Vulcan-Hart 52386 manual

VULCAN-HART COMPANY, P.O. BOX 696, LOUISVILLE, KY 40201- 0696, TIL. (502) 778-2791 FORM 30911 (12-94) MODEL GPC12S SHOWN SER VICE MANUAL FOR GPC12 & GPC12S, GPC16 & GPC16S GAS P AST A COOKER ML NOS. 52386, 52423, 52387 AND 52424[...]

2 IMPORT ANT FOR YOUR SAFETY THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO SERVICE AND ADJUST 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. IMPORT ANT IN THE EVENT A GAS ODOR IS DET[...]

3 T ABLE OF CONTENTS Important Safety Information Page 2 Codes and Standards Information Page 3 Manual Use Information Page 3 Data Plate Information Page 3 Service Warnings Page 3 Tools Required for Servicing Page 3 Section l Service Checks Pages 4-8 Section ll Service Adjustments Pages 9-10 Section lll Removal and Replacement of Controls Pages 11-[...]

4 SECTION I SERVICE CHECKS WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE APPLIANCE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. VENTILATION CHECKS Insure that adequate ventilatio[...]

5 COMBINATION VALVE GAS PRESSURE CHECK 1. Check pressure rating of appliance as stated on the cooker door. 2. Turn on all appliance burners. 3. Connect a manometer to the pressure tap of the gas combination valve (gas tap is marked on valve). 4. Open the pressure tap of the manometer. 5. The manometer reading should match the pressure rate inches w[...]

6 TRANSFORMER CHECK 1. Follow steps 1-3 under Accessing of Controls Inside the Control Box. 2. Follow Steps 1-4 under Removal of Transformer. 3. With a volt meter and the appliance "on", check the voltage across the load and line terminals. Voltage should match that of the transformer markings. EXAMPLE: Transformer marked - PRI. 120V SEC.[...]

7 1 2 3 4 5 6 7 8 9 MV BUR 24V 24V W MV PV PV GND GNDHOT TH SEN SPK If erratic ignitor operation is experienced check for the following: 1. If you are experiencing system lock out reset system by turning power switch off, wait several minutes and turn switch on. 2. Check for good metal to metal contact between the pilot bracket and main burner. 3. [...]

8 3. Push power switch ON and immediately touch one end of the jumper firmly to the GND terminal on the module. Do not touch the jumper to the SPARK terminal, but, move the free end of the jumper slowly towards the SPARK terminal until a spark is established. Pull the jumper slowly away from the SPARK terminal and note the length of the gap when th[...]

9 SECTION II P AST A COOKER SER VICE ADJUSTMENTS ADJUSTMENT OF GAS REGULATOR 1. Follow steps 1-6 under Combination Gas Valve Regulator Check in Section I of this manual. 2. Remove the regulator adjustment cap from the combination valve. (Fig. 1) Fig. 1 3. Turn the gas adjustment screw clockwise to increase pressure and counterclockwise to decrease [...]

10 LIFT ARM ADJUSTMENT BOL T 4. Remove temperature dial knob and insert flat head screw driver into the thermostat shaft rotating the thermostat adjustment screw to match pyrometer reading to 225 degrees F. at the dial boil setting. Turn clockwise to increase and counterclockwise to decrease setting. One quarter turn will change the temperature by [...]

11 CONTROL PANEL COOKER 1. With a 1 ⁄ 4 " socket, remove (2) screws from the upper right and left hand corners of the control panel. (Fig. 4) Fig. 4 2. With a 1 ⁄ 4 " socket, remove (2) #8 hex head screws located on the under flange of the control panel (Fig. 5). Fig. 5 SECTION Ill REMOV AL AND REPLACEMENT OF CONTROLS WARNING: UNPLUG [...]

12 3. Remove the cooker door panel. (Fig. 6) Fig. 6 4. Fold control panel down. (Fig. 7) Figs. 7[...]

13 5 . Disconnect the main and basket lift (if applicable) wire harness and carefully remove the panel from the fryer. (Figs. 8) Fig. 8 REMOVAL OF RINSE STATION CONTROL PANEL 1. With a 1 ⁄ 4 " socket, remove (2) screws from the upper left and right hand corners of the panel. (Fig. 9) Fig. 9[...]

14 2. Open the door and with a 1 ⁄ 4 " socket, remove (2) screws from the right and left corners of the under flange of the panel. (Fig. 10) Fig. 10 3. Lift door panel off of the rinse station. (Fig. 11) Fig. 11[...]

15 4. With a 1 ⁄ 8 " size allen wrench, loosen the hot and cold water control knob set screws. (Fig. 12) Fig. 12 5. Pull knobs from the appliance. (Fig 13) Fig. 13[...]

16 6. Note that this step is only required if the water valves need to be replaced. If fittings are good go on to step 7. With a flat blade screwdriver and a 5 ⁄ 16 " deep socket or wrench, remove (4) screws securing the water fittings to the control panel. (Fig. 14) Fig. 14 7. Disconnect the water hoses and remove panel from the rinse stati[...]

17 8. Reinstall rinse station panel by reversing steps 1-7. REMOVAL OF INDICATOR LIGHT 1. Follow steps 1-5 under Control Panel Removal. 2. From the rear of the control panel unscrew the wire cap of light to be replaced. 3. Squeeze the tabs on both sides of the indicator light being replaced and pull the light out through the front of the panel. (Fi[...]

18 4. Reinstall new switch by reversing steps 1-3. REMOVAL OF BASKET LIFT TIMER 1. Remove the timer knob using a 1 ⁄ 32 " allen wrench. (Fig. 18) Fig.18 2. Remove the timer mounting hardware. (Fig. 19) Fig. 19[...]

19 3. Follow steps 1- 5 under removal of control panel. 4. Note and remove all wiring associated with the removal of the timer. (Fig. 20) Fig. 20 5. Install new timer by reversing steps 1-4. REMOVAL OF RELAY 1. Follow steps 1-5 under Removal of Control Panel. 2. With panel down note and remove all wiring leading to the relay. (Fig. 21) Fig. 21[...]

20 3. With 1 ⁄ 4 " socket, remove (2) holding nuts and pull the relay off of the panel. (See Fig. 7) 4. Install new relay by reversing steps 1-3. REMOVAL OF THERMOSTAT 1. Drain water from tank. 2. Follow steps 1- 5 under Removal of Cooker Control Panel. 3. Follow steps 1-4 under Removal Burner to remove the right hand burner from the cooker.[...]

21 6. From the control panel using a flat blade screwdriver, remove (2) screws securing the thermostat to the panel. (Fig. 24) Fig. 24 7. Note and using a flat blade screwdriver, disengage all wiring form the thermostat body. (Fig. 25) Fig. 25 8. Install new thermostat by reversing steps 1-7. Be sure that the thermostat wire is not kinked and that [...]

22 REMOVAL OF COOKER CONTROL BOX HOUSING 1. Follow steps 1-5 under Removal of Control Panel. 2. Disconnect limit and basket lift wire harnesses inside the control housing. (See Figs. 8) 3. With a 5 ⁄ 16 " socket, remove (4) screws holding the housing to the cooker frame. (Fig. 26) Fig. 26 4. Pull housing from the cooker. (Fig. 27) Fig. 27 5.[...]

23 REMOVAL OF HIGH LIMIT 1. Drain water from the cooker. 2. Open cooker door and disengage wire harness located below the control housing to the right side of the cooker. (Fig. 28) Fig. 28 3. Follow steps 1- 4 for Removal of Cooker Control Housing. 4. From inside cooker tank with a 1 ⁄ 4 " socket, remove (2) screws and the bracketing piece h[...]

24 6. With (2) hands grasp the burner body and push it upward over the bullet nose pilots. Then tilt the burner head back and pull the burner away from the cooker. Note that if more room is required to reach the limit hardware the left side burner may be removed in the same manner. (Fig. 30) Fig. 30 7. The high limit fitting is the one toward the r[...]

25 8. With an 11 ⁄ 16 " wrench, remove the limit holding nut. (Fig. 32) Fig. 32 9. Carefully pull the limit bulb and wiring from the unit. 10. Note and remove the limit body wiring. (Fig. 33) Fig. 33[...]

26 11. With a 1 ⁄ 4 " socket, remove (2) holding screws securing the limit body to the mounting bracket. (Fig. 34) Fig. 34 12. Install new limit by reversing steps 1-9. When installing new limit do not kink the limit wire or bend the limit probe. Make sure that the probe is mounted intimately against the burner tube. Wrap limit holding nuts [...]

27 REMOVAL OF BULLET NOSE BURNER PILOT AND ORIFICE 1. Follow steps 1-4 under Removal of Cooker Burners. 2. With a 5 ⁄ 16 " wrench, remove the pilot orifice. (Fig. 35) Fig. 35 3. With channel locks remove the pilot body. (Fig. 36) Fig. 36 4. Install new orifice or pilot body by reversing steps 1-3. Use pipe dope when installing pilot body.[...]

28 Fig. 37 3. With a 7 ⁄ 16 " wrench, loosen the pilot tube holding nut. (Fig. 38) REMOVAL OF PILOT IGNITOR 1. Follow steps 1-4 under Removal of Burners. 2. Pull the igniter boot from the ignitor. (Fig. 37) Fig. 38[...]

29 4. With an offset screwdriver, remove (2) screws from the ignitor/pilot holding bracket and pull the assembly from the cooker. (Fig. 39) Fig. 39 Install new ignitor/pilot assembly by reversing steps 1-4 above. REMOVAL OF GAS COMBINATION VALVE 1. Note and remove all wiring associated with the combo valve. (Fig. 40) Fig. 40[...]

30 2. With a 7 ⁄ 16 " wrench, loosen the pilot tube holding nut. (Fig. 41) Fig. 41 3. With a 3 ⁄ 4 " wrench, remove the gas line compression elbow fitting. (Fig. 42) Fig. 42[...]

31 4. With channel locks loosen the burner gas line union attached to the combo valve pipe fittings. (Fig. 43) Fig. 43 5. Remove the combo valve from the cooker. GAS LINE UNION[...]

32 REMOVAL OF DISCARD HOSE (COOKER AND DRAIN STATION) 1. Drain station to be worked on. 2. Open cabinet door. 3. Follow steps 1-5 for the Removal of Control Panel. 4. Follow steps 1-4 under Removal of Cooker Control Box Housing ( this procedure is not required for the rinse station). 5. With a standard flat blade screwdriver, loosen the hose clamp.[...]

33 7. Pull hose from scrap box. (Fig. 46) Fig. 46 8. Install discard hose by reversing steps 1-7. REMOVAL OF SCRAP BOX (COOKER AND DRAIN STATION) 1. Open cooker door. 2. Pull scrap box handle away from cooker. (Fig. 47) Fig. 47[...]

34 3. Support box with one hand on the under side and remove box from the cooker. (Fig. 48) Note that you may need to lift the box up slightly to remove it from the slide track. Fig. 48 4. Reinstall box by reversing steps 1-3. Be sure to align the scrap box drain tube into the scrap box housing tube in the rear of the cooker. REMOVAL OF HOT AND COL[...]

35 3. With standard flat blade screwdriver, loosen the (2) rear drain coupling holding clamps and pull the coupling from the appliance. Retain the clamps for installation of new part. (Fig. 49) Fig. 50 Fig. 49 4. Install coupling by reversing steps 1-3. REMOVAL OF DRAIN STATION FAUCETS ASSEMBLY AND SPRAY HOSE 1. Turn main water supply of the rinse [...]

36 2. With a 5 ⁄ 16 " socket, remove (4) screws holding the faucet hosing to the rinse station. (Fig. 51) Fig. 51 3. With a standard flat blade screwdriver, remove the faucet head holding screw. (Fig. 52) Fig. 52[...]

37 4. With a philips head screwdriver, remove the hot and cold water faucet handle holding screws. (Fig. 53) Fig. 53 5. Remove the faucet handles and head from the rinse station. 6. Disconnect the hot and cold water hoses. (Fig. 54) Fig. 54[...]

38 7. To change fitting washer with an adjustable wrench remove the faucet stem and nut assembly from the cast iron body. (Fig. 55) Fig. 55 8. To tighten the handle stem use an adjustable wrench. Be sure not to over tighten. If stem is too tight it will wear quicker and cause leaks . 9. With a 3 ⁄ 4 " wrench, disconnect the spray hose water [...]

39 FRONT CHANNEL BEHIND FRONT CHANNEL 10. Reinstall faucet by reversing steps 1-10 as needed. REMOVAL OF SCRAP BOX HOUSING Note that the scrap box has formed flanges on all 4 corners. These flanges are used to attach the box to the appliance base frame. There are (3) screws in each flange. Removal of these screws in the front and back sections of t[...]

40 5. Remove the housing from the appliance. 6. Install new housing by reversing steps 1-5. REMOVAL OF DRAIN BALL VALVE 1. Drain tank. 2. Close drain ball valve. (Fig. 59) Fig. 59 3. With a 1 ⁄ 2 " wrench, remove nut and washer securing the ball valve handle. (This is an optional step if the ball valve being removed is located on the sink si[...]

41 4. With a pipe wrench remove nipple. (Fig. 61) Fig. 61 5. With pipe wrench remove the ball valve. (Fig 61) 6. Install new valve by reversing steps 1-5. REMOVAL OF BASKET LIFT BACK (OPTIONAL FEATURE) 1. Remove all baskets and basket support racks from tank. 2. Drain appliance tank, disconnect unit power and tipping restraint. Move appliance to an[...]

42 5. Lift back up and over the lift mechanism. (Fig. 63) Fig. 63 6. Disconnect the gas line and remove the lower basket lift back by disengaging (2) screws at each lower side of the cover and (2) screws from each lower back corner using a 1 ⁄ 4 " socket . (Fig. 64) Fig. 64[...]

43 LIFT ROD A TT ACHMENT NUT 7. To reinstall basket back panels reverse steps 1-6. REMOVAL OF LIFT ROD MECHANISM 1. Follow steps 1-6 under Removal of Basket Lift Backs 2. With a 1 ⁄ 2 " wrench, remove the nut that attaches the lift rod to the lift bar. (Fig. 65) Fig. 65 3. With a 5 ⁄ 16 " socket, remove (6) screws from the rod mechani[...]

44 4. With 5 ⁄ 16 " socket, remove (2) nuts holding the cam lift bracket to the cooker back. (Fig. 67) Fig. 67 5. Remove motor wiring. (Fig. 68) Fig. 68[...]

45 Fig. 69 7. Remove the motor from the cooker. To install new motor reverse steps 1-6. REMOVAL OF BASKET LIFT CAM SWITCH 1. Follow steps 1-6 under Removal of Basket Lift Backs 2. Note and remove wiring. With a standard flat blade screwdriver, and a 5 ⁄ 16 " wrench, remove (2) screws and holding nuts from the cam switch. (Fig.70) Fig. 70 6. [...]

46 3. Install new switch by reversing steps 1-3. REMOVAL OF BASKET LIFT CAM 1. Follow steps 1-6 under Removal of Basket Lift Back. 2. With a 1 ⁄ 2 " wrench or socket, remove the lift bar and cam assembly holding nut. (Fig. 71) Fig. 71 3. With an allen wrench loosen the cam set screw. (Fig. 72) Note: When reassembling make sure wires do not t[...]

47 REMOVAL OF PASTA COOKER POWER SUPPLY BOX (STAND ALONE) 1. Follow steps 1-6 under Removal of Basket Lift Back if appliance is equipped with this option. 2. Note and disconnect all wiring and wire harnesses. (Fig. 73) Fig. 73 3. Follow steps 1-2 under Removal of Lift Rod Mechanism if basket lift option is included on the appliance. 4. With a 5 ⁄[...]

48 7. With a 5 ⁄ 16 " socket and a wrench, disconnect the electric supply cord holding strap(s). (Fig. 75) Fig. 75 Fig. 76 9. Pull the power supply box out through the back of the unit. To reinstall box reverse steps 1-8. 8. If necessary with a 5 ⁄ 16 " socket, remove (4) screws securing the basket lift bottom plate to the appliance f[...]

49 REMOVAL OF PASTA COOKER POWER SUPPLY BOX ( WITH RINSE STATION) 1. Follow steps 1-8 under Removal of Pasta Cooker Supply Box ( stand alone) 2. From the rinse station with a 7 ⁄ 16 " wrench, disconnect the "U" bolt bracket from the hot and cold water fitting assemblies. (Fig. 77) Fig. 77 3. Disconnect the rinse station hot and col[...]

50 4. With a 5 ⁄ 16 " socket, remove (4) screws holding the rinse station support back bracket. (Fig. 79) Fig. 79 5. Pull the cooker power supply box through the rinse station back and out of the appliance. (Fig. 80) Fig. 80[...]

51 6. Reinstall box by reversing steps 1-5. ACCESS OF CONTROLS INSIDE THE POWER SUPPLY BOX 1. Follow steps 1-8 (stand alone) or 1-5 (with rinse station) under Removal of Power Supply Box. 2. With a 5 ⁄ 16 " socket, remove (2) screws securing the supply box cover. (Fig. 81) Fig. 81 3. Controls are now exposed and can be serviced. To reinstall[...]

52 4. With a 1 ⁄ 4 " socket, remove (4) screws holding the module to the supply box. (Fig. 83) Fig. 83 5. Install new module by reversing steps 1-4. REMOVAL OF TRANSFORMER 1. Follow steps 1-9 (stand alone) or 1-5 (with rinse station) under Removal of Power Supply Box. 2. Follow steps 1-2 under Access of Controls Inside the Power Supply Box. [...]

53 4. With 1 ⁄ 4 " socket, remove (2) screws securing the transformer to the supply box. (Fig. 85) Fig. 85 5. Install new transformer by reversing steps 1-4. REMOVAL OF ELECTRICAL SUPPLY CORD 1. Follow steps 1-9 (stand alone) or 1-5 (with rinse station) under Removal of Power Supply Box. 2. Follow steps 1-2 under Access of Controls Inside th[...]

54 4. With small flat blade screwdriver, remove all wiring with in the box that attaches the supply cord to the terminal block and the ground lug. (Fig. 87) Fig. 87 5. Pull the cord from the appliance. Install the cord by reversing steps 1-4. REMOVAL OF COOKER TANK 1. Remove basket(s) and basket hanger. (Fig. 88) Fig. 88[...]

55 2. Drain cooker tank and scrap box. Disconnect appliance from the power supply line. 3. Remove the basket lift arm if applicable to the appliance. (See Fig. 3) 4. With 5 ⁄ 16 " socket, remove (2) screws at the top of the flue box. (Fig. 89) Fig. 89 5. Follow steps 1- 6 under Removal of Basket Lift Back if the appliance is so equipped. 6. [...]

56 9. Carefully fold the thermostat wiring and body so that it will set between the burners. Wedge it securely so that it will not fall out when the tank assembly is lifted from the appliance. 10. Follow steps 1-5 under Removal of Cooker Power Supply Housing. 11. Remove the ignitor boot. (Fig. 90) Fig. 90 12. With a 7 ⁄ 16 " socket, remove ([...]

57 16. Note wiring and remove all controls from the old tank. Retain the controls and hardware for reassembly to the new tank. (Review section lll, Removal of Thermostat, High Limit, Combo Valve Burners, Burner Pilot and Orifice and Ignitor and Pilot Assembly). If you are in doubt of control removal procedures. 17. Install all the old controls onto[...]

58 6. Follow steps 1-6 and step 10 under Removal of Drain Station Faucet and Spray Hose. 7. Remove the scrap box from the appliance. (See Fig. 48) 8. With a 7 ⁄ 16 " socket, remove (2) 1 ⁄ 4 -20 nuts from under the front base frame that secures the tank support bracket to the frame. (Fig. 93) 9. Follow step 16 under Removal of Cooker Tank.[...]

59 SECTION IV WIRING INFORMA TION DRAWING NO. REV 420843-1 B BASKETLIFT CONTROL ASSEMBLY REFER TO D-418519 FOR WIRING INFORMATION[...]

60 FORM 30911 (12-94)[...]