exposed to food.
1. Adjust by-pass flame. Refer to STANDARD
OVEN THERMOSTAT BY-PASS FLAME
ADJUSTMENT.
NOTE: Thermometer test instrument needed for
calibration.
2. Place thermocouple of test instrument in
geometric center of oven using oven rack.
3. Light burner by turning thermostat to 350°F (122°
C).
4. Allow unit to heat until burner flame is observed
going into bypass.
5. Wait approximately 10 minutes until burner flame
has cycled on and into bypass.
6. Compare test instrument reading with dial setting
when burner goes into bypass.
• Reading within +/- 25°F (13.9°C) of dial
setting is correct calibration.
• Reading not within tolerance,
RECALIBRATE.
Recalibrate
A. Pull dial straight off dial shaft.
B. Place screwdriver through dial shaft to push
metal dial insert out of dial.
C. Replace dial back onto unit.
D. Hold thermostat dial in place.
E. Insert screwdriver into dial shaft to engage
calibration stem adjustment screw and push
inward.
DO NOT TURN SCREW, this will damage thermostat.
Fig. 117
F. Hold calibration stem screw in place and
turn thermostat dial until it is set on actual
temperature shown on test device.
G. Release calibration screw and reinstall dial
metal insert.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND
ADJUSTMENTS
F45471 Rev. G (0121) Page 46 of 56
Fig. 118
Front of Thermostat Shown in Fig. 118
Item Description
1 Inner screw for temperature adjustment .
2 Outer Shaft.
3 Direction to temperature.increase
4 Direction to temperature.decrease
5 1/4 turn equals 35 °F.
GRIDDLE THERMOSTAT VALVE
CALIBRATION
Operation
The thermostat valve is self-regulating and the
thermostat is internally connected to the valve. When
thermostat dial is set to 350°F and the griddle is below
setpoint, the valve opens to allow gas flow and burner
lights. As the griddle temperature rises, the pressure
from the sensor bulb secured to the bottom of the
griddle plate increases. Fluid in the capillary tube
expands with the temperature increase and presses
against a diaphragm in the thermostat. When the
griddle temperature reaches setpoint, the internal
valve closes to stop gas flow to burner.
When the griddle temperature decreases below
setpoint, the pressure is reduced in the capillary which
reduces the force on the diaphragm allowing the valve
to open again.
Calibration
1. Clean temperature test area on griddle zone
surface. Apply a small amount of clean cooking
oil to the test area to ensure good surface probe
contact.
2. Place a thermocouple surface probe in center of
griddle zone to verify actual temperatures
throughout adjustment. See TOOLS for
thermocouple type. See table for proper testing
locations according to griddle size.
NOTE: This procedure will need to be performed for
each testing location on all griddle zones.
Griddle
Size Distance(s) From Left Edge of Griddle
12" 6"
24" 6", 18"
36" 6", 18", 30"
NOTE: All readings taken 12" from front of griddle.
3. Turn thermostat knob to 350°F and allow griddle
to cycle 3 complete times.
A. If the customer has a preferred temperature
setting that they always operate the oven at
such as 325°, 375° or 400°, you may
calibrate to that temperature instead.
NOTE: Most calibrations are made at 350°F.
Thermostat tolerance will increase at higher
temperature settings.
4. Observe burner flame. Note temperature tester
reading when burner turns ON and OFF.
5. Add these two temperatures together, then
divide the sum by 2 to obtain an average
temperature. If the average temperature is more
than ±25° from knob setting, calibrate as follows:
A. Pull off knob. Do not rotate knob during
removal.
Do not turn the adjustment screw more than 3/8 turn
or damage to the thermostat may occur.
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. 118 under CONVECTION
OVEN THERMOSTAT-COMBO VALVE
CALIBRATION.
C. Verify temperature setting at 350°F (or
customers preferred setting). Allow griddle
to cycle 3 times.
NOTE: You must allow the griddle to cycle 3 times to
stabilize oven temperature or the calibration
adjustment may be invalid. DO NOT TURN KNOB.
D. Take a temperature reading. If temperature
is within acceptable limits, continue to next
step. If temperature is not within ±25°F then
readjust as outlined in this procedure. If 3
consecutive adjustments do not produce
acceptable results, replace thermostat and
verify calibration.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND
ADJUSTMENTS
F45471 Rev. G (0121) Page 48 of 56
E. Apply a small amount of a non permanent
type sealer (preferably fast drying) such as
nail polish or equivalent around the inner
screw head to prevent movement during
outer shaft rotation. Allow sufficient time for
the applied sealer to dry then install knob.
See TOOLS.
F. If calibrating at 350°F, verify temperature at
400°F. If calibrating at a customer preferred
temperature setting, select one temperature
setting above the customer preferred
setting. If the customers temperature setting
is 450°F, then calibrate at that temp only.
Allow oven to cycle 3 times at the
temperature setting. If actual oven
temperature is not within ±25°F of the
setting, replace thermostat and verify
calibration.
THERMOCOUPLE TEST
Operation
The thermocouple supplies a DC millivolt signal (MV)
to the gas safety valve when heated by the pilot flame.
The gas safety valve will shut off gas flow to the pilot
and main burner in case of a pilot outage. When
energized by the thermocouple voltage, the gas safety
valve is held open to permit gas flow to the pilot and
provide gas for the burner when the thermostat calls
for heat. The pilot flame height is controlled by an
adjustable needle valve located under a small cover
screw on the gas safety valve.
Pilot Checks
If experiencing pilot outages, perform the following:
Visually check pilot flame for the proper contact on
thermocouple and adjust as outlined under PILOT
FLAME HEIGHT. If adjustment does not result in a
pilot flame of proper height, then gas might not be
flowing properly to the pilot.
Check for:
• A plugged pilot orifice.
• Kinked or plugged pilot gas tubing.
• Low gas supply pressure.
Thermocouple Checks
NOTE: Tubing connection from the thermocouple tip
to gas safety valve is an electrical connection and
must be clean and dry. Do not use any sealing
compound on the threads of thermocouple nut.
Do not overtighten the thermocouple nut or the
insulator could be crushed, shorting the
thermocouple. Finger tighten the nut plus 1/4 turn with
a wrench only.
If pilot flame is correct and there are no excessive air
drafts in the room, then problem is either the
thermocouple output voltage or the gas safety valve.
Visually check the thermocouple tip (hot end) and tube
lead for:
• Loose thermocouple connection (electrical) at
the safety valve.
• Corrosion or debris on the threaded connector or
thermocouple tip causing a poor electrical
connection.
• Kinks or pinches that might cause a short
between the tube and the wire inside.
If thermocouple is loose, tighten mounting nut as
described above in NOTICE. If thermocouple
connection shows signs of corrosion or debris that
cannot be cleaned; or damage as described, replace
it and check pilot operation as outlined under PILOT
FLAME HEIGHT.
Thermocouple Test
Check the thermocouple output voltage (DC millivolts)
with a VOM as outlined in the steps below.
• If thermocouple adaptor (see TOOLS) is
available, check closed circuit voltage as outlined
in the test procedure.
• If thermocouple adaptor is not available, check
open circuit voltage as outlined in the test
procedure.
• If a VOM is not available, replace the
thermocouple with a new one as outlined under
the appropriate procedure below and check
operation.
• STANDARD OVEN PILOT ASSEMBLY
AND THERMOCOUPLE.
• CONVECTION OVEN PILOT ASSEMBLY
AND THERMOCOUPLE.
• GRIDDLE PILOT ASSEMBLY AND
THERMOCOUPLE (PREVIOUS
PRODUCTION)
• SAFETY VALVE (FLAME SAFETY
OPTION).
1. Disconnect thermocouple from gas safety valve.
2. Select the test to perform.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND
ADJUSTMENTS
Page 49 of 56 F45471 Rev. G (0121)

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Márka: Vulcan
Kategória: sütő
Modell: 36C-2B24GT

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