Frymaster FPHD565 Service Manual
High Efficiency Decathlon (HD)
Series Gas Fryers
Service & Parts Manual
HDC, CFHDC, SCFHDC,
FPHDC, LHDC, Y/KSCF/C/HC, BK1814
(High Efficiency Common Cabinet
Decathlon Fryers)
Dean, a member of the Commercial Food Equipment Service Association, recommends using
CFESA Certified Technicians.
PRINTED IN THE UNITED STATES
OF AMERICA
24-Hour Service Hotline
1-800-551-8633
*8196314*
NOV 2013
Please read all sections of this manual and retain for future reference.
This product has been certified as commercial cooking equipment and MUST be installed by
professional personnel as specified. Installation, maintenance and repairs should be performed
by your FRYMASTER AUTHORIZED SERVICER.
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 in a prominent location in
the event the operator detects a gas leak. This information can be obtained from the local gas
company or gas supplier.
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.
DANGER
Safe and satisfactory operation of your equipment depends on proper installation. Installation
MUST conform with local codes, or in absence of local codes, with the National Fuel Gas Code,
ANSI Z223.1; The Natural Gas Installation Code, CAN/CGA-B149.1; The Propane Installation
Code, CAN/CGA-B149.2; or The latest edition of the National Electric Code, N.F.P.A. 70.
NOTICE
If, during the warranty period, the customer uses a part for this Manitowoc Food Service
equipment other than an unmodified new or recycled part purchased directly from Frymaster
and Dean, or any of its authorized service centers, and/or the part being used is modified from
its original configuration, this warranty will be void. Further, Frymaster and Dean and its
affiliates will not be liable for any claims, damages or expenses incurred by the customer which
arise directly or indirectly, in whole or in part, due to the installation of any modified part and/or
part received from an unauthorized service center.
DANGER
The crumb tray in fryers equipped with a filter system must be emptied into a fireproof container
at the end of frying operations each day. Some food particles can spontaneously combust if left
soaking in certain shortening material. Additional information can be obtained in the filtration
manual included with the system.
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.
WARNING
Drawings and photos used in this manual are intended to illustrate operational, cleaning and
technical procedures and may not conform to on-site management operational procedures.
WARNING
No structural material on the fryer should be altered or removed to accommodate placement of
the fryer under a hood. Questions? Call the Frymaster and Dean Service Hotline at 1-800-551-
8633.
This equipment is to be installed in compliance with the basic plumbing code of The Building
Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation
Manual of the Food and Drug Administration.
COMPUTERS
FCC
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
1) This device may not cause harmful interference, and 2) This device must accept any interfere nce
received, including interference that may cause undesired operation. While this device is a verified Class
A device, it has been shown to meet the Class B limits.
CANADA
This digital apparatus does not exceed the Class A or B limits for radio noise emissions as set out by the
ICES-003 standard of the Canadian Department of Communications.
Cet appareil numerique n’emet pas de bruits radioelectriques depassany les limites de classe A et B
prescrites dans la norme NMB-003 edictee par le Ministre des Communcations du Canada.
DANGER
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE
CANCER AND/OR BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
Operation, installation, and servicing of this product could expose you to airborne particles of
glasswool or ceramic fibers, crystalline silica, and/or carbon monoxide. Inhalation of airborne
particles of glasswool or ceramic fibers is known to the State of California to cause cancer.
Inhalation of carbon monoxide is known to the State of California to cause birth defects or other
reproductive harm.
WARNING
Do not bang fry baskets or other utensils on the fryer’s joiner strip. The strip is present to seal
the joint between the fry vessels. Banging fry baskets on the strip to dislodge shortening will
distort the strip, adversely affecting its fit. It is designed for a tight fit and should only be
removed for cleaning.
High Efficiency Decathlon (HD) S eries Gas Fryers
Service and Parts Manual
TABLE OF CONTENTS
1. SERVICE PROCEDURES……..……..……………………………………………...
1.1 Functional Description............................................................................................1-1
1.2 Accessing Fryers for Service...................................................................................1-7
1.3 Cleaning the Gas Valve Vent Tube (if applicable)................................................1-9
1.4 Adjusting Burner Manifold Gas Pressure.............................................................1-9
1.5 Adjusting the Pilot Flame......................................................................................1-10
1.6 Calibrating the Thermatron Controller and Backup Thermostat....................1-10
1.7 Replacing Fryer Components...............................................................................1-11
1.8 Troubleshooting and Problem Isolation..............................................................1-29
1.9 Troubleshooting Guides........................................................................................1-37
1.10 Wiring Diagrams....................................................................................................1-38
1.11 Probe Resistance Charts........................................................................................1-52
2. PARTS LIST…….…………………………………..………………………………
2.1 Decathlon(HDC) Primary Components................................................................2-1
2.2 Orifices ....................................................................................................................2-16
2.3 Additional Optional Components and Controllers.............................................2-17
2.4 Drain Components .................................................................................................2-19
2.5 Oil Return System..................................................................................................2-23
2.6 Additional Oil Return Components.....................................................................2-25
2.7 Oil Disposal (Popeye's and Church’s)..................................................................2-27
2.8 Oil Return Wand....................................................................................................2-28
2.9 Over-the-Top Oil Return System.........................................................................2-29
2.10 Filtration Components...........................................................................................2-30
2.11 Basket Lift Components........................................................................................2-38
2.12 Accessories ..............................................................................................................2-40
2.13 Fasteners (Screws, Nuts, Bolts).............................................................................2-41
2.14 Flexlines...................................................................................................................2-42
APPENDIX: Pre-Common Cabinet HD65 Parts List..................................................2-43
Flue Cap
Top Cap
Electronic
Operating
Thermostat
Oil Return Handle
Gas Valve
Filter Unit
configuration and date of manufacture.
Basket Hanger Frypot
Drain Valve Handle (Red)
Oil Return Handle (Yellow)
Drain Flush Handle (Blue)
Burners
Note: The appearance of your fryer may differ slightly from that shown depending upon
Controller
Drain Tubes
FINDING YOUR WAY AROUND THE DEAN HIGH EFFICIENCY DECATHLON
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.1 Functional Description
High Efficiency Decathlon (HD) Series gas fryers contain a welded stainless steel frypot heated by
gas flames diffused evenly through tubes built into the frypot.
Flames originate from orifices in a burner manifold positioned beneath cast-steel burners. The
burners are positioned in the tube openings at the front of the frypot. The diameter of the orifices
differs for natural and LP gas as indicated in the accompanying table.
GAS INFORMATION (Altitudes of 2000 feet or less)
MODEL
HD50G 95
HD60/63/65G 125
INPUT
(BTU)
GAS
TYPE
NAT
LP
NAT
LP
ORIFICE
MM
(INCH)
2.26(#43)
1.40(#54)
2.26(#43)
1.40(#54)
ORIFICE
PART NO.
810-2938
810-2939
810-2938
810-2939
QTY
4
4
5
5
EQUIPMENT
PRESSURE
MBAR
10
27.5
10
27.5
INCH W.C.
4
10
4
10
An electromechanical gas valve regulates gas flow to the manifold. HD Series gas fryers are
equipped with either a 24V valve system. Unit configurations include either a pilot ignition system
or an electronic ignition system.
1-1
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.1 Functional Description (cont.)
Pilot System Configuration
The pilot system is comprised of the pilot orifice, pilot hood, and a thermopile (some systems
incorporate a thermocouple). The pilot serves two purposes: light the burner and heat the
thermopile. In operation, the thermopile is in contact with the pilot flame and generates millivolts.
The millivolt output energizes the gas valve pilot coil, which in turn opens the pilot valve. If the
pilot flame is extinguished, the gas valve pilot coil loses voltage and the pilot valve closes. The
main valve of the gas valve will not open if the pilot valve is not open. The pilot flame must be
manually lit when the fryer is first placed into operation. A separate 24V circuit, activated by the
fryer ON/OFF switch, provides voltage through the Thermatron to the gas valve main coil, which
opens the main valve.
Electronic Ignition Configuration
In units configured for electronic ignition, an ignition module connected to an ignitor assembly
replaces the pilot system. The ignition module performs three important functions: It provides an
ignition spark, supplies voltage to the gas valve, and proofs the pilot flame.
The module contains a 90-second time delay circuit and a coil that activates the gas valve. The
ignitor assembly consists of a spark plug, a pilot, and a flame sensor element.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Electronic Ignition Configuration (cont.)
At start-up the ON/OFF switch is placed in the ON position, supplying 12 VDC to the heat control
circuitry in the controller or controller and to one side of the heat relay coil on the interface board. If
resistance in the temperature probe indicates the temperature in the frypot is below 180°F (82°C),
the current flows through a melt cycle circuit where a timer switch alternately closes for 3 seconds
and opens for 24 seconds. If the temperature is 180°F (82°C) or above, the current flows through a
heat circuit, bypassing the timer switch. In either case, current is supplied to the other leg of the heat
relay coil which then closes an electronic switch in the 24 VAC circuit to provide current to the
ignition module. NOTE: The listed melt cycle times and exit temperature pertain to the Compu-Fry
controller only.
Circuitry in the ignition module sends 24 VAC current to the gas valve via a normally closed highlimit switch and a drain safety switch. Simultaneously, the module causes the ignitor to spark for up
to 90 seconds to light the pilot flame. A flame sensor verifies that the pilot is lit by measuring the
flow of microamps through the flame. If the pilot does not light (or is extinguished), current to the
ignition module is interrupted, preventing the main valve from opening, and the ignition module
"locks out" until the power switch is turned OFF, then back ON.
A temperature probe monitors the temperature in the frypot. When the programmed setpoint
temperature is reached, resistance in the probe causes the heat cycle circuitry in the controller to
interrupt current flow through the heat relay. This in turn interrupts the 24 VAC current to the
ignition module, resulting in closure of the gas valve.
NOTE: Unlike previous modules, microamp readings on these black modules will move up and
down as the module pulses on and off and this is an indication that the module is functioning.
Control Options
HD Series gas fryers may be equipped with Thermatron controls, Compu-Fry controllers, 3-Lane
controllers or FAST controllers.
In fryers equipped with Thermatron controls, the fryer is turned on and off by means of a rocker
switch and the temperature is set by adjusting a potentiometer. An interface board is located in the
component box (shield) behind the control panel (controller-equipped) or a Thermatron board is
located in a component box inside the cabinet (Thermatron-equipped).
Interface Boards
The interface board provides a link between the controller/controller and the fryer’s individual
components without requiring excessive wiring, and allows the controller to execute commands
from one central point. Two types of interface boards may be used in HD Series gas fryers; the type
used depends on the fryer configuration.
In units configured for electronic ignition and constant pilot, P/N 826-2434 is used; in units
configured with a manually lit pilot (non-electronic ignition), P/N 826-2425 is used.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Interface Boards (cont.)
106-3729 (24V): These boards are used in HD fryers equipped with Thermatron control systems.
THERMATRON BOARD P/N 106-3729
Thermatron systems incorporate a temperature probe, a potentiometer, and a temperature control
circuit board. This system is more accurate and reliable than a standard thermostat. The temp erature
probe measures oil temperature via resistance (ohms); as oil temperature rises, resistance decreases.
The potentiometer sets the oil temperature via resistance (ohms). The temperature control circuit
board compares the resistance from the probe and potentiometer and cycles the burner on and off as
necessary.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Interface Boards (cont.)
826-2434: These interface boards are used in HD fryers equipped with electronic ignition and
constant pilot.
INTERFACE BOARD P/N 826-2434
Used on fryers equipped with electronic ignition and constant pilot.
1-5
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Interface Boards (cont.)
FREQUENTLY USED TEST POINTS FOR HIGH EFFICIENCY DECATHLON (HD) FRYER S
106-6669 INTERFACE BOARD
Test Meter Setting Pins Test Results
12VAC Power to Controller 50 VAC Scale 1 and 3 on J3 12-18
12VDC Power to Right BL Relay 50 VDC Scale 4 on J2 and 5 on J2 12-18
12VDC Power to Left BL Relay 50 VDC Scale 7 on J1 and 5 on J2 12-18
24VAC Power to High-Limit 50 VAC Scale 6 on J2 and GROUND 22-28
24VAC Power 50 VAC Scale 2 on J2 and GROUND 22-28
24VAC Power To 24VAC Gas Valve 50 VAC Scale 7 on J2 and GROUND 22-28
Probe Resistance* R x 1000 Ohms 10 and 11 on J2 **
* Disconnect 15-pin harness from controller before testing probe circuit.
** See Probe Resistance Chart at the end of this chapter.
HIGH EFFICIENCY DECATHLON (HD) FRYER
LED DIAGNOSTIC LIGHTS
(106-6669 INTERFACE BOARD)
CMP
24V
HI
HT
AL
Indicates power from 12V transformer.
Indicates power from 24V transformer.
Indicates output (closed) from latch relay (K4).
Indicates output from heat relay (K3).
Indicates output (open) from latch relay (K4).
The board contains four relays. K3 is the heat relay and K4 is the latch relay. K1 and K2 are only
used in "dual" or "split" pot applications.
NOTE: On factory-original units not equipped with basket lifts and on service interface boards, the
board will have no basket lift relays installed.
1-6
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Thermostats
Different types of thermostats are used in High Efficiency Decathlon Series gas fryers, depending on
fryer configuration.
Fryers equipped with a Thermatron use a dial to adjust temperature. In this configuration, the probe
resistance varies inversely with the temperature. As the temperature rises, resistance decreases at a
non-linear rate. A chart is located at the end of this chapter.
Fryers equipped with controller controls have a temperature probe. In this configuration, the probe
resistance varies directly with the temperature. As the temperature rises, resistance increases at a
rate of approximately 2 ohms for every 1°F (approximately 3.7 ohms for every 1°C). Circuitry in the
controller monitors the probe resistance and controls burner firing when the resistance exceeds or
falls below programmed temperatures (setpoints). The temperatures are programmed by means of a
keypad on the face of the controller.
All HD Series gas fryers are equipped with a high-limit thermostat. In the event that the fryer fails
to control the oil temperature, the high-limit thermostat prevents the fryer from overheating to flash
point. The high-limit thermostat acts as a normally closed power switch that opens when exposed to
temperatures above 450°F/232°C.
1.2 Accessing Fryers for Service
DANGER
Moving a fryer filled with cooking oil may cause spilling or splattering of the hot
liquid. Follow the draining instructions included with the fryer before attempting to
relocate a fryer for servicing.
1. Shut off the gas supply to the unit. Unplug the power cords. Remove any attached restraining
devices.
2. Disconnect the unit from the gas supply.
3. Relocate the fryer for service accessibility.
4. After servicing is complete, reconnect the unit to the gas supply, reattach restraining devices, and
plug in the electrical cords.
DANGER
No structural material on the fryer should be altered or removed to accommodate
placement of the fryer under a hood. Questions? Call the Frymaster Dean Service
Hotline at 1-800-551-8633.
1-7
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Restraints
Once the fryer has been positioned at the frying station, use a carpenter’s level placed across the top
of the frypot to verify that the unit is level, both side-to-side and front-to-back.
To level fryers equipped with legs, the bottom of the legs can be screwed out up to one inch for leveling.
Legs should also be adjusted so that the fryer(s) are at the proper height in the frying station.
For fryers equipped with casters, there are no built-in leveling devices. The floor where the fryers
are installed must be level.
When the fryer is leveled in its final position, install the restraints provided with the unit to limit its
movement so that it does not depend on or transmit stress to the electrical conduit or connection.
Install the restraints in accordance with the provided instructions (see illustration below). If the
restraints are disconnected for service or other reasons, they must be reconnected before the fryer is
used.
DANGER
Adequate means must be provided to limit the movement of this appliance without
depending on or transmitting stress to electrical conduits or gas supply line. A
restraint kit is provided with the fryer. If the restraint kit is missing contact your
local Frymaster Factory Authorized Service Center (FASC) for part number 826-0900.
NOTE: If you need to relocate a fryer installed with legs, remove all weight from each leg
before moving. If a leg becomes damaged, contact your service agent for immediate repair or
replacement.
DANGER
Hot oil can cause severe burns. Avoid contact. Under all circumstances, oil must be
removed from the fryer before attempting to move it to avoid oil spills, falls, and
severe burns. This fryer may tip and cause personal injury if not secured in a
stationary position.
1-8
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.3 Cleaning the Gas Valve Vent Tube (if applicable)
1. Set the fryer power switch and the gas valve to the OFF position.
2. Carefully unscrew the vent tube from the gas valve. NOTE: The vent tube may be straightened
for ease in removal.
3. Pass a piece of wire through the tube to remove any obstruction. Remove the wire and blow
through the tube to ensure it is clear.
4. Reinstall tube and bend so that the opening is pointing downward.
1.4 Adjusting Burner Manifold Gas Pressure
WARNING
This task should be performed by qualified service personnel only.
1. Ensure that the gas valve knob is in the OFF position.
2. Remove the pressure tap plug from the gas valve (see arrows in photos below for location).
Pilot Ignition Valve
(Line Voltage)
Electronic
Ignition Valve
3. Insert the manometer fitting into the pressure tap hole.
4. Place the gas valve in the ON position then place the fryer power switch in the ON position.
When the burner lights and continues to burn, check the gas pressure reading against the table on
page 1-1.
5. To adjust burner gas pressure, remove the cap from the gas valve regulator and adjust to correct
pressure.
6. Place the fryer power switch and the gas valve in the OFF position. Remove the manometer
fitting from the pressure tap hole and reinstall the pressure tap plug.
1-9
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.5 Adjusting the Pilot Flame
1.5.1 Main Pilot
1. Remove the cap from the pilot adjustment screw hole on the gas valve.
2. Using a small, flat-tipped screwdriver, turn the pilot adjusting screw counterclockwise to
increase length of flame or clockwise to decrease length of flame. Adjust to obtain a flame from
1 inch to 1½ inches long.
3. Reinstall the pilot adjustment screw cap.
1.5.2 Trailing Pilot
Unlike older Decathlon units, current production HD units do not have a trailing pilot adjustment.
1.6 Calibrating the Thermatron
1. Fill the frypot to the lower OIL-LEVEL line with cooking oil. If solid shortening is used, it must
be melted before starting the calibration procedure.
2. Ensure the fryer ON/OFF switch is in the OFF position and light the pilot.
3. Place the fryer ON/OFF switch in the ON position. Set the potentiometer dial to 325°F (162°C).
4. Allow the oil to equalize at setpoint temperature. This is evident when the burners have cycled
on and off several times.
5. Insert a thermometer or pyrometer into the frypot within 3 inches of the probe bulb. Ensure the
tip of the thermometer/pyrometer does not touch the frypot burner tube.
6. If the temperature on the thermometer is higher or lower than 325°F (162°C), the knob is out of
calibration.
7. Calibrate the knob by first loosening the setscrews and slowly turning the knob to match the
temperature reading of the thermometer. Tighten the setscrews, ensuring the knob does not
move on the shaft during tightening.
8. Allow burners to cycle on and off several times, then recheck oil temperature as described in
Step 5. If the thermostat dial temperature matches the thermometer temperature, the thermostat
is calibrated. If not, repeat Step 7.
1-10
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7 Replacing Fryer Components
1.7.1 Replacing the Controller
1. Disconnect the fryer from the electrical
supply.
2. Unscrew the two controller panel screws.
The controller panel is hinged at the bottom
and will swing open from the top.
3. Unplug the fryer wiring harness and ground
wire from the back of the controller.
4. Remove the controller by lifting it from the
hinge slots in the fryer control panel frame.
5. Reverse the procedure to install a new
controller.
Computer panel in “down” position.
Disconnect the 15-pin connector and ground
wire (arrows) from the computer.
1-11
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.2 Replacing Control Box Components including Ignition Module, Interface
Board, Transformers, etc.
1. Disconnect the fryer from the electrical
supply.
2. Unscrew the two controller panel screws.
The controller panel is hinged at the bottom
and will swing open from the top.
3. Locate the component to replace.
4. Mark the location of the wires to facilitate
easy reassembly.
5. Disconnect the wires.
6. Remove the screws attaching the component
to the control box.
7. Reverse steps to complete the replacement
and return the fryer to service.
1-12
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.3 Replacing the Temperature Probe; Controller-equipped Fryers
1. Disconnect the fryer from the electrical supply.
2. Drain cooking oil from the frypot. Allow the
frypot to cool completely before proceeding.
3. Remove fryer door for easier access to the
temperature probe. First, remove top hinge
from bracket. Then, lift door off bottom
hinge pin.
Remove the fryer door for easier access to the
temperature probe.
4. Disconnect the probe harness connector
(arrow). Use a pin pusher to remove plug
from probe wires (probe side only). Retain
the plug for re-assembly on new probe.
5. Remove the drain manifold. Only the drain
tubes directly blocking the frypot being
Disconnect the two-pin probe harness
connector (arrow).
replaced require removal.
- Remove the nuts holding the drain valve
strap onto the drain tube stud.
- Disconnect the Teflon tube at the back of
the center dump tube piece and any other
components attached to the tubes,
including drain flush flexlines.
- Loosen the nut on each clamp holding the
rubber boots and drain sections together.
Remove the nuts, Teflon tube (not pictured), clamp,
boot, and drain tubes.
- Carefully remove the tubes by pulling
down at an angle, straight out of the drain
valves, and working them gently out of
the rubber boots. Set aside for
reassembly.
1-13
)
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.3 Replacing the Temperature Probe; Controller-equipped Fryers (cont.)
6. Remove the burner shield by loosening the
screw on each end.
7. Remove the burner rail by loosening the
screw on each end. The burner rail secures
the burners in the burner manifold. Be
careful to ensure that the burners do not fall
out of the gas manifold, as they might be
damaged and dented.
Remove the burner rail and burner shield.
8. Remove the burners to gain access to the
temperature probe and to ease frypot
removal. Lean each burner slightly away
from the frypot to clear the burner seal
(metal box attached to frypot). Then, pull
the burner up and off of the orifice. The
burners should be easy to remove and do
not require force.
9. Loosen and unscrew the compression nut
Remove burners to gain access to temperature
probe (arrow).
and the pass-through nut completely from
the frypot. Proceed to the next step before
removing the probe from the frypot.
Loosen and unscrew completely the compression
nut (bottom arrow), then the pass-through nut (top
arrow
.
1-14
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.3 Replacing the Temperature Probe; Controller-equipped Fryers (cont.)
10. Locate the temperature probe inside the
frypot.
11. The temperature probe can be removed
through the bottom of the frypot as follows:
Ensure the two-pin connector has been
Locate the temperature probe.
removed from the probe wiring harness
(step 4, above). Carefully bend the two tabs
(one forward and toward the back) so the
probe will clear the tabs. Remove the
harness insulation. The probe can be pulled
through the frypot from the bottom
(complete step 7, above, prior to removing
probe).
12. Carefully remove the probe from the frypot.
As the probe is removed, tilt the probe at an
angle to facilitate removal (curved probes
only).
After removing the probe mounting hardware, the
temperature probe can be removed through the
bottom of the frypot. Retain the mounting hardware
for reassembly.
13. Follow the steps on the next page to install
the new temperature probe.
IMPORTANT: When installing new probe, use
Loctite PST567 or equivalent pipe thread sealant
on threads and ensure probe is positioned properly
with the mounting hardware installed prior to
tightening the compression nut. Once tightened,
the probe cannot be repositioned.
1-15
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
Installing the New Temperature Probe:
1. Feed the probe wire through the probe nipple from the top side of the frypot.
2. Loosely install the bladder nut.
3. Mount the probe into the mounting hardware. Carefully bend the two tabs back into alignment to
retain probe.
4. Tighten the bladder nut.
5. Install the insulation and plug.
1.7.4 Replacing the High-limit Thermostat
1. Turn fryer off and drain oil from the frypot. Allow the frypot to cool completely before
proceeding.
2. Perform steps 1-4 in Section 1.7.1, Replacing the Controller.
3. Remove fryer door for easier access to the temperature probe. First, remove top hinge from
bracket. Then, lift door off bottom hinge pin.
4. Remove two screws securing the high-limit
mounting-bracket. Do not disconnect wires from
high-limit at this time.
Remove screws (arrows) securing high-limit to
fryer.
5. Loosen and completely unscrew the compression
nut, then the pass-through nut on the frypot bottom.
Proceed to the next step before removing high-limit
from frypot.
Compression nut unscrewed. Unscrew
the pass-through nut (arrow).
1-16
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.4 Replacing the High-limit Thermostat (cont.)
6. Locate the high-limit probe inside the frypot.
Carefully bend the outer tab at the rear of the high
limit until the high limit can slid back and out of the
retaining bracket.
7. Carefully pull high-limit capillary tube and bulb out
of the frypot from the bottom.
Remove high-limit capillary tube and bulb
from the bottom of the frypot.
Locate the high-limit probe.
1-17
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.4 Replacing the High-limit Thermostat (cont.)
8. Mark and disconnect wires at the high-limit in the
component box.
9. Remove high-limit from fryer by pulling the
capillary tube and bulb through the component box
opening (arrow). This may require removal of the
control panel frame.
10. Reverse the above steps for high-limit installation.
IMPORTANT: When installing new high-limit,
ensure the capillary tube and bulb are positioned
properly with tab back in alignment prior
to tightening
the compression nut. Once tightened, the capillary
tube cannot be repositioned.
Mark and disconnect high-limit wiring
(arrows). Reconnect wires to the same
terminals on the replacement high-limit.
Component box opening (arrow).
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.5 Replacing Rocker Switches
1. Disconnect the fryer from the electrical supply.
2. If switches are located in a control box within the fryer, remove the six screws securing the
switch panel to the control box. Do not allow the switch panel to hang from the switch wiring
harness or other wires.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.5 Replacing Rocker Switches (cont.)
3. Depress the retaining clips (see illustration below) and push the switch out of the slot. If there is
a switch-guard present, retain it for installation of the replacement switch.
Depress clips on each
side to remove switch
from control panel.
4. Remove wires one at a time from the switch being removed and connect to the replacement
switch until all wires are transferred.
5. Reverse the above steps for reassembly.
1.7.6 Replacing the Gas Valve
DANGER
Drain the frypot or remove the handle from the drain valve before proceeding further.
1. Disconnect fryer from electrical and gas supplies.
2. Disconnect the wires from the gas valve terminal block, marking each wire to facilitate
reconnections. For 120VAC gas valves, disconnect the black wire from the high-limit, then
remove the bobtail connecting the white wire.
3. Remove the high-limit thermostat wire from the gas valve pilot coil (all but 120 VAC valves).
4. Remove the pilot gas line fitting from the gas valve.
5. Remove the pipe union collars to the left and right of the gas valve and remove the valve.
6. Remove the pipefitting from the old gas valve and install on the replacement valve, using Loctite
PST567 or equivalent pipe thread sealant on threads. Do not apply sealant to the first two pipe
threads. Doing so will clog and damage the gas valve.
7. Reverse steps 1-5 to install the replacement gas valve.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.7 Replacing the Pilot Assembly
1. Remove the pilot tubing from the bottom of the pilot assembly.
2. If the pilot is an electronic ignition pilot, disconnect the ignition cable and the sense wire.
3. Remove the pilot mounting screw(s) from the pilot mounting bracket and remove the pilot.
4. Reverse the procedure to replace the pilot assembly.
NOTE: The above procedure is applicable to standing pilot, electronic ignition, and
trailing pilot assemblies.
1.7.8 Adjusting the Ignitor Assembly
1. Disconnect the fryer from the electrical supply.
2. Remove the outer cover plate by removing two screws as
shown in Figure 1.
3. Remove the air shutter plate if applicable by removing the
four screws in the four corners as shown in Figure 2.
Figure 1
4. Gently bend the ignitor spark probe until the gap distance is
approximately ¼” inch between the two points as shown in
Figure 3.
5. Reverse steps to reassemble.
Figure 2
1.7.9 Replacing the Frypot
1. Open fryer doors and remove filter pan (if applicable). Ensure controller and
all power switches are off. Drain and dispose of or store oil from all frypots
prior to moving fryer.
Figure 3
DANGER
Hot cooking oil will cause severe burns. Never attempt to move this appliance when
filled with hot cooking oil or to transfer hot cooking oil from one container to
another.
2. Turn gas valve off, then turn gas off at supply valve or meter. Disconnect supply line from gas
manifold at rear of fryer.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
NOTE: If restraints are installed on the fryer, disconnect restraints prior to disconnecting
the gas supply line.
3. Unplug fryer from electrical supply source.
4. Remove fryer door for easier access to the temperature probe. First, remove top hinge from
bracket. Then, lift door off bottom hinge pin.
5. Remove the basket hanger from the flue cap by lifting
up and off of fryer. Some units may have a built-in
flue deflector on the basket hanger. Units with basket
lifts will require the removal of the lift arms prior to
removing the basket hanger.
6. Remove the top cap. It is held in place by one screw
on each side of the fryer. If the fryer has a controller
on the front, the top cap may also be held in place
Removing the basket hanger from the flue cap.
by two screws on the front of each pot. FPHD65
units may have two screws on each end of the top cap.
7. Remove the joiner strips on either side of the frypot. Be
careful not to bend the joiner strip during removal.
Removing the joiner strip.
8. Remove back panels of the fryer. There
may be both upper and lower panels and
several screws secure them. Screw
location and orientation will vary
according to fryer model.
Typical screw locations on the back panel (may vary by
model
.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.9 Replacing the Frypot (cont.)
9. Remove screw securing brace (and back panel) to the
flue cap. Support the brace with hand while removing
screw to prevent brace from falling away. Remove
brace and set aside for reassembly.
Removing brace holding back panel to flue
cap.
10. Remove screws securing flue cap to frypot (access from above; a nut-driver with an extension or
long screwdriver is required). Use care not to drop the screws into the flues. If this happens, the
screws can be retrieved when the flue is removed (Step 12). Use a screwdriver or similar tool to
free flue cap from frypots. Remove flue cap by lifting up and off of fryer.
Remove the screws (arrow) securing the flue cap
to the frypot on the long edge. There will be two or
three screws depending on configuration. (view
from above, looking down into flue)
11. Remove gas manifold pipe for access to gas
manifold shield by disconnecting at the unions.
Ensure gas supply is shut off and supply line is
disconnected prior to removing. Set gas
manifold aside. Remove screws securing gas
manifold shield. Remove shield to access oilreturn plumbing components connected to the
frypots.
NOTE: For units without built-in filtration
skip the steps pertaining to removal and
replacement of oil-return plumbing.
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Remove the screws (arrows) securing the flue
cap to the frypot on the short edge. There will be
two screws on each end of the flue. (view from
above, looking down into flue)
Removing gas manifold shield.
HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.9 Replacing the Frypot (cont.)
12. Remove screws securing flue to frypot (access
from above; a nut-driver with an extension or
long screwdriver is required). Retrieve any
screws dropped into the flue during removal of
the flue cap and frypot bracket.
13. Remove the clevis clip and oil return handle
rod from the oil return valve at the rear of the
fryer. Slip Section A of the clevis clip off of
the oil return handle by pulling up on the rings.
Slide the oil return handle out of the bracket
and Section B of the clevis clip. Repeat for the
drain flush handle (if applicable).
14. Loosen the two screws on the front of the oil
return handle bracket at the front of the fryer.
Remove the bracket and handle and set aside
for reassembly. Repeat for the drain flush
handle (if applicable).
Removing bolts (arrows) securing flue to
frypot.
Disconnect oil-return handle from clevis clip
and valve.
Oil-return handle bracket and screws.
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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS
CHAPTER 1: SERVICE PROCEDURES
1.7.9 Replacing the Frypot (cont.)
15. Remove the drain manifold. Only the drain
tubes directly blocking the frypot being
replaced require removal.
- Remove the nuts holding the drain valve
strap onto the drain tube stud.
- Disconnect the Teflon tube at the back of
the center dump tube piece and any other
components attached to the tubes,
including drain flush flexlines.
- Loosen the nut on each clamp holding the
rubber boots and drain sections together.
- Carefully remove the tubes by pulling
down at an angle, straight out of the drain
valves, and working them gently out of the
rubber boots. Set aside for reassembly.
16. Remove the nipple attaching the oil return line
to the bottom of the frypot at the rear of the
fryer using a wrench. This may require
removal of other pieces of the oil return
manifold, as needed.
17. Remove the burner shield by loosening the
screw on each end.
18. Remove the burners to gain access to the
temperature probe and to ease removal. Remove
one burner at a time. Loosen the two screws
attaching the burner to the burner rail. Slide the
burner up until the heads of the two screws reach
the round key holes and lean it slightly toward
from the frypot to clear the burner rail and seal
(metal box attached to frypot). Then, pull the
burner up and off of the orifice. The burners
should be easy to remove and do not require
force.
19. Remove the burner rail when all burners have
been uninstalled. Loosen the screws on each
end of the rail and set it aside.
Valve
Stud &
Boot
Nut
Clamp
Strap
Drain manifold parts.
Oil-return nipple, burner shield, and burner rail.
Remove drain valve handle and
burners from fryer.
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