Vulcan-Hart EG160 User manual

SERVICE MANUAL
VULCAN-HART COMPANY, P.O. BOX 696, LOUISVILLE, KY 40201-0696, TEL. [phone]
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

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IMPORTANT FOR YOUR SAFETY
THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL GAS
EQUIPMENT, WHO SHOULD PERFORM THE INITIAL FIELD START-UP AND
ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL.
POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE
EVENT THE SMELL OF GAS IS DETECTED. THIS INFORMATION CAN BE OBTAINED
FROM THE LOCAL GAS SUPPLIER.
IMPORTANT
IN THE EVENT A GAS ODOR IS DETECTED,
SHUT DOWN UNITS AT MAIN SHUT-OFF VALVE
AND CONTACT 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, SERVICE OR MAINTENANCE CAN
CAUSE PROPERTY DAMAGE, INJURY OR
DEATH. READ THE INSTALLATION,
OPERATING AND MAINTENANCE
INSTRUCTIONS THOROUGHLY BEFORE
INSTALLING OR SERVICING THIS EQUIPMENT.
IN THE EVENT OF A POWER FAILURE, THE PILOTS WILL REMAIN LIT AND THE UNIT
WILL CONTINUE TO FUNCTION. UNITS EQUIPPED FOR 120 VOLT OPERATION WILL
AUTOMATICALLY SHUT DOWN. SHOULD THIS HAPPEN, TURN POWER SWITCH OFF.
DO NOT ATTEMPT TO OPERATE UNIT UNTIL POWER IS RESTORED.

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EG60 EG260 EG160
EG24EG48
EG36
PL-53006
GAS RESTAURANT RANGE MODELS

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SERVICE MANUAL
GAS RESTAURANT RANGES INDEX
PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE
DESCRIPTION PAGE
SERVICE NOTATIONS 6
UNITS MOUNTED ON CASTERS 7
SERVICING SIMPLE CHECKS AND ADJUSTMENTS 7-10
GAS CONNECTIONS 11, 12
TESTING THE GAS SUPPLY SYSTEM 12
ORIFICE SIZE REQUIREMENTS FOR DIFFERENT ELEVATIONS 12
PILOT LIGHTING AND ADJUSTMENTS 13-17
THERMOSTAT ADJUSTMENTS 18-21
REGULATOR CHECK, ADJUSTMENT, INSTALLATION 22-24
STANDARD OVEN & GRIDDLE THERMOSTAT REPLACEMENT 24-27
OVEN PILOT 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, REPLACEMENT 35
PILOT ADJUSTMENT VALVE REPLACEMENT 35
TOP SECTION BURNER VALVE AND NOZZLE CHECK, REPLACEMENT 36

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DEDICATED TECHNICAL SERVICE HOT LINE-
(1-502-778-2791)
SERVICE NOTATIONS:
1. The procedures outlined in this manual are to be performed only by Vulcan-Hart authorized service
representatives.
2. An authorized Vulcan-Hart service representative is one who is familiar with Vulcan equipment and who has been
endorsed by Vulcan-Hart Company to service the equipment. All authorized service personnel are required to stock
a minimum amount of parts and should be equipped with a complete set of 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. Some service testing is required while the unit is in operation.
During these test procedures, it is advisable not to leave the unit unattended and to exercise caution during all testing
operations.
WARNING: THE RANGE AND ITS PARTS ARE HOT. BE VERY CAREFUL WHEN OPERATING OR SERVICING THE
RANGE.

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UNITS MOUNTED ON CASTERS
Units mounted on casters utilizing a flex hose and quick-disconnect must be installed with a restraining device. The
restraining device must be connected at all times. If disconnection of the device is necessary, turn off the gas supply before
disconnection. Reconnect the restraint before turning the gas supply on and returning the unit to its original installation
position and before beginning unit operation.
SERVICING SIMPLE CHECKS AND ADJUSTMENTS
The following is a list of simple checks and adjustments which are commonly associated with the malfunctioning of
this equipment. Perform these checks and adjustments for relevant unit symptoms before the removal of any major
parts or controls. Any service related questions for these units can be answered by calling the number on the front of this
manual.
CHECKS
1. Check the unit rating plate and verify that 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 product seems to be lopsided, check the leveling of the unit. Place a carpenter’s level inside the oven cavity
across the oven rack(s). Level the unit from front to back and from side to side.
To adjust the leveling of the unit, tilt the unit to one side and, using channel locks, unscrew the adjustable leg insert as
required. Repeat this procedure as necessary for each leg.
NOTE: Casters for this range are of the non-leveling type. Therefore, the surface which the unit is resting on must be level.
If floor surface is not level, the unit will experience cooking problems until the range is level.
Check the unit leveling again before leaving the store to ensure that the problem has been corrected.

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2. Oven Door Turnbuckle
NOTE: For the 24L units, refer to procedure outlined under 2A.
If the oven door is not closing properly, the door turnbuckle may require adjustment. To adjust the turnbuckle, flip down
the lower front kick panel. The turnbuckle is connected between the right- and left-hand door springs (Fig. 1). With your
hand, rotate the cast center piece of the turnbuckle two rotations at a time, then check the door tension. Repeat this
procedure until the door works as 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 the two 1⁄4-20 locknuts. Turn each nut in a clockwise direction to increase tension on the door; turn
each nut in a counterclockwise direction to decrease the tension. Repeat this procedure until door works as desired. After
adjustment has been made, tighten the locknuts.
Fig. 2

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SERVICING SIMPLE CHECKS AND ADJUSTMENTS (Cont.)
3. Pilot Flame Height
TOOLS REQUIRED: Standard flat blade screwdriver.
Top Burners: To adjust pilot flame height of the unit top burners, locate the pilot adjustment screws found on the front
manifold pipe. It is not necessary to remove the manifold cover, as adjustment access holes have been provided in the
panel. With screwdriver, turn the adjustment screw of the pilot valve experiencing the pilot flame height problems
(Fig. 3). 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
R
O
B
E
R
T
S
H
A
W
C
R
A
Y
S
O
N
Oven Pilot
Control Button
Pilot Adjustment Cap
PL-50117

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2. With screwdriver, adjust pilot key (located under pilot adjustment cap) to provide the proper size flame.
3. Replace pilot adjustment cap.
NOTE: If unit still is not heating correctly, refer to THERMOSTAT ADJUSTMENTS on Page 18.
4. Air Shutter Adjustment
TOOLS REQUIRED: Standard flat blade screwdriver.
The efficiency of the oven depends on a delicate balance between the air supply and the volume of gas. 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 the burner flame begins to lift from the burner, then close the shutter slightly down again and lock it
into place (Fig’s. 5 & 6).
SERVICING SIMPLE CHECKS AND ADJUSTMENTS (Cont.)
Fig. 6
Fig. 5

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GAS CONNECTIONS
CAUTION: All gas supply connections and any pipe joint compound used must be resistant to the action of
propane gases.
Each unit is factory-equipped with the type gas specified on the rating plate. The installation gas connection is a
3⁄4" (19mm) 14 FPT thread ANSI schedule #40 standard pipe.
Codes require that a gas shutoff valve be installed in the gas line ahead of the range.
Standard units are equipped with fixed burner orifices which coincide with the proper unit operation elevation. See Orifice
Size Requirements for Different Elevations on Page 12. NOTE: Do not attempt to drill out orifice sizes. Obtain proper
conversion kit from Vulcan-Hart depot.
Install the gas pressure regulator.
NOTE: Before installing, check regulator supplied against unit rating plate gas supply.
As of 7/11/90, the gas pressure regulator is NOT factory installed to this equipment. The regulator 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 are preset for 3.7" W.C. (Water Column) (.92 kPa); propane gas regulators for 10.0" W.C.(2.5 kPa).
1. Locate 3⁄4" (19mm) gas connection pipe extending from rear of range.
2. Cover pipe threads with leak sealant.
3. Screw regulator hand-tight onto pipe with regulator arrow pointing towards range body back (see Fig. 7).
4. Using pipe wrench, tighten regulator securely in an upright position (see Fig. 7).
The arrow on the regulator shows the direction of the gas flow (Fig. 7). While connecting the range to the gas supply, the
pressure regulator must be mounted horizontally to ensure proper preset outlet pressure. If the regulator is reinstalled in
any other position, the outlet pressure must be reset (Fig. 8).
Fig. 8
Fig. 7

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GAS CONNECTIONS (Cont.)
INPUT AT SEA LEVEL
PER BURNER (BTU’S)
ORIFICE SIZE REQUIREMENTS
FOR DIFFERENT ELEVATIONS
FOR RESTAURANT RANGE
ORIFICE SIZE
SEA LEVEL
TO
2000 FT
2000 FT
TO
4000 FT
4000 FT
TO
6000 FT
6000 FT
TO
8000 FT
OPEN TOP HOT TOP GRIDDLE BRO/GRID OVEN
(STD)
17,500 20,000 15,000 10,000 30,000
5.124 kW 5.856 kW 4.392 kW 2.928 kW 8.784 kW
NAT/PROP NAT/PROP NAT/PROP NAT/PROP NAT/PROP
Drill Drill Drill Drill Drill
47/56 44/55 48/57 52/62 36/52
mm mm mm mm mm
2.00/1.5 2.20/1.35 1.95/1.10 1.60/1.00 2.7/1.60
Drill Drill Drill Drill Drill
48/56 45/55 49/58 53/65 39/53
mm mm mm mm mm
1.95/1.15 2.10/1.35 1.85/1.05 1.50/0.9 2.50/1.50
Drill Drill Drill Drill Drill
49/57 46/56 50/60 53/66 40/54
mm mm mm mm mm
1.48/1.10 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 JOINTS IN THE GAS SUPPLY LINE FOR LEAKS. USE SOAP AND
WATER SOLUTION. DO NOT USE AN OPEN FLAME.
After piping has been checked for leaks, all piping receiving gas should be fully purged to remove air.
TESTING THE GAS SUPPLY SYSTEM
IMPORTANT: When test pressures exceed 1⁄2psig (3.45 kPa), the range and its individual shutoff valve must be
disconnected from the gas supply piping system.
When test pressures are 1⁄2psig (3.45 kPa) or less, the range must be isolated from the gas supply system by closing its
individual manual shutoff valve.

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NOTE: Although pilot lighting procedures are to be performed by both installation and operation personnel, only the
installation/service personnel should attempt to make any pilot, burner, or temperature adjustments to this unit. The
operation personnel are authorized only to perform the procedures for pilot lighting. All adjustment procedures associated
with pilot lighting must be performed by an authorized Vulcan-Hart installation or service person. While performing
these procedures, do not turn the burner valves “ON”with the burner heads removed.
HOT TOP AND GRIDDLE TOP BURNERS
1. Turn main gas supply “ON”.
2. Wait 30 seconds and, using a taper, light the 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 pilot is lit, adjust pilot burner flame, if necessary, by rotating the adjustment screw of the pilot valve located on the
manifold pipe (see Fig. 3).
1. Turn burner “ON”. Burner flame should appear on burner head within a second.
2. Rotate the screw clockwise to decrease and counterclockwise to increase the flame.
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”.

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OPEN TOP BURNERS
1. Turn main gas supply “ON”.
2. Wait 30 seconds and, using a taper, light the open top pilot (Fig. 10).
Fig. 10
3. If pilot fails to light, turn main gas supply “OFF”. Wait 5 minutes and repeat the above procedures.
4. Turn one open top burner valve “ON”to remove air from the gas line. Turn burner “OFF”when gas begins to flow.
OPEN TOP BURNER ADJUSTMENTS
TOOLS REQUIRED: Standard flat blade screwdriver.
1. 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.
Complete Shutdown
1. Turn burner valve “OFF”; pilot will remain lit.
2. Turn main gas supply “OFF”.
PILOT LIGHTING AND ADJUSTMENTS (Cont.)

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BROILER/GRIDDLE
1. Turn main gas supply “ON”.
2. Wait 30 seconds and, using a taper, light broiler/griddle pilot (see Fig. 9).
3. If pilot fails to light, turn main gas supply “OFF”. Wait 5 minutes and repeat Steps 1 and 2.
4. Turn burner valve “ON”to purge air from the lines. Turn burner valve “OFF”when gas begins to flow.
BROILER/GRIDDLE ADJUSTMENTS
TOOLS REQUIRED: Standard flat blade screwdriver, lighter taper.
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
NOTE: Perform open top/griddle lighting instructions before lighting oven pilot.
1. Open unit kick panel and lift up the pilot lighting hole cover (Fig. 11).
PILOT LIGHTING AND ADJUSTMENTS (Cont.)
Fig. 11

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2. Light pilot by depressing the reset button located behind the kick panel (Fig. 12). Light pilot and continue to hold reset
button in for 1 minute. If pilot fails to light, turn main gas supply “OFF”and wait 5 minutes before repeating Step 2.
3. After pilot is lit, turn the temperature dial to the desired setting.
Nightly Shutdown: Turn oven burner valve “OFF”.
Complete Shutdown
1. Turn oven burner valve “OFF”.
2. Turn main gas supply “OFF”.
PILOT LIGHTING AND ADJUSTMENTS (Cont.)
Fig. 12
PL-21433 PL-21434

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PILOT LIGHTING AND ADJUSTMENTS (Cont.)
OVEN BURNER ADJUSTMENTS
NOTE: These procedures should be performed only by a qualified Vulcan-Hart service representative.
TOOLS REQUIRED: Standard flat blade screwdriver.
All Restaurant Range series units equipped with pressure regulator and fixed orifices have been adjusted at the factory
and should require no further adjustments. However, the efficiency of the range depends on a delicate balance between
the air supply and the volume of gas. 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 insufficient air. To correct this condition, open the air shutter
until the burner flame begins to lift from the burner, then close the shutter slightly down and lock into place.

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THERMOSTAT ADJUSTMENTS
NOTE: These procedures should be performed only by a qualified Vulcan-Hart service representative.
STANDARD OVEN
Although the unit thermostats are factory positioned to their proper setting, it is not unusual for the thermostat to be knocked
out of adjustment during shipment. If the oven or griddle heat response seems to be lacking after burner air shutter
adjustments have been checked, perform the following adjustments.
NOTE: There are two possible conditions of the thermostat that must be checked: bypass adjustment and temperature
calibration.
Bypass Adjustment
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 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 rack. Light the main burner by turning the
thermostat to 500°F (260°C).
Allow at least 10 minutes for temperatures to stabilize. Check reading against dial setting.
2. If temperature is out of calibration, allow unit to cool until the oven bottom or griddle plate (whichever is being tested)
is cool to the touch. Remove oven bottom or griddle plate to expose burner area (Fig. 16). (Removal of oven bottom
is an optional procedure. Burner flame may also be observed through the oven view port.)
Fig. 16

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THERMOSTAT ADJUSTMENTS (Cont.)
3. Light the burner. Turn the dial to the highest set temperature.
4. After 10 minutes, turn the dial clockwise to the point slightly beyond the first mark on the dial (shown by an “X”).
5. Remove the dial and sleeve (Fig. 17).
Fig. 17 Fig. 18
6. With a screwdriver, turn the left-hand bypass adjustor screw counterclockwise to increase the flame, clockwise to
decrease it, until the flame appears to be 1⁄8" (3.175mm) over the entire burner area (Fig. 18).
7. Reinstall the sleeve and dial. Turn the dial clockwise until it locks into the “OFF”position.
8. Reinstall 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 temperature (whichever is in question concerning
heat response) against the thermostat dial setting.
For Ovens: Place the thermocouple of the test instrument in the center of the oven rack.
For Griddles: Place the thermocouple in the center of each individual griddle section. Each griddle section must be
tested.
2. Light the main burner by turning the thermostat to 500°F (260°C).

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THERMOSTAT ADJUSTMENTS (Cont.)
3. Allow unit to heat until the burner flame is heard cutting “OFF”. Wait about 10 minutes until the burner flame has cycled
“ON”and “OFF”several times. Then compare the test instrument reading with the dial setting. If the reading is within
± 15°F (-9.4°C) of the dial setting, its calibration is correct. If reading is not within this temperature window, then
recalibrate by performing Steps 4 through 13.
4. Pull the dial straight off the dial shaft (see Fig. 17).
5. Using a screwdriver 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 minutes until two successive readings within
5°F (-15°C) of one another are obtained.
9. Check the successive reading against the thermostat dial. If the reading is within ± 15°F (-9.4°C) of the dial setting,
the thermostat calibration is correct. If the reading is incorrect, the thermostat must be recalibrated.

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THERMOSTAT ADJUSTMENTS (Cont.)
10. To recalibrate, hold the thermostat dial in place. Insert screwdriver into dial shaft to engage the calibration stem
adjustment screw (Fig. 20). Push inward (do not turn stem).
Fig. 20
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 device (Fig. 21).