Frymaster Super Marathon Series manual

NON-CE & Dean, a member of the C ommercial Food Equipm ent Service Associati o n, recomm ends using CFESA Certified Technicians. MAY 2008 www.frymaster.com 24-Hour Service Hotline 1-800-551-8633 Email: service@frymaster.com *8195948* Dean Millivolt Gas Fryers Service & Parts Manual Super Runner and Super Marathon Series[...]

ii Please read all sections of this manual and retain for future reference. NOTICE This appliance is intended for professional use only and is to be operated by qualified personnel only. A Dean Factory Authorized Service Center (FASC) or other qualified professional should perform installation, maintenance, and repairs. Installation, maintenance, o[...]

iii DANGER The front ledge of the fryer is not a step. Do not stand on the fryer. Serious injury can result from slips or contact with the hot oil. DANGER Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other cooking appliance. DANGER Instructions explaining procedures to be followed MUST be posted [...]

iv Dean Millivolt Gas Fryers Service and Parts Manual TABLE OF CONTENTS Page # 1. SERVICE PROCEDUR ES 1-1 1.1 Functional Description 1-1 1.2 Accessing Fryers for Servicing 1-3 1.3 Cleaning the Gas Valve Vent Tube 1-3 1.4 Calibrating the Operating Thermostat 1-4 1.5 Check Burner Manifold Pressure 1-5 1.6 Adjusting the Pilot Flame 1-6 1.7 Replacing F[...]

v Dean Millivolt Gas Fryers Service and Parts Manual TABLE OF CONTENTS (CONT.) Page # 2. PARTS LIST 2-1 2.1 Cabinetry Components, Single Fryers 2-1 2.2 Cabinetry Components, Multi-Battery Systems 2-4 2.3 Component Box Components and Related Components (Non-CE and CE) 2-6 2.4 Frypot and Burner System Components 2-8 2.4.1 SM220 and SM20/20/~ Systems [...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 1: SERVICE PROCEDURES 1-1 1.1 Functional Description Dean Super Runner an d Super Marathon Series fryer s are millivolt fryers , which require no electricity to operate (systems with built -in filtration and/ or other acces sorie s will require electric power). Dean millivolt f ryers conta in a welded s teel frypo [...]

1-2 1.1 Functional Description (cont.) An electromechanical millivolt ga s valve regulates gas flow to the burner manifold. Dean m illivolt fryers use a pilot ignition syst em to control burner firing. Operating Thermostat Thermopile Pilot High-Limit Main Valve Magnet Pilot Magnet Gas Valve Pilot Ignition System The pilot ignition system is made up[...]

1-3 1.2 Accessing Fryers for Servicing DANGER Moving a fryer filled with cooking oil ma y cause spilling or splattering of the hot liquid. 1. Drain all cooking oil from the fryer. 2. Shut off the gas supply to the unit and disconnect the unit from the gas supply. 3. Remove any attached restraining devices. DANGER Fryers must be at room temperature,[...]

1-4 1.4 Calibrating the Operating Thermostat 1. Ensure the frypot is filled to the proper lev el with oil before proceeding. 2. Light the pilot. 3. Set the temperature control knob to 350°F (177°C). 4. Let the burners cycle on and off automatically three tim es in order for th e oil temperature to become uniform. If using solid shortening, stir t[...]

1-5 1.5 Check Burner Manifold Pressure WARNING This task should be performed by qualified service personnel only. 1. Ensure that the gas valve knob is in the "OFF" position (non-CE), or press red button to turn gas valve off (CE). 2. Remove the pressure tap plug from th e gas valve (see illustration below). 3. Insert the fitting for a gas[...]

1-6 1.6 Adjusting the Pilot Flame 1. Remove the cover shown in the illustration be low to access the pilot flame adjustm ent screw in the gas valve. 2. Using a small, flat-tipped screwdriver, turn the pilot flame adjustment screw counterclockwise to increase the length of the flame or clockwise to decrease the length of the flam e. Adjust the flame[...]

1-7 1.7.1 Replacing the Oper ating Thermostat (cont.) 6. First, loosen the capillary tube com pression fittin g until it slid es freely on the capillary tube. Second, loosen the frypot pass-through nut until it slides freely on the capillary tube. Remove the capillary tube and bulb from the frypot. 7. Install the replacement thermostat capillary tu[...]

1-8 1.7.2 Replacing the High-Limit Thermostat 1. Follow instructions for replacing operating thermostat, section 1.7.1, om itting steps 2 and 12. 1.7.3 Replacing the Gas Valve DANGER Drain the frypot or remove the handle from the drain valve before proceeding further. 1. Disconnect fryer from the gas supply. 2. Disconnect wiring from the gas valve [...]

1-9 1.7.4 Replacing the Frypot (cont.) 9. Recover the drain valve, high-limit thermost at, operating thermostat, and burner m anifold assembly from the failed frypot. 10. Clean the threads on the r ecovered parts, apply Loctite PST 567 or equivalent th read sealer, and install them on the repla cement frypot. 11. Reverse Steps 1-9 to ins tall the r[...]

1-10 ROBERTSHAW-UNITROL 7000 SYSTEM CHECK 1. Complete System Check With thermostat contacts closed and ga s cock dial in the “ON” position, the main burner should ignite. Measure the readin g between the 2 & 3 terminals. If the reading is more than 100MV, replace the gas valve. 2. System Resistan ce Check With thermos tat contac ts closed a[...]

1-11 Pilot failures fall into on e of two categories – failure to ligh t or f ailure to remain lit. Pilot Fails to Light 1. Gas is not being supplied to the valve: Check fo r a closed gas cutoff valve upstream of the gas valve. Also verify that the gas line quick di sconnect fitting at the re ar of the fryer (if so equipped) is properly connected[...]

1-12 1.8.2 Improper Burner Functioning Fluctuating flame intensity is norm ally caused by improper or fluctuating incoming gas pressure, but may also be the result of variations in the kitchen atmosphere. Variation in the kitchen atmosphere is usually caused by air conditioni ng and/or ventilation un its starting and stopping. Changes in airflow pa[...]

1-13 1.8.4 Filtration Problems The majority of filtratio n problems arise from operato r error. One of the m ost common errors is placing the filter paper on the bottom of the f ilte r pan rather than over the f ilter screen. Whenever the complaint is "the pump is running, but no oil is being filtered ", check the installation and size of[...]

1-14 1.8.4 Filtration Problems (cont.) 3. Prior to reassembly, the inside housing must be clean and free of any sedim ent or debris. Failure to completely clean the inside housing and ring gear will cause gear binding after reassembly. Incorrectly sized or installed pa per will allow food particles and se dim ent to pass through and clog the suctio[...]

1-15 1.9 Wiring Diagrams 1.9.1 Current Production Units wi th Honeywell Gas Valve (Non-CE) HONEYWELL 1/2 P.S.I. 1/2 P.S.I. HONEYWELL OFF ON PILOT C HONEYWELL 1/2 P.S.I. ADJ. PILOT 17C 17C 12C PILOT GENERATOR HIGH-LIMIT THERMOSTAT SAFTY DRAIN SWITCH (OPTIONAL) IN-LINE SPLICE ON/OFF SWITCH (OPTIONAL) FENWALL OPERATING THERMOSTAT IN-LIN E SPLICE 80504[...]

1-16 1.9.2 Current Production Units wi th Honeywell Gas Valve (CE) FENWALL OPERATING THERMOSTAT HIGH-LIMIT THERMOSTAT PILOT THERMOCOUPLE PILOT GENERATOR 8050531A ROBERTSHAW OPERATING THERMOSTAT TH TH PP PP[...]

1-17 1.9.3 Current Production Units with R obertshaw Gas Valve (After May, 2002) Therm opile Op erat ing The rm os t at High-Limit Thermost at 1C 2C TH TH TP TP[...]

1-18 1.9.4 UFF Filtra tion Wiring Diagram T3 P2 T8 HEAT TAPE - 25 WATT P/N 810-2100 MOTOR COVER PLATE P/N 807-3643 FUSE HOLDER P/N 807- 1321 FUSE P/N 807-3 59 2 LOW VO LTAG E SHO WN BLK WHT#1 P/N 807-3538 5 AMP- 480V JUCTION BOX P/N 80 7-3 642 P1 BLK J BOX P1 HIGH VOLT AGE SHO WN AMP CONNECT T2 P2 T3 T5 T4 T8 WHT#1 2 1 T2 T5 T4 120V W/OUT XFORMER B[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-1 2.1 Cabinetry Components, Single Fryers 1 2 3 4 6 7 8 12 13 14 15 16 17 18 19 20 22 23 24 25 27 28 26 5 21 9 10 11 ITEM PART # COMPONENT * 810-2793 Basket Hanger SR142 (Hook Over the Flue) Thumbscrews not needed * 200-1360 Basket Hanger SR42 (Thumbscrew 809-017 1, Cage Nut 826-1351) * 210-1595 Bas[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-2 2.1 Cabinetry Components, Single Fryers (cont.) ITEM PART # COMPONENT 4 810-0357 Caster, Swivel- With Brake- All Millivolt Fryers 5 810-0356 Caster, Swivel- Witho ut Brake- All Millivolt Fryers SUFF Base Components- SM Series With SUFF F iltration 6 823-3791 Support, Leg- Left- SUFF 50- SM40G, SM5[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-3 2.1 Cabinetry Components, Single Fryers (cont.) ITEM PART # COMPONENT * 210-3419 Top Cap (Front Canopy)- SM50GDD * 210-2821 Top Cap (Front Canopy)- SM60G, SR62G * 210-2811 Top Cap (Front Canopy)- SM80G 19 12-0366-2 Flue Cap- SR38G obsolete * 823-4175 Flue Cap- SR42G, SR52G (A fter Feb. 2003 ) obso[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-4 2.2 Cabinetry Components, Multi-Battery Fry ing Systems 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 18 17 20 See Sec tion 2.1 for si ngle fryer com ponents. ITEM PART # COMPONENT 1 211-3261 Side, Left- S/S- (Use When SM20G Is On End) * 211-2787 Side, Left- S/S- (Use When SM50G Is On End) * 201-3369 [...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-5 2.2 Cabinetry Components, Multi-Battery Fry ing Systems ITEM PART # COMPONENT 15 200-2830 Base, Filter Frame- Lowe r- SM 20/50 & 50 Series Multi-Battery Fryers w/ UFF 16 200-2785 Base, Filter Frame- Uppe r- SM 20/50 & 50 Series Multi-Battery Fryers w/ UFF 17 823-3634 Fluecap, SM250G * 823-[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-6 2.3 Component Box Components a nd Related Components (CE and Domestic)* * Components are applicable to al l Millivolt fryers covered in th is manual unless otherwise noted. 1 2 9 10 11 12 13 14 15 16 17 3 4 5 6 8 7[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-7 2.3 Component Box Components a nd Related Components (CE and Domestic- cont.) ITEM PART # COMPONENT 1 826-2013 Thermostat, Sunne (Use 807-1692 for CE) * 810-2047 Spring, Spacer- T hermost at Capillary Bulb * 210-1302 Clamp, Thermostat/High Limit Capilla ry Bulb (Use 210-1433 for 2 hole) * 200-1320[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-8 2.4 Frypot and Burner System Components 2.4.1 SM220 and SM20/20/~ Systems 1 2 3 4 5 7 8 9 6 10 11 12 13 14 15 17 18 16 19 22 20 21 ITEM PART # COMPONENT 1 813-0737 Nipple, ½" NPT x 21" BM * 810-2043 Clamp, Pipe- ½" BM Pipe * 809-0805 Bolt, Pipe Clamp- ¼" -20 x ½" Hex *[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-9 2.4.1 SM220 and SM20/ 20/~ Systems (cont.) ITEM PART # COMPONENT 2 813-0003 Tee, ½" NPT BM 3 813-0087 Nipple, ½" NPT x 1-½" BM 4 813-0173 Union, ½" NPT BM 5 813-0780 Bushing, ⅜ " NPT x ½" BM 6 813-0631 Elbow, ⅜ " NPT 90° BM 7 813-0676 Nipple, ⅜ "[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-10 2.4.2 SR Series, SM35G, SM40G and SM50G Systems 1 2 3 5 6 7 8 9 10 11 4 12 13 15 16 17 18 14 19 21 20 25 SM50G Shown 22 23 24[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-11 2.4.2 SR Series, SM35G, SM40G and SM50G Systems (cont.) ITEM PART # COMPONENT 1 12188-1 Frypot- M/S (After 6/98)- SR38G obsolete * 12188-2 Frypot- S/S (After 6/98)- SR38G obsolete * 12082NV Frypot- M/S (P&S Prior to 6/98)- SR38G obsolete * 12202-1 Frypot- M/S (Japan/Singap ore )- SR38G obsole[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-12 2.4.2 SR Series, SM35G, SM40G and SM50G Systems (cont.) ITEM PART # COMPONENT Gas Valve and Related Plumbing- SM50G – Plumbing Will Vary From Model to Model- Use the Follow ing Parts As A Reference W h en Ob tainin g Parts F or System s in This Section Other Than SM50G 12 813-0165 Elbow, Street[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-13 2.4.3 SR62, SM60G and SM80G Systems 16 20 1 2 3 5 4 18 6 7 8 15 9 10 11 12 13 14 21 24 30 17 19 22 23 SM80G Shown 25 26 27 29 28[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-14 2.4.3 SR62, SM60G and SM80G Systems (cont.) ITEM PART # COMPONENT 1 823-3506SP Frypot- M/S- SM80G (After 10/99) obsolete use 823-3494SP * 823-3494SP Frypot- S/S- SM80G (After 10/99) 1¼” (Use 823-3 39 6SP for 1 ½”) * 20004-3SK Frypot- M/S- SM80G (Prior To 10/99) obsolete use 826-1891 * 826-1[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-15 2.4.3 SR62, SM60G and SM80G Systems (cont.) ITEM PART # COMPONENT 22 810-2043 Clamp, Pipe- ½" 23 809-0805 Bolt, Pipe Clamp- ¼”-20 x ½" Hex * 200-1450 Bracket, Gas-Supply Clamp Suppo rt (UFF-Equi pped Systems) 24 813-0031 Bushing, ¾” NPT x ½" NPT BM 25 810-2032 Burner, Pilo[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-16 2.5 Oil Drain Manifold Componets 2.5.1 1½” Oil Drain Ma nifold, Drain Flush and Drain Valve Components* *Typical components illustrated below. Co mponents will vary according to system. 1 To Drain Valve To Drain Valve To Drain Valve 2 3 4 5 6 7 9 10 11 12 13 14 8 15 17 18 19 20 21 22 23 16 24 [...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-17 2.5.1 Oil Drain Manifold , Drain Flush and Drain Va lve Components (cont.) ITEM PART # COMPONENT 1 823-3565 Elbow, with Bracket (LH)- 1-¼"- UFF 50 * 823-3566 Elbow, with Bracket (RH)- 1-¼"- UFF 50 2 812-1524 Drain Pipe, Left Side (Use 823-3418 for Chili’s) 3 813-0784 Drain Pipe, Rig[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-18 2.5.2 3” Oil Drain Manifold, Dr ain Flush and Drain Valve Components To Drain Valve To Drain Valve To Drain Valve To Drain Valve Stud located on underside of tube Place Over Stud Place Over Stud 23 22 13 18 15 17 19 16 21 13 20 19 14 20 21 14 1 3 6 7 9 5 4 8 2 22 11 12 10[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-19 2.5.2 3” Oil Drain Mani fold, Drain Flush & Drain Valve Components (cont.) ITEM PART # COMPONENT 1 823-4712 Tube, 3” Oval Dump 2 823-4681 Tube, 3” Right Drain (closed end) 3 823-4682 Tube, 3” Center Drain (open ends) 4 823-4844 Tube, 3” Left Drain (closed end) 5 823-5188 Tube, 3” [...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-20 2.6 Oil Return Manifold Components 2.6.1 Oil Return Ma nifold Components; Fryers with 1½” Drains* *Typical components illustrated below. Co mponents will vary according to system. 1 2 3 4 5 6 11 8 7 9 10 12 13 14 15 16 19 17 6 18 5 SM460G Oil Return (Typical) 2 ITEM PART # COMPONENT 1 813-0003[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-21 2.6.1 Oil Return Manifold Components; Fryers with 1½” Drains (cont.) ITEM PART # COMPONENT 13 813-0673 Nipple, ½” x 8-½" NPT BM 14 810-2125 Oil Return Valve, ⅜ " * 810-0051 Coupling, ½” NPT x 1- 7 / 16 ” to adapt return hose to valve * 200-1143 Retainer, Oil Return Valve N[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-22 2.6.2 Oil Return Manifold Com ponents; Fryers with 3” Drains ITEM PART # COMPONENT 106-4100 Oil Return Assembly – Middle 106-4101 Oil Return Assembly – End 1 106-4006 Valve Assembly, ½” Oil Return (see Page 2-25) * 106-3997 Valve Assembly (use with wand) * 106-5516 Valve Assembly, 3-way [...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-23 2.7 Oil Return and Oil Flush Components 2.7.1 Oil Return and Oil Flush Co mponents; Fryers with 1½” Drains* *Typical components illustrated below. Co mponents will vary according to system. 1 12 11 14 15 13 2 3 4 5 6 7 8 9 10 16 17 Rear View 18[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-24 2.7.1 Oil Return and Oil Flush Compone nts; Fryers with 1½” Drains (cont.) ITEM PART # COMPONENT 1 Microswitch Bracket Assembly , Oil Return * 201-1233 Bracket, Oil Return Micro switch- Left * 202-1233 Bracket, Oil Return Micro switch- Right * 810-2144 Space r, Aluminum, 4-40- ¼" x 3/8&q[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-25 2.7.2 Oil Return and Oil Flush Co mponents; Fryers with 3” Drains[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-26 2.7.2 Oil Return and Oil Flush Compone nts; Fryers with 3” Drains (cont.) ITEM PART # COMPONENT 106-4006 Microsw itch Bracket Ass embly, Oil Return 1 901-2772 Han dle, RF Left 2 900-2935 Retainer, Nut 3 816-0220 Insulatio n, RF Switch 4 810-0278 Ball Valve, ½” Oil Retu rn 5 826-1366 Nut, 4-4[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-27 2.8 Under Fryer Filter (U FF) Components 2.8.1 SM50 and SM60 Series Fryers (Except IHOP) 1 2 3 4 5 6 7 8 9 10 11 12 ITEM PART # COMPONEN T 1 823-3576 Filter Pan- UFF 50 * 106-2115SP Filter Pan Assembly- UFF 50 * 106-0749SP Filter Pan Assembly- UFF 60 2 809-0805 Screw, ¼"-20 x ½" 3 809[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-28 2.8.2 SM50 Series Fryers, IH OP UFF 50 with Filter Leaf 1 2 3 4 5 6 7 8 10 11 9 ITEM PART # COMPONENT 106-2109SP Filter Pan Assembly- UFF 50 IHOP (include s items 1-5) 1 823-3703 Filter Pan- UFF 50 IHOP 2 810-2805 Caster, 2"-Swivel 3 809-0823 Nut, Nylock ¼ " -20 4 813-0336 Plug, Pipe- [...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-29 2.8.3 SM80 Series Fryers 1 2 3 4 5 6 7 8 12 9 10 11 ITEM PART # COMPONEN T 1 106-1584SP Filter Pan, UFF 80 2 823-3365 Support Grid (Bottom P an Screen) (Use 823-4938 for Chili’s) 3 803-0303 Filter Paper, 26" x 34" (100 Sheets) 4 823-3439 Hold-down Ring, Weighted 5 823-3443 Crumb Baske[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-30 2.9 Single Under Fryer Filter (SUFF) Components 2.9.1 SM50 Series Fryers 1 2 3 4 5 6 7 8 12 9 10 11 ITEM PART # COMPONENT 106-2257SP Filter Pan Assembly SUFF 50 1 823-3796 Filter Pan, SUFF 50 * 813-0684 Plug, Hex Socket, ⅜ " NPT * 813-0679 Plug, ⅛ " S/S Square Head (Female Disconnec[...]

DEAN MILLIVOLT GAS FRYERS CHAPTER 2: PARTS LIST 2-31 2.9.2 SM60 and SM80 Series Fryers 1 2 3 4 5 6 7 8 12 9 10 11 ITEM PART # COMPONENT 1 823-3774 Filter Pan, SUFF 60 (Use 106-222 8SP for Assembly) * 823-3821 Filter Pan, SUFF 80 (Use 106-238 1SP for Assembly) * 813-0684 Plug, Hex Socket, ⅜ " NPT * 813-0679 Plug, ⅛ " S/S Square Head (F[...]

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Dean, 8700 Line Avenue, PO Box 5100 0, Shreveport, Louisiana 71135-1000 Shipping Address: 8700 Line Av enue, Shreveport, Louisiana 71106 TEL 1-318-865-1711 FAX (Parts) 1-31 8-327 -3343 FAX (Tech Support) 1-318-219-7135 PRINTED IN THE UNITED STATES SERVICE HOTLINE 1-800-551-8633 819-5948 MAY 2007[...]