Vulcan-Hart EG160 Service Manual Download Page 1

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SERVICE MANUAL

V U L C A N - H A R T C O M P A N Y , P . O . B O X 6 9 6 , L O U I S V I L L E , K Y 4 0 2 0 1 - 0 6 9 6 , T E L . ( 5 0 2 ) 7 7 8 - 2 7 9 1

FORM 31054 Rev. A (5-98)

GAS RESTAURANT RANGE

EG24, 36, 48, 60, 160 AND 260

MODEL

EG24

ML-52486

EG36

ML-52487

EG48

ML-114956

EG60

ML-52488

EG160

ML-52489

EG260

ML-52490

EG36

Summary of Contents for EG160

Page 1: ...COMPANY P O BOX 696 LOUISVILLE KY 40201 0696 TEL 502 778 2791 FORM 31054 Rev A 5 98 GAS RESTAURANT RANGE EG24 36 48 60 160 AND 260 MODEL EG24 ML 52486 EG36 ML 52487 EG48 ML 114956 EG60 ML 52488 EG160 ML 52489 EG260 ML 52490 EG36 ...

Page 2: ... THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICEORMAINTENANCECAN CAUSE PROPERTY DAMAGE INJURY OR DEATH READ THE INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THI...

Page 3: ... 4 EG60 EG260 EG160 EG24 EG48 EG36 PL 53006 GAS RESTAURANT RANGE MODELS ...

Page 4: ...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 CHECK REPLACEMENT 28 STANDARD OVEN PILOT SAFETY VALVE CHECK REPLACEMENT 29 31 THERMOCOUPLE CHECK REPLACEMENT 32 OVEN BURNER NOZZLE AND ORIFICE CHECK REPLACEMENT 33 OVEN BURNER CHECK REPLACEMENT 34 TOP SECTION PILOT CHECK RE...

Page 5: ...f wiring diagrams service and parts manuals covering all Vulcan Hart equipment 3 For all field conversion service installation procedures refer to the codes and compliances outlined in the installation and operation manual 4 The unit rating plate stating model no serial no and unit gas type is located on the inside of the lower kick panel 5 Caution should be taken when servicing this equipment Som...

Page 6: ... the gas type pressure rating and voltage ratings if applicable are correct for the unit and the installation site affected If not correct make required adjustments 2 Ensure that all unit and main gas and electrical supply lines are connected properly For electrical problems check for tripped circuit breakers ADJUSTMENTS 1 Legs Casters TOOLS REQUIRED Carpenter s level channel locks If the cooked p...

Page 7: ... desired After adjustment has been made tighten the locknuts SERVICING SIMPLE CHECKS AND ADJUSTMENTS Cont Fig 1 2A 24L Oven Door J Bolt Assembly If the oven door is not closing properly the door J bolt assembly may require adjustment To adjust the J bolt assembly flip down the lower front kick panel The J bolt assembly is connected to the right hand bell crank arm Fig 2 The adjustment is made by t...

Page 8: ...fold 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 Rotate the screw clockwise to decrease and counterclockwise to increase the flame height Fig 3 Oven On rare occasions the oven pilot may need adjustment To do this 1 Remove the pilot adjustment cap Fig 4 Fig 4 OUT IN ...

Page 9: ...nd the volume of gas Whenever this balance is disturbed poor operating characteristics and excessive gas consumption will occur The gas mixer balance is controlled by an air shutter on the front of the oven burner A yellow streaming flame on the burner is an indication of insufficient air To correct this condition loosen the screw locking the shutter into position Rotate the air shutter open until...

Page 10: ...for this unit gas type is sealed within a plastic bag attached to the oven rack inside the oven cavity This regulator must be field installed by a qualified installation service representative The installer must adhere to all installation and pressure testing codes outlined in the Installation and Operation manual supplied with the equipment and local installation ordinances Natural gas regulators...

Page 11: ... 2 05 1 15 1 80 1 00 1 50 0 8 2 50 1 40 Drill Drill Drill Drill Drill 50 58 47 57 51 63 54 67 41 55 mm mm mm mm mm 1 80 1 05 2 00 1 10 1 70 0 9 1 40 0 8 2 45 1 35 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 JOIN...

Page 12: ... hot top or griddle top pilot Fig 9 PILOT LIGHTING AND ADJUSTMENTS Fig 9 3 If pilot fails to light turn main gas supply OFF Wait 5 minutes and repeat the above procedures 4 Turn one hot top or griddle top burner valve ON to remove air from the gas line Turn burner valve OFF when gas begins to flow HOT TOP AND GRIDDLE TOP PILOT BURNER ADJUSTMENTS TOOLS REQUIRED Standard flat blade screwdriver After...

Page 13: ...flow OPEN TOP BURNER ADJUSTMENTS TOOLS REQUIRED Standard flat blade screwdriver 1 After pilot is lit turn open top burners ON 2 Adjust the burner flame if necessary by rotating the adjustment screw of the pilot valve located on the manifold pipe see Fig 3 Rotate the screw clockwise to decrease and counterclockwise to increase the flame Nightly Shutdown Turn burner valve OFF pilot will remain lit C...

Page 14: ... taper Adjust pilot burner flame if necessary by rotating the pilot adjustment screw clockwise to decrease and counterclockwise to increase the burner flame The pilot adjustment valve is located on the broiler griddle manifold pipe Nightly Shutdown Turn burner valve OFF pilot will remain lit Complete Shutdown 1 Turn burner valve OFF pilot will remain lit 2 Turn main gas supply OFF STANDARD OVEN NO...

Page 15: ...nute 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 PILOT LIGHTING AND ADJUSTMENTS Cont Fig 12 PL 21433 PL 21434 ...

Page 16: ...ments However the efficiency of the range depends on a delicate balance between the air supply and the volume of gas Whenever this balance is disturbed poor operating characteristics and excessive gas consumption will occur The gas mixer balance is controlled by an air shutter on the front of the oven burner Fig 15 PL 21446 Fig 15 A yellow streaming flame on the burner is an indication of insuffic...

Page 17: ... screwdriver WARNING 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 Using a test instrument or thermometer check the oven or griddle temperature whichever is in question of heat response against the thermostat dial setting Place the thermocouple of the test instrument on the center of the oven...

Page 18: ...stall oven bottom or griddle plate Temperature Calibration TOOLS REQUIRED Thermometer test instrument not of bi metal or mercury type standard flat blade screwdriver WARNING 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 Using a test instrument or thermometer check the oven or griddle temperat...

Page 19: ...r placed through the dial shaft push the metal dial insert out of the dial Fig 19 Fig 19 6 Replace the dial back onto the unit Turn the dial to the 400 F 204 4 C mark and light the oven burner 7 After the oven has been on for at least 15 minutes check the oven temperature NOTE Keep door open only as long as necessary to obtain the reading 8 Continue to monitor the oven temperature readings every 5...

Page 20: ...0 Fig 21 12 Release the calibration screw and reinstall the dial insert 13 Set the dial to 450 F 232 2 C and recheck temperature reading as described in Steps 7 through 9 If calibration is not within 15 F 9 4 C of the dial setting the thermostat must be replaced 11 While holding stem calibration screw in place turn thermostat dial until it is set on the actual temperature shown by the testing devi...

Page 21: ...shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 45 kPa In addition the appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valves during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 45 ...

Page 22: ...as or 10 0 Water Column 2 5 kPa propane gas turn two open top burners ON 4 Recheck the pressure reading The reading should not fluctuate more than 10 0 7 kPa If reading is not within tolerance replace the regulator NOTE When the burners are OFF if the pressure reading climbs to an outlet regulator pressure stated in Step 2 check the regulator vent for obstruction Figs 24 25 Fig 24 Fig 25 Check als...

Page 23: ...ounterclockwise rotation decreases pressure After resetting the pressure to the correct setting reinstall the adjustment cap and remove the testing equipment REGULATOR INSTALLATION TOOLS REQUIRED Slip joint plier or pipe wrench NOTE The pressure regulator must be attached to the unit in the horizontal position with the arrow pointing in the direction of the gas flow unless at some point in time th...

Page 24: ...RMOSTAT 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 From inside the oven cavity remove the capillary bulb from the clips mounted to the cavity back wall Fig 28 3 Remove the top grates or griddle sections required to access the thermostat and capillary wiring Fig 29 STANDARD...

Page 25: ...nel in place 7 Disconnect the thermostat burner tubing Fig 31 8 Remove top burners if required to access the thermostat 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 Fig 31 ...

Page 26: ...all 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 The capillary wire may be wrapped loosely around the gas tube to keep the wire from laying detached in the top section burner area Also using a soap and water solution the thermostat must be tested for gas leak after being installed Fig 35 STANDARD OVEN GRIDDL...

Page 27: ...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 Lift bracket away from oven burner 6 Remove pilot from bracket 7 Remove pilot by following Steps 1 through 5 in reverse order OVEN PILOT CHECK REPLACEMENT ...

Page 28: ...NS PROVIDED IN THE FLOW METER KIT Fig 36 The meter should show signs of massive flow If flow is not found replace the thermostat and recheck gas flow If meter does show signs of gas flow then perform the following checks on the safety valve If there is an obvious problem with the pilot safety valve the unit will not heat and pilot outage will occur 1 Fold down lower kick panel 2 Perform the pilot ...

Page 29: ...eplace 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 38 ...

Page 30: ...m the safety valve Fig 39 Fig 39 4 Disconnect right and left hand burner gas tubing from the safety valve Fig 40 STANDARD OVEN PILOT SAFETY VALVE CHECK REPLACEMENT Cont 5 Remove safety valve from unit 6 Install new valve by reversing Steps 1 through 4 Fig 40 ...

Page 31: ...PLE REPLACEMENT TOOLS REQUIRED 7 16 open end wrench 3 8 open end wrench 1 4 socket and socket driver 1 Disconnect unit from main gas supply 2 Remove 7 16 nut holding thermocouple to pilot bracket 3 Remove thermocouple from bracket Fig 42 4 Feed thermocouple assembly through front burner box Fig 43 5 Remove thermocouple lead from safety valve see Fig 38 6 Install new thermocouple by reversing Steps...

Page 32: ...ool 2 Follow steps listed under the replacement of the safety valve in order to access the oven burner nozzle 3 Remove burner nozzle 4 Remove orifice spud 5 Check for blockage or damages Fig 44 NOTE If blockage is apparent the obstruction can either be cleaned or the entire nozzle assembly replaced Verify also that the proper nozzle orifice size is being used and verify BTU rating with flow meter ...

Page 33: ...LS 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 Tilt burner upward and slide burner away from burner nozzle see Fig 43 5 Reinstall new burner by reversing Steps 1 through 4 OVEN BURNER CHECK REPLACEMENT ...

Page 34: ...ockage is found clean pilot tip and replace or install new pilot tip 5 If blockage is not found but pilot appears to be malfunctioning check pilot tube and pilot adjustment valve for obstructions PILOT ADJUSTMENT VALVE REPLACEMENT TOOLS REQUIRED 7 16 open end wrench pipe wrench or a 6 adjustable wrench 1 Disconnect unit from main gas supply 2 Disconnect pilot tubing Fig 46 Fig 46 3 Remove valve fr...

Page 35: ...LS 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 Remove control panel cover and top grates or griddle section 3 Remove and check valve and valve nozzle for obstructions and damage 4 Remove obstruction or if necessary replace nozzle or entire valve When reinstalling or if the installation of a new valve is r...

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Vulcan-Hart EG160, Service Manual

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