Sub-Zero Wolf BBQ242BI Service Manual Download

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General Information

Controls & Operation

Installation Information

Component Access & Removal

Troubleshooting Guide

Technical Data

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BBQ

Service Manual

Summary of Contents for Wolf BBQ242BI

Page 1: ...General Information 2 Controls Operation 6 Installation Information 13 Component Access Removal 18 Troubleshooting Guide 39 Technical Data 43 subzero com 800 222 7820 BBQ Service Manual ...

Page 2: ...bserved INTRODUCTION This Wolf Outdoor BBQ Grills Technical Service Parts Manual Part 803332 has been compiled to provide the most recent technical service information about the Wolf Appliance Inc BBQ Grills This information will enable the serv ice technician to troubleshoot and diagnose malfunctions perform necessary repairs and return a Wolf Outdoor BBQ Grill to proper operational condition The...

Page 3: ...R UNDER THIS APPLIANCE 2 NEVER FILL THE CYLINDER BEYOND 80 PERCENT FULL 3 IF THE INFORMATION IN 1 AND 2 IS NOT FOLLOWED EXACTLY A FIRE CAUSING DEATH OR SERIOUOS INJURY MAY OCCUR ANSIZ21 58A CAN CGA 1 6A 1998 OUTDOOR COOKING APPL FOR INSTALLATION IN NON COMBUSTIBLE LOCATIONS UNLESS USED WITH APPROVED INSULATING JACKET 800116 Figure 1 1 Typical Serial Plate Layout FOR USE WITH A GAS PRESSURE REG ULA...

Page 4: ...s have a 16 000 BTU rating LP Gas Models LP gas units include a regulator hose and 5 gallon LP tank MODEL NUMBER DESCRIPTIONS This section briefly describes the reason for different model numbers The BBQ s are manufactured as either natural gas or LP gas built in or on a free standing cart The two digits 24 36 48 following the letters BBQ indicate the width of the grill chassis in inches Example B...

Page 5: ...n example of the model numbers Model BBQ362BI LP Product Type Size Side Burners Features Fuel Product Type BBQ Size 24 24 Grill Space 36 30 Grill Space 48 36 Grill Space Side Burners 2 Features Built In Cart Fuel LP Propane Gas No LP indicates the unit is manufactured for Natural gas ...

Page 6: ... BBQ36BI LP BBQ36C BBQ36C LP 36 Grill Built In Nat Gas 36 Grill Built In LP 36 Grill on 36 Cart Nat Gas 36 Grill on 36 Cart LP All 36 Grills have Six Grill Burners BBQ362BI BBQ362BI LP BBQ362C BBQ362C LP BBQ48BI BBQ48BI LP BBQ48C BBQ48C LP 36 Grill with Two Open Burners Built In Nat Gas 36 Grill with Two Open Burners Built In LP 36 Grill with Two Open Burners on 48 Cart Nat Gas 36 Grill with Two O...

Page 7: ... The variance is due to the various other substances found in natural gases The more ethane propane or butane in the gas raises the heating value Propane or LP gas has a heating value of about 2500 2800 BTU per cubic foot and butane about 3200 BTU per cubic foot Specific Gravity of Gas The specific gravity of a gas is the weight of one cubic foot or the gas compared to one cubic foot of dry air Wh...

Page 8: ...to assure complete burning of the gas The total air primary secondary and excess are expressed as percentages of the amount needed About ten cubic feet of air is required to com pletely burn one cubic foot of gas For this reason an appliance should not be operated in an air tight home Limits of Flammability Not all air to gas mixtures will burn Mixtures with 0 4 natural gas in air are too lean to ...

Page 9: ...g Tube Throat Serves to carry the gas air mixture from the venturi tube to the burner body Burner Body The accumulation chamber below the burner base which allows the gas and air to mix together fully Burner Head The component containing the burner ports where the gas air mixture ignites The burner ports are distributed in a useful pattern to optimize heat transfer The flames should be spread so t...

Page 10: ...conditions are perfect products from the inner cone burn here The final products of burning are carbon dioxide and water vapor An outer mantle surrounds the outer cone where burning is usually completed It is nearly invisible and glows only because of the high temperature of the final combustion Infrared Burner All Wolf gas BBQ s use an infrared burner for the rotisserie This infrared burner is a ...

Page 11: ...lockwise to HIGH 3 Keep your face as far away from the burners as possible 4 Turn the black igniter knob clockwise which corresponds with the gas control knob you have turned on until you hear a loud click Repeat immediately if the burner does not light on the first try 5 Listen for a whoosh sound If the burner does not light by the fourth attempt with the igniter turn the control knob to the OFF ...

Page 12: ... HIGH and light the burner Repeat for the other burners The open burners can be lit directly from the top along the orifice holes around the burner heads Fig 2 8 The rotisserie burner must be lit at the pilot Once the pilot is lit the burner will light within 30 seconds Fig 2 7 Fig 2 7 Fig 2 6 Position the Match Lanyard with a lit match over the Open Burner Head Push and turn Burner Valve Knob cou...

Page 13: ...mer and fall when spiders are most active These nests can obstruct gas flow and cause a fire in and around the valve Such a fire can cause operator injury and serious damage to the grill To help prevent a blockage and ensure full heat output follow these steps to clean and inspect the venturis once or twice a month 1 Using a flashlight look inside of the end of the burn ers for webs or mud nests S...

Page 14: ...a service technician may need to know when servicing a Wolf BBQ If additional installation information is needed after reviewing this section of the manual please refer to the Installation Guide or contact the Wolf Appliance Customer Service Department Electrical Requirements A Wolf BBQ rotisserie motor requires 110 120 volts AC to operate The power supply cord on the rotisserie motor is equipped ...

Page 15: ...38 1 4 50 1 4 50 1 4 D Rough Opening Width Non Combustible Enclosure 36 1 4 36 1 4 48 1 4 48 1 4 Pre Installation Dimensions Combustible Enclosure Non Combustible Enclosure E Rough Opening Depth 27 3 4 26 3 4 F Rough Opening Height 10 1 2 9 1 2 G Minimum Clearance to Side Walls 12 6 H Minimum Clearance to Back Wall 12 4 1 2 I Gas Supply Location Back Wall Bottom Location 3 1 8 2 1 8 J Gas Supply L...

Page 16: ...be connected to the gas supply line through a pressure regulator The burner orifices are sized for the pressure delivered by the regula tor Never attempt to operate a Wolf gas appliance without the use of the proper pressure regulator The maximum gas supply pressure to the regulator is 14 WC Water Column Pressure 1 2 psi 3 5kPa and should not be exceeded Natural Gas Hook Up Hook up to a natural ga...

Page 17: ...e LP gas supply cylinder must be provided with a listed over filling prevention device DPD Approximate running time for a 20 pound LP tank BBQ Model BTU Rating Running Time BBQ36 BBQ36C 69 000 BTU 6 1 2 hours BBQ242 BBQ242C 80 000 BTU 5 1 2 hours BBQ48 BBQ48C 89 000 BTU 5 hours BBQ362 BBQ362C 101 000 BTU 4 1 2 hours Fig 3 5 Coupling Nut Manifold Pipe LP Gas Cylinder Use in upright position only Re...

Page 18: ...sconnected or replaced This applies to both natural and LP gas Test for leaks at the cylinder valve cylinder welds regulator especially attached to cylinder valves hose and con nections NOTE DO NOT use a flame such as a lighted match to test for leaks Use only a leak testing solution of soapy water or an electronic leak detector Leak Testing Procedure 1 Check that all control knobs are in the OFF ...

Page 19: ...ccess or remove any components from a Wolf Appliance take note of the following warnings TO AVOID SERIOUS BURNS AND OR EXPLOSIONS KEEP COMBUSTIBLES AWAY FROM THE APPLIANCE WHENEVER A FLAME IS PRESENT KEEP IN MIND THAT SURFACES AND COMPONENTS GET HOT DURING THE USE OF THE APPLIANCE TO AVOID ELECTRICAL SHOCK POWER TO THE UNIT MUST BE DISCONNECTED WHENEVER ACCESS ING AND OR REMOVING COMPONENTS POWERE...

Page 20: ...g 4 2 Fig 4 3 Open Top Grates The open top grates are used to place pots and pans on the open top burners for cooking To remove the open top grates lift them off of the open top frame See Fig 4 2 Step Up Frame The step up frame is stainless steel and is used to ele vate the rear open top burner To remove the step up frame you will need to extract the screws at the back of the frame which mount it ...

Page 21: ...ront Venturi The burner head sits on top of the front venturi The front venturi sits on the burner support bracket and slides over the burner valve orifice To remove the front venturi you must remove the open top grate Now lift the venturi up and off of the burner support bracket and slide it off of the burner valve orifice Now lift the front venturi out through the burner support bracket See Fig ...

Page 22: ...gniters To remove the pilot tube bracket you will need to remove the open top burner grates and the spark electrode with mounting bracket Now extract the screw that mounts the pilot tube to the support bracket and remove the pilot tube See Fig 4 10 Burner Support Bracket The burner support bracket is used to support the open top burners To remove the burner support bracket you will need to remove ...

Page 23: ...e the stainless steel burner tubes you need to first remove the broiler grates and the radiant Then lift the back of burner tube out of the slot and slide the burner tube off of the burner valve orifice and out See Fig 4 14 Radiant The radiant is placed on pins that are welded to the grill chassis at both the front and back When the radiant is placed on top of the holding pins it is raised just ab...

Page 24: ... Spark Electrode Ground Strap The spark electrode ground strap secures the spark electrode to the spark electrode mounting bracket To remove the spark electrode ground strap you will need to remove the broiler grates and radiant Now extract the screw that secures the ground strap to the mount ing bracket and remove ground strap See Fig 4 15 Spark Electrode The spark electrode emits the spark suppl...

Page 25: ... is riveted to the bottom of the control panel To replace it you will have to drill out the rivet See Fig 4 21 Rotary Igniter To remove the rotary igniter first remove the rotary igniter knobs and the control knobs Remove the con trol panel and unplug the electrode wire from the rotary igniter Next extract the two screws that mount the rotary igniter to the control panel Then pull the rotary ignit...

Page 26: ...ifold assembly To remove a burner valve you will need to turn off the gas supply remove the broiler grates radiant stainless steel burner tube control knobs control panel and unplug the spark electrode wires from the rotary igniters Now using a wrench loosen and remove the burner valve See Fig 4 23 Burner Valve Orifice Hood The burner valve orifice is threaded onto the end of the burner valve To r...

Page 27: ...dapter tee assembly as one unit Once the assembly is removed from the unit you can remove the nipple from the connector and the tee See Fig 4 24 Pilot Valve The pilot valve is threaded into the bottom of the tee It allows for a separate gas supply to go to the pilot light for the infrared burner To remove the pilot valve you need to turn off the gas supply remove the control knobs control panel an...

Page 28: ...rt bracket on the right side Now pull the rod out of the rotisserie motor See Fig 4 25 Rotisserie Motor The rotisserie motor is equipped with metal gears and is capable of turning a balanced 25 lb cut of meat or poultry The motor is mounted to a metal bracket which attaches to the sides of the grill and must be electrically grounded To remove the rotisserie motor you first need to unplug the rotis...

Page 29: ...nd right side of the hood Lift off the front hood See Fig 4 29 Rear Hood Top The rear hood top is connected to the right and left side hood and is slotted for ventilation It covers the infrared burner and gas tubing In order to remove the rear hood the front hood will need to be removed To remove the rear hood remove the screws along the right and left side hood Remove the screws along the middle ...

Page 30: ...frared Burner The infrared burner is used for rotisserie cooking The intensity of this radiant heat is preferred over other methods because of its ability to sear the natural juices and nutrients into the food The location of the burner allows for the placement of a basting pan beneath the food to collect all juices and drippings To remove the infrared burner make sure you have the gas supply turn...

Page 31: ...ilot burner which in turn allows the safety valve to open and supply gas to the infrared burner for the rotisserie The spark electrode is a one piece electrode with a wire which is plugged into the rotary igniter on the con trol panel When you turn the rotary igniter you create a spark from the electrode which lights the gas to the pilot burner supplied from the pilot valve To remove the spark ele...

Page 32: ...extracting the two screws that mount the bracket to the unit See Fig 4 40 Side Plate Shelf Brackets These brackets provide the support for mounting the side plate shelf To remove the brackets first remove the plate shelf Now extract the two screws from the bracket and remove the bracket Repeat this process for each bracket See Fig 4 39 Side Plate Shelf The Side Plate Shelf is a stainless steel fol...

Page 33: ...at the Tee connector at the manifold In order to do this you will have to remove the control panel and disconnect the spark electrodes from the rotary igniters Now remove the flexible gas tube from the unit See Fig 4 43 FOR USE WITH A GAS PRESSURE REG ULATOR THE REGULATOR SUPPLIED MUST BE USED WITH THIS UNIT CET APPARIEL REQUIERT L INSTALLA TION D UN DETENDEUR DE PRESSION LE DETENDEUR FOURNI DOIT ...

Page 34: ...ety valve and remove the flexible gas tube from the unit See Fig 4 44 Pilot Valve Gas Tubing This is a gas tube that goes between the pilot valve at the Tee connector on the manifold and to the pilot burn er at the infrared burner Once the infrared burner valve is turned on it supplies gas for the pilot light at the pilot burner To remove this gas tube you will have to turn off the gas supply If t...

Page 35: ...he inside of the door that mount the handle to the door See Fig 4 47 Door Assembly To remove the stainless steel door assembly you will need to open the door and extract the two screws that mount the door hinge to the inside of the cart frame NOTE If replacing the door the door handles will have to be removed and reinstalled on the new door NOTE The door hinges are not replaceable They are welded ...

Page 36: ...he cart door Reach around the back of top catch holder and push in the two locking tabs on each side of the magnetic catch Now push the magnetic catch towards the front and out of the top catch holder and remove See Fig 4 51 Bottom Panel To remove the bottom panel inside the cart you will first need to open the cart doors Now extract the doorstops and extract the screws around the perimeter of the...

Page 37: ...e Now lift the back flange of the side panel off of the cart frame and slide the side panel towards the front and off of the cart frame See Fig 4 54 Top Trim The top trim is the center strip of stainless steel that runs the entire length of the cart just above the cart doors To remove the top trim you will need to turn off and disconnect the gas supply Remove the rear panel control panel side pane...

Page 38: ...ter locking bracket you will need to prop the unit up on one end so you have access to the locking bracket under the cart Now extract the two screws that mount the caster locking bracket to the cart assembly and remove it Non swivel Caster There are two of these casters mounted on one end of the cart assembly They are stationary and do not swiv el To remove the non swivel caster you will need to p...

Page 39: ... assembly you will need to remove the BBQ chassis door assembly doorstops top catch holder bottom panel rear panel side panel top trim swivel caster w brake caster locking bracket and non swivel caster See Fig 4 60 Cart Partition 48 Cart Only The cart partition separates the side shelf from the enclosed portion of the cart assembly To remove the cart partition you will need to remove the shelf and...

Page 40: ...e causes for the problem The information to the right of the possible causes will explain what tests to perform in order to determine if what you are checking is the cause and or what action to take to correct the problem page Problems Associated with the Burners A No spark 5 3 B No ignition 5 3 C Poor ignition 5 3 D Burner noise or whistle 5 3 E Yellow flame 5 3 F Incomplete flame 5 3 G Flame blo...

Page 41: ...r Replace or clean spark electrode Reconnect spark electrode may need to crimp end of electrode for tighter connection Knobs need to be off when supply gas is first turned on Turn gas on or fill LP tank Turn regulator so vent hole is pointing down See page 3 5 figures 3 5 3 6 Clean venturi burner ports orifice unkink hose Clean air shutter opening or adjust air mixture Install venturi over orifice...

Page 42: ...switch in Off position No power at receptacle GFCI receptacle tripped Rotisserie rod not seated into motor Rotisserie forks not pushed into food Rotisserie fork thumb screws not tight or missing Food is too heavy for motor Not using counter weight with rotisserie rod Defective motor Coil hose around Cylinder See pg 3 5 Check clean and or replace burner Clean orifice Adjust air shutter Check fuel s...

Page 43: ...at Discoloration from heat Discoloration from heat Discoloration from heat Handle needs to be removed when using open top burners Replace hood assembly This is normal Always test cleaning solutions on a non conspicuous stainless steel spot first This is normal Always test cleaning solutions on a non conspicuous stainless steel spot first This is normal Always test cleaning solutions on a non consp...

Page 44: ...red Burner Large 9 000 50 714555 Orifice 800048 Pilot Burner w Orifice 720513 ORIFICE CHART Natural Gas 5 WC Description BTU Stamp No Part No Valve Burner Side 16 000 56 720484 Orifice 800807 Valve Burner Grill 16 000 63 720484 Orifice 800808 Infrared Burner Small 9 000 65 715554 Orifice 800804 Infrared Burner Large 9 000 64 714555 Orifice 800803 Pilot Burner w Orifice 720511 Liquid Propane Gas 10...

Page 45: ... B BBQ G GRILLS 3 1 8 Ensure burner is fully seated Towards ther rear of the bracket 3 4 Center the Igniter between the charge ports Fig 6 1 Proper Charge Tube Length is 3 1 8 Fig 6 2 Igniter Module and Gas Charge Tube Assembly ...

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