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ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION, OPERATION AND CLEANING . . . . . . . .
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEQUENCE OF OPERATION - CONVECTION OVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - GENERAL GENERAL INTRODUCTION • Loctite® 242™ for sealing thermostat adjustment screw. This manual is for the EQGXUDQFH CKDOOHQJHU ;L 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. • Adaptor to test thermocouple closed circuit DC voltages (purchase locally). Adaptors vary between manufacturers.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS RE0O9AL AND RE3LACE0ENT O) 3ART6 0ANI)OLD CO9ER CONTROL 3ANEL O9EN6 Shut off the gas before servicing the Disconnect the electrical power to the machine and follow lockout / tagout procedures. unit. 1. Pull crumb tray out. 2. Loosen set screw in the open top burner control knobs and remove knobs. 3. Remove screws that secure manifold cover and remove cover. unit. 4. Reverse procedure to install.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 2. Remove screws securing kick panel mounting brackets (2) to the oven and remove kick panel. 3. Reverse procedure to install. CONTROL %RAC.ET Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. 1.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 2. Remove cavity bottom by lifting up and sliding out. 3. Remove screws securing oven pilot assembly to burner carrier. )LJ 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. )LJ 4. Lower the KICK PANEL (24" & 30" OVENS). 5.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 6TANDARD O9EN T+ER0O6TAT O9EN Shut off the gas before servicing the unit. )LJ 4. 5. Pull burner carrier out through opening in lower oven frame enough to access the oven pilot assembly. Remove screws securring oven pilot assembly to burner carrier. Move oven pilot assembly away from burner. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles).
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 7. Open oven door and remove oven racks. 8. Remove screws securing capillary tube mounting clips (5) inside the oven cavity. 2. Remove screws securing capillary tube mounting clips (5) inside the oven cavity. 6WDQGDUG RYHQ NOTE Capillary tube is permanently attached to thermostat. )LJ 3. NOTE Capillary tube is permanently attached to thermostat-combo valve.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 2. Remove screws securing burner carrier to oven frame. )LJ 3. )LJ 7. Remove gas line tubing from thermostat. 8. Pull capillary tube through the hole in oven sidewall and remove thermostat from oven. A. Pull burner carrier out through opening in lower oven frame enough to access the oven pilot assembly.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS CON9ECTION O9EN %URNER Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. 1. Lower the KICK PANEL (24" & 30" OVENS). 2. Remove screws securing burner carrier to oven frame. )LJ 8.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS Clean pipe threads and apply thread sealant that is suitable for use with propane gases. When installing, do not bend and kink the capillary tube or damage to the control may occur. NOTE When installing thermostat capillary tube, push any insulation back through grommet and remove loose insulation from oven cavity. 9. Reverse procedure to install and check for proper operation.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS %URNER ORI)ICE +OOD 6TANDARD AND CON9ECTION O9EN6 )LJ 8. Loosen bolts (2) securing blower to motor shaft then remove blower. 9. If replacing blower only, proceed to last step. If replacing motor, continue with procedure. 1. Access burner for the type of oven being serviced as outlined under STANDARD OVEN BURNER or CONVECTION OVEN BURNER. 2. Remove the orifice hood from fitting. 3. Perform BURNER NOZZLE CHECK.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS TO3 %URNER 3ILOT 9AL9E Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. GDV 6DIHW\ 9DOYH RQ 6WDQGDUG OYHQ 1.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS TO3 %URNER A66E0%L< Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. 6. Check for proper operation. 1. Remove top burner grates (front and rear) from the module section being serviced. 7.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 5. Inspect the top control valve for wear and damage, replace as necessary. 6. Reverse procedure to install. Clean pipe threads and apply thread sealant that is suitable for use with propane gases. 5. Close door leaving enough space to clear the oven gas manifold cover during removal. As the door approaches this position, you should notice a decrease in the spring tension on the door. 6.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS GA6 3RE66URE REGULATOR Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. )LJ 3. Fully open door to check operation.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS CON9ECTION O9EN DOOR 6:ITC+ 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. )LJ 7.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS GRIDDLE T+ER0O6TAT CO0%O 9AL9E Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. )LJ 3. 4. 5. Remove compression nuts on the inlet and outlet of solenoid.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 9. Remove compression nuts from thermostatcombo valve fittings for the thermostat being replaced. )LJ 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. )LJ 10.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS 11. Reverse procedure to install and check for proper operation. GRIDDLE GA6 6A)ET< 9AL9E Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with a soap and water solution (bubbles). Do not use an open flame. 1. Remove CONTROL BRACKET. 2.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - REMOVAL AND REPLACEMENT OF PARTS NOTE When installing, ensure orifice hood is aligned and centered in the burner assembly opening. )LJ 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.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS 6ER9ICE 3ROCEDURE6 AND AD-U6T0ENT6 panel. You may need to remove a knob depending on the orientation of the pilot adjustment screw. 3ILOT )LA0E +EIG+T 1. OYHQ 3LORW AGMXVWPHQW 1. Remove CONTROL PANEL (30" OVENS). 2. Lower the KICK PANEL (24" & 30" OVENS) to access gas safety valve on 24" standard ovens and to view pilot flame height on all ovens. 3. Remove pilot adjustment cover screw from gas safety valve.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS TRS %XUQHU ALU 6KXWWHUV )LJ 1. Connect manometer to either of the pressure taps provided on the range gas piping between the burner control valve sets. OYHQ %XUQHU ALU 6KXWWHU 6KRZQ REGULATOR AD-U6T0ENT 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.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS 6TANDARD O9EN T+ER0O6TAT %< 3A66 )LA0E AD-U6T0ENT NOTE By-pass flame can be viewed through the kick panel for adjustment. 1. Turn the thermostat knob to 350°F. 2. Wait 10 minutes for oven to heat up. 3. Turn thermostat knob to lowest setting. DO NOT TURN O)). 4. Remove thermostat knob. 5.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS 1. Turn knob to 350°F. Wait 10 minutes for oven to heat up. 2. Turn knob to the lowest setting and check the bypass flame for proper adjustment as outlined under STANDARD OVEN THERMOSTAT BYPASS FLAME ADJUSTMENT. 3. Turn knob back to 350°F. When the flame stabilizes take a temperature reading. If temperature is more than 15°F from knob setting, calibrate as follows: 4. Pull off knob. 5.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS )LJ GRIDDLE T+ER0O6TAT CO0%O 9AL9E AD-U6T0ENT OSHUDWLRQ The thermostat-combo 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.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - SERVICE PROCEDURES AND ADJUSTMENTS D. 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. 4. OSHQ CLUFXLW A.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - ELECTRICAL OPERATION ELECTRICAL O3ERATION CO03ONENT )UNCTION 3RZHU CRUG . . . . . . . . . . Connects range to power source. OQ OII 6ZLWFK . . . . . . . . Provides power for the convection oven motor and solenoid valve. 6ROHQRLG 9DOYH . . . . . . . Allows gas flow to the convection oven burner assembly when solenoid is energized by the door switch (normally closed valve). DRRU 6ZLWFK . . . . . . . . . .
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - ELECTRICAL OPERATION 6C+E0ATIC DIAGRA0 CON9ECTION O9EN6 )LJ F45471 (0913) Page 30 of 33
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - ELECTRICAL OPERATION :IRING DIAGRA0 CON9ECTION O9EN6 )LJ Page 31 of 33 F45471 (0913)
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - TROUBLESHOOTING TROU%LE6+OOTING TROU%LE6+OOTING GENERAL 6<03TO0 Pilot does not remain lit. Burner flame too yellow Slow to heat or not hot enough. Oven temperature too hot. Low burner flame (all burners). Low burner flame (individual burner). Flame floats on burner. 3O66I%LE CAU6E 1. Incorrect gas pressure. 2. Pilot burner not adjusted properly. 3. Pilot burner blocked. 4. Thermocouple not positioned correctly or malfunctioning. 5.
ENDURANCE / CHALLENGER MODULAR SERIES GAS RANGES - TROUBLESHOOTING CON9ECTION O9EN6 ONL< 6<03TO0 3O66I%LE CAU6E Convection motor noisy. 1. Motor mounting loose. 2. Fan loose on motor shaft. 3. Fan excessively dirty or debris stuck in fan. 4. Motor malfunction. 1. Low gas pressure. 2. Thermocouple not positioned correctly or malfunctioning. 3. Solenoid malfunction. 4. Pilot gas flow too low. Adjust on gas safety valve. Pilot does not remain lit (no gas flow to oven burner).