Component Access and Removal

COMPONENT ACCESS AND REMOVAL

This section explains how to access and remove components from a Wolf Gas Cooktop. Depending on which component you are going to access or remove in the following sections, you may have to remove other components first. Refer to appropriate section in this manual that explains how to access and remove those various components. When reassembling, just reverse steps that were used to access and remove the components.

Access to the manifold, valves, connections and wiring can be gained through access covers on the burner box. Although space is limited, it will help in some diagnosis and repairs.

Before attempting to access 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 APPLIANCE WHENEVER A FLAME IS PRESENT. SURFACES AND COMPONENTS GET HOT DURING THE USE OF THE APPLIANCE.

TO AVOID ELECTRICAL SHOCK, POWER TO UNIT MUST BE DISCONNECTED WHENEVER ACCESSING AND/OR REMOVING COMPONENTS POWERED BY ELECTRICITY OR COMPONENTS NEAR OTHER ELECTRICAL COMPONENTS.

TO AVOID POSSIBLE GAS LEAKS AND/OR EXPLOSIONS, GAS TO UNIT MUST BE SWITCHED OFF AT SUPPLY SOURCE WHENEVER ACCESSING AND/OR REMOVING COMPONENTS.

TO ENSURE PROPER BURNER OPERATION, THE O-RINGS MUST BE REPLACED ANY TIME THE UNITS IS DISASSEMBLED FOR ANY REASON.

WHEN REASSEMBLING GAS SUPPLY LINE TO REGULATOR, ONLY PIPE THREAD COMPOUND SHOULD BE USED. DO NOT USE TEFLON TAPE TO SEAL GAS PIPE CONNECTIONS.

WHEN REASSEMBLING REGULATOR TO MANIFOLD, ONLY PIPE THREAD COMPOUND SHOULD BE USED. DO NOT USE TEFLON TAPE TO SEAL GAS CONNECTIONS.

Surface Burner Components

Preliminary Steps

• Disconnect power cord from electrical supply source.
• Turn off gas supply source to cooktop.

Burner Grate and Burner Assembly

The burner grate locates on raised dimples formed on the burner pan. The burner assemblies have screws that pass through the assemblies, then thread into the orifice holder located under the burner pan. Burner caps are then placed over the burner assembly.

To remove the burner assembly:

1. Remove burner grate from unit.
2. Remove burner caps from burner assembly.
3. Extract the two screws securing burner assembly to orifice holder.
4. Lift assembly off burner pan and remove wire lead from spark ignitor.
5. To remove spark ignitor from burner, extract screw from underside of burner assembly and separate.

A textual description of Figure 4-1: Burner Removal shows the burner cap, screws, burner assembly, ignitor, screw, wire lead, and burner pan.

Burner Pan Removal

The burner pan is removed by first removing the burner assemblies. Next, pull the control knobs off of the unit. Then, lift the burner pan off of the burner box. The grommets are removed by simply pulling them out of the control panel.

A textual description of Figure 4-2: Burner Pan Removal shows control knobs, grommets, and the burner pan.

Orifice Removal

The main and simmer orifice are threaded into the orifice holder and may be extracted without removing the orifice holder from its installation position.

To remove the orifice:

1. Remove burner grate and pan.
2. Use a 9/32" wrench or socket with extension, to extract orifice from orifice holder. (See Figure 4-3)

A textual description of Figure 4-3: Orifice Removal shows the main orifice and simmer orifice.

Orifice Holder

Each orifice holder assembly consists of an orifice holder, the main and simmer orifice, hat bracket and the mounting hardware. Screws secure the orifice holder to the hat bracket.

To remove the orifice holder:

1. Remove burner grate and pan.
2. With a 3/8" and a 7/16" open end wrenches, remove the gas supply lines from orifice holder. (See Figure 4-4)
3. Extract the screws securing the orifice holder to the hat bracket. Lift orifice holder from the hat bracket.

WHEN REASSEMBLING ORIFICE TO ORIFICE HOLDER, ONLY PIPE THREAD COMPOUND SHOULD BE USED. DO NOT USE TEFLON TAPE TO SEAL GAS CONNECTIONS.

A textual description of Figure 4-4: Orifice Holder Removal shows the orifice holder, gas line, screw, and hat bracket.

Electrical System Components

Ring Light, Valve Switch, Spark Module, Spark Module Mounting Plate, Power Cord with Grip

Preliminary Steps

• Unplug the power cord from electrical supply source
• Turn off gas supply source to cooktop.
• Remove grates
• Remove burner heads with caps
• Remove control knobs
• Remove cooktop pan

Ring Light Removal

The ring light is located under the control panel glass, and is mounted to each burner valve switch. When the control knob is turned on, the entire ring light will illuminate the wording highlighted in the red portion of the control panel glass.

To remove the ring light you will need to follow the preliminary steps listed at the beginning of this section first, then:

1. Extract the Phillips head screw that secures the ring light and foam switch cover to the valve switch.
2. Lift the ring light off of the valve switch and disconnect the electrical wires attached to the ring light and remove.

A textual description of Figure 4-5: Ring Light Removal shows a foam switch cover, screw, ring light, and electrical leads.

Valve Switch

The valve switch is located below the ring light. When the control knob is turned, the shaft of the burner valve makes contact with the valve switch and closes the electrical circuit to the spark module (which provides the high voltage spark needed to ignite the burner).

To remove the valve switch you must first follow the preliminary steps listed at the beginning of this section, then:

1. Extract the screw which secures the ring light and foam switch cover to the gas valve and remove screw and foam cover.
2. Lift the ring light off from the valve switch. The valve switch locates on a pin formed on the gas valve.
3. Disconnect the electrical leads from the valve switch and remove valve switch from unit.

A textual description of Figure 4-6: Gas Valve Switch shows a valve switch and electrical leads.

Spark Module (Domestic Only)

DISCONNECT ELECTRICAL SUPPLY BEFORE ATTEMPTING THE FOLLOWING REPAIRS.

The spark modules are mounted on a plate that is located in the center of the burner box. Wire leads connect the spark modules and gas valves switches. A single wire lead then runs to the spark ignitor mounted to the burner. The spark module mounting plate is secured from the underside of the burner box with bolts.

To access the spark modules, you must first follow the preliminary steps listed at the beginning of this section, then:

1. Disconnect electrical leads from spark modules.
2. Extract screws securing spark modules to module plate and remove spark modules from unit.
3. To remove the spark module mounting plate, the underside of the burner box will need to be accessed. Extract screws securing mounting plate to unit frame. The mounting plate will hinge away from the burner box until lip of plate can be removed from the slot in the burner box.

A textual description of Figure 4-7: Spark Module Removal shows screws, spark modules, electrical leads, and a mounting plate.

Igniter Control Removal (ICB Only)

To remove Igniter Control, follow the preliminary steps listed at the beginning of this section first, then:

1. Disconnect the wire harness from the Igniter Control.
2. Extract the screw that fastens the mounting plate to the outer pan.
3. Slide Control and Mounting plate off the pem locating stud and from the outer pan assembly.

A textual description of Figure 4-8: ICB Igniter Control Removal.

Power Cord with Grip Removal (Domestic Only)

To remove the power cord, follow the preliminary steps listed at the beginning of this section first, then:

1. Disconnect the power cord plug connector at the harness.
2. Extract the nut that secures the ground terminal of the power cord to the burner box.
3. Squeeze the tabs of the grip connector (grip connector secures the power cord to the burner box) and pull the power cord down through the opening and out of the burner box.

A textual description of Figure 4-9: Power Cord Removal shows a power cord plug connector, ground wire connection, and grip connector.

Manifold System Components

TO AVOID HAZARDOUS EXPLOSION OR GAS LEAKS, GAS TO THE UNIT MUST BE TURNED OFF AT THE GAS SUPPLY SOURCE WHENEVER ACCESSING AND/OR REMOVING COMPONENTS.

Gas Valve, Gas Valve Orifice, Gas Tubing, Manifold and Regulator Removal

The following components will need to be removed in order to gain access to the components of the manifold. Refer to the appropriate component access removal section for proper removal instructions of these components.

Preliminary Steps

• Unplug power cord from electrical supply source.
• Turn off gas supply source to cooktop.
• Remove covers and grates.
• Remove burner heads with caps.
• Remove control knobs.
• Remove burner pans.
• Remove electrical connections from spark modules

Gas Valve

The gas valve is mounted to the side of the manifold and is secured in place by a bracket with two screws that pass through the bracket and fasten into the gas valve body. The gas valve has a rubber gasket that makes a seal with the manifold.

To remove the gas valve, follow the preliminary steps listed on the previous page first, then:

1. Disconnect electrical leads from valve.
2. Disconnect the flexible gas tubes from gas valve.
3. Extract bolts from bracket on the side of the manifold tube.
4. Remove the valve from the manifold tube.

A textual description of Figure 4-10: Gas Valve Removal shows the valve orifice, valve body, and bolts.

Gas Valve Orifice

Each gas valve has two bypass screw orifices installed on the left side of the valve body. To remove these orifices, first follow the preliminary steps listed at the top of this page. Then, using a small flat bladed screwdriver, turn the bypass screw orifice counterclockwise to remove, and lift the orifice out of the valve. (See Figure 4-10).

WHEN REASSEMBLING MANIFOLD COMPONENTS, ONLY PIPE THREAD COMPOUND SHOULD BE USED. DO NOT USE TEFLON TAPE TO SEAL GAS CONNECTIONS.

Gas Flex Tubing

The gas flex tubing transports gas from the manifold to the orifice holder assemblies. To remove tubing, first follow the preliminary steps listed on the previous page. Using open end wrenches, disconnect the flexible gas tubing from the gas valve on the manifold and from the orifice holder assembly.

A textual description of Figure 4-11: Manifold Removal shows a nut, washer, threaded studs, and manifold.

Manifold and Regulator Removal (Domestic Only)

The manifold is a formed tube that connects to the gas regulator from the underside of the burner box, and has ports in which the gas valves are mounted. The regulator is attached to the threaded end of the manifold pipe that protrudes out of the bottom of the burner box. To remove the manifold and/or the gas regulator, follow the preliminary steps listed on the previous page, then:

1. Remove gas valves from manifold.
2. Extract nuts from threaded studs that secure manifold to burner box.

To gain better access to the regulator you may have to pull the entire cooktop from its installation.

1. To remove the regulator, turn off the gas supply source. Unplug the power cord from its electrical supply source. Then, remove gas connections coming into the regulator from the supply source. Now, unthread the regulator from the end of the manifold pipe. (See Figure 4-12).

NOTE: ICB units do not have a regulator installed.

WHEN REASSEMBLING MANIFOLD COMPONENTS, ONLY PIPE THREAD COMPOUND SHOULD BE USED. DO NOT USE TEFLON TAPE TO SEAL GAS CONNECTIONS.

A textual description of Figure 4-12: Regulator Removal shows a 1/2" adapter, pressure regulator, 1/2" nipple, flexible metal connector, 1/2" adapter, 1/2" nipple, and manual shut-off valve.

Shut off Valve Removal (ICB Only)

To remove Shut Off Valve, follow the preliminary steps listed at the beginning of this section first, then:

1. Disconnect the wire harness from the Safety Valve.
2. Disconnect the gas lines.
3. Extract the screw that fastens the Shut off Mounting Bracket to the outer pan.
4. Slide off the pem locating stud and from the outer pan assembly.

A textual description of Figure 4-13: ICB Shutoff Valve Removal.