Frymaster FPHD565 Service Manual

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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

ORIFICE

(INCH)

2.26(#43)

1.40(#54)

2.26(#43)

1.40(#54)

ORIFICE

PART NO.

810-2938 810-2939

QTY

4 4

5 5

EQUIPMENT

PRESSURE

MBAR

27.5

INCH W.C.

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.

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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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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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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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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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

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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.

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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).

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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).

1-18

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.

1-19

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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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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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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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.

1-23

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.

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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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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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1.7.9 Replacing the Frypot (cont.)

20. If the fryer is equipped with drain-valve microswitches, mark the wires and microswitch

terminals, then disconnect wires from the switch. Secure the wires to prevent damage when frypot is removed.

Left: Microswitch wires marked for removal (ensure microswitch terminals are marked the same as the wires removed). Right: Microswitch mounted to drain valve.

21. Remove the drain valve handle by loosening

the drain valve nut and removing attached hardware. Depending on placement and configuration, the valve may be turned in a different direction than pictured.

22. Remove the pilot assembly from the frypot.

Remove the drain valve nut and attached

hardware.

- If trailing pilot, disconnect the pilot supply line from the trailing pilot valve on the burner manifold.

Remove the mounting screw(s) to detach the pilot assembly from the pilot bracket.

Remove the pilot assembly from the pilot bracket on the fr

ot.

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1.7.9 Replacing the Frypot (cont.)

23. Remove the temperature probe from frypot. (See Section 1.7.2, Replacing the Temperature

Probe: Controller–equipped Fryers, for specific instructions.)

24. Remove the high-limit from the frypot (see Section 1.7.3, Replacing the High-limit Thermostat).

25. Remove bolts from brackets securing burner

manifold to frypot. Leave the manifold in place.

Removing bolts (arrows) from burner manifold support brackets (both sides). Leave the burner manifold in place after removing bolts.

26. Using a sharp knife or box-cutter, cut the

silicon seal around the frypot. Use care not to scratch stainless steel surfaces.

27. Ensure wires and tubes will not be caught on

the frypot when it is removed.

Cutting frypot seal prior to frypot removal.

28. Remove frypot from fryer by lifting up and

out.

Lifting frypot from fryer.

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1.7.9 Replacing the Frypot (cont.)

29. Position the frypot upside down on a

suitable work surface.

30. Record position of the valve stem in

relation to the frypot prior to removing the drain valve. If equipped, remove microswitches and mounting hardware from valve prior to removal. Using a suitable wrench, remove the drain valve from the frypot. Use Loctite PST567 sealant when installing drain valve on replacement frypot.

31. Remove all other hardware and

accessories from the frypot.

32. Reverse the above steps to install the

replacement frypot.

33. Add a bead of silicon around the edges of

the new frypot, sealing the seam where the frypot and the cabinet meet. Only do this when the frypot is completely installed.

Removing drain valve from frypot.

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1.8 Troubleshooting and Problem Isolation

Because it is not feasible to include every issue that might occur, this section is intended to provide technicians with a general knowledge of the broad problem categories associated with this equipment and the probable causes of each. With this knowledge, the technician should be able to isolate and correct any problem encountered.

You are likely to encounter problems in these broad categories:

1. ignition failure,

2. improper burner function,

3. improper temperature control,

4. improper controller function,

5. improper filtration function,

6. frypot leakage, and

7. basket lift malfunction.

The probable causes of each category are discussed in the following sections. Troubleshooting guides are included in Section 1.9 to assist in identifying some of the more common problems.

1.8.1 Ignition Failure

Ignition failure occurs when the ignition module fails to sense a flame within the 60-second time delay period and locks out. Turn the fryer off, locate and fix the problem, then turn fryer back on to clear the module lock.

There are three primary reasons for ignition failure, listed in order of probability:

1. The gas and electrical power supplies,

2. The electronic circuits, or

3. The gas valve.

The Gas and Electrical Power Supplies

The main indicators that the gas or electrical power supply is the cause of ignition failure are as follows: an entire battery of fryers fails to light, and/or there are no indicator lights illuminated on the fryer experiencing ignition failure. Verify that the quick disconnect hose is properly connected, the fryer is plugged in, the main gas supply valve is open, and the circuit breaker for the fryer electrical supply is not tripped.

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1.8.1 Ignition Failure (cont.)

The Electronic Circuits

If gas and electrical power are supplied to the fryer, the next most likely cause of ignition failure is a problem in the 24 VAC circuit of fryers equipped with electronic ignition systems, or in the pilot system for those without electronic ignition. If the fryer is equipped with a SUFF/UFF filtration system, verify that the drain valve is fully closed. (The valve is equipped with a microswitch that must be closed for power to reach the gas valve. The valve handle can appear to be closed when the microswitch is open.) If the valve is fully closed, or the fryer does not have a filtration system, refer to the troubleshooting guides in this chapter.

The Gas Valve

If the problem is not in the 24 VAC circuit or pilot system, it is most likely in the gas valve. Before replacing the gas valve, refer to the troubleshooting guides in this chapter.

1.8.2 Improper Burner Function

In these instances, the burner ignites but exhibits abnormal characteristics, such as popping, incomplete lighting of the burner, fluctuating flame intensity, and flames “rolling” out of the fryer.

Popping indicates delayed ignition. In most cases, the main gas valve is opening, but the burner is not immediately lighting. When ignition does take place, excess gas ignites rapidly rather than smoothly.

The primary causes of popping are:

1. low or fluctuating gas pressure,

2. misdirected or weak pilot flame,

3. clogged burner orifices,

4. clogged burners,

5. inadequate make-up air,

6. heat damage to the controller or ignition module,

7. an out-of-adjustment igniter or broken ignition wire,

8. a defective ignition module,

9. missing or misaligned burners,

10. clogged vent tube (causing incorrect gas pressure), or

11. make-up air is blowing down the flue.

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1.8.2 Improper Burner Function (cont.)

If popping occurs only during peak operating hours, the problem may be incorrect or fluctuating gas pressure. Verify that the incoming gas pressure (pressure to the gas valve) is in accordance with the appropriate requirements listed in the Installation and Operation manual that came with the fryer, and that the pressure remains constant throughout all hours of usage. Refer to Adjusting Burner Manifold Pressure in Section 1.4 if burner manifold pressure is suspected of being incorrect.

If popping is consistent during all hours of operation, verify that the pilot is properly positioned above the burner orifice and that the pilot pressure is correct. Correct pilot pressure is indicated by a flame 1 to 1½" long. Also verify that igniter is properly adjusted (electrode tip 1/8" from pilot hood corner). Refer to Section 1.5 for pilot adjustment procedure.

Clogged burners or burner orifices are also likely causes of delayed ignition. Clogged burners are indicated by uneven flame or partial flame on the burner face. Clogged orifices are indicated by no flame.

Another cause of popping is an insufficient air supply or drafts that are blowing the pilot flame away from the burner. Check for "negative pressure" conditions in the kitchen area. If air is flowing into the kitchen area, this indicates that more air is being exhausted than is being replenished and the burners may be starved for air.

If the fryer’s gas and air supplies are okay, the problem most likely is with one of the electrical components. Examine the ignition module for signs of melting, distortion, or discoloration due to excessive heat build-up in the fryer. Also, examine the controller for the same conditions. This condition usually indicates improper flue performance. A melted or distorted ignition module is automatically suspect and should be replaced, but unless the condition causing excessive heat in the fryer is corrected, the problem is likely to recur.

Next, ensure the ignition wire is tightly connected at both ends and examine it for obvious signs of damage. Again, if damage is due to excessive heat in the fryer, that problem must also be corrected.

Check for proper operation by disconnecting the wire from the igniter, inserting the tip of a screwdriver into the terminal, and holding it near the frame of the fryer as the power switch is placed in the "ON" position. A strong, blue spark should be generated for at least 60 seconds.

DANGER

MAKE SURE YOU ARE HOLDING THE INSULATED HANDLE OF THE SCREWDRIVER

AND NOT THE BLADE. THE SPARKING CHARGE IS APPROXIMATELY 25,000

VOLTS.

Ensure the gap setting of the igniter is correct (electrode tip 1/8" from pilot hood corner).

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1.8.2 Improper Burner Function (cont.)

Burners lighting on the left side only may be caused by a trailing pilot problem (four- and five-tube frypots) or improper burner manifold pressure.

Fluctuating flame intensity is normally caused by either improper or fluctuating incoming gas pressure, but may also be the result of variations in the kitchen atmosphere. Verify incoming gas pressure in the same way as for "popping,” discussed in the preceding paragraphs. Variations in the kitchen atmosphere are usually caused by air conditioning and/or ventilation systems starting and stopping during the day. As air conditioning/ventilation systems start and stop, the pressure in the kitchen may change from positive or neutral to negative, or vice versa. Changes in airflow patterns may affect flame intensity.

Flames "rolling" out of the fryer are usually an indication of negative pressure in the kitchen and make up air blowing down the flue. Air is being sucked out of the fryer enclosure and the flames are literally following the air. If negative pressure is not the cause, check for high burner-manifold gas pressure in accordance with the procedures in Section 1.4. An obstructed flue, which prevents the fryer from properly exhausting, may also be the cause.

Excessively noisy burners may indicate that the burner gas pressure is too low, the tube diffusers are defective or burned out, or it may simply be that the gas valve vent-tube is blocked (if applicable). If the gas pressure is correct, the tube diffusers are intact and in good condition, and the vent-tube is unobstructed (if applicable), the gas valve regulator is probably defective.

1.8.3 Improper Temperature Control

Temperature control is a function of several interrelated components, including the melt cycle. Each must operate correctly. The principal component is the temperature probe. Depending upon the specific configuration of the fryer, other components may include the interface board, the controller/controller itself, and the ignition module.

Improper temperature control problems can be categorized into melt cycle problems and failure to control at setpoint.

In fryers equipped with a Thermatron, the problem will be with the thermostat. Possible causes are that the thermostat is out of calibration or defective. Refer to Section 1.6 for instructions on calibrating the thermostat.

In fryers equipped with controllers, the problem may be with the temperature probe, the interface board, or the controller. Refer to the troubleshooting guides in this chapter.

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1.8.4 Improper Controller Function

Sensitivity or "Stretch Time." Sensitivity—or stretch time—is a programmable feature that increases the cook time countdown based on variations in the oil temperature from the setpoint (e.g., when cold product is dropped into the oil, causing the oil temperature to drop).

The sensitivity for each product button has 10 settings (0 through 9). A "0" sensitivity setting will disable the feature (no change in cooking time), while a nine will provide the highest sensitivity or the most change. The correct sensitivity for any product is based on the product type, its density, the setpoint temperature, and the customer’s own requirements.

Common Controller Complaints. Most problems concerning controllers have to do with programming them. There are four common complaints. The complaints, their causes, and corrective actions are as follows for the Dean Compu-Fry controller:

1. Fryer constantly displays " ".

Cause: Setpoint incorrect or missing.

Corrective Action: Press 1 6 5 0, enter the correct setpoint using keypad, then press and

then this to lock in the setpoint.

2. Temperature is displayed in Celsius.

Cause: Controller is programmed to display in Celsius. Corrective Action: Press 1 6 5 8.

3. Temperature is constantly displayed.

Cause: Controller is programmed for constant temperature display. Corrective Action: Press 1 6 5 L.

4. Controller times down too slowly or too quickly.

Cause: Controller is compensating for oil temperature via the sensitivity setting.

Corrective Action: Reprogram sensitivity setting for each product in accordance with

programming instructions in the Compu-Fry Operation and Programming manual, P/N 819-

5865.

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1.8.5 Improper Filtration Function

The majority of filtration problems arise from operator error. One of the most common errors is placing the filter paper on the bottom of the filter pan rather than over the filter screen. Anytime the pump is running, but no oil is being filtered, check the installation and size of the filter paper. Verify that the O-rings on the slip-connection are in good condition. Missing or worn O-rings allow the pump to suck air, decreasing its efficiency.

If the pump motor overheats, the thermal overload will trip and the motor will not start until it is reset. If the pump motor does not start, press the red reset switch located on the rear of the motor. Also, reset the filter circuit breaker located under the fryer control panel. If the pump then starts, something caused the motor to overheat. The pump most likely overheated for one of the following reasons:

• Shortening was solidified in the pan or filter lines.

• Multiple frypots were filtered one-after-another. Allow the pump to cool for 30 minutes before

using again.

• The operator attempted to filter unheated oil. Cold oil is thick and will cause the pump motor to

work harder and overheat.

If the motor runs, but the pump does not, the pump is blocked. Incorrectly sized or installed paper allows food particles and sediment to pass through the filter pan and into the pump. When sediment enters the pump, the gears bind and cause the motor to overheat, tripping the thermal overload. Solidified shortening in the pump will produce the same result. A pump seized by debris or hard shortening must be disassembled, cleaned, and reassembled in the following manner:

1. Disconnect power to the filter system.

2. Remove the front cover of the pump to access the gears inside, if the pump is accessible while

still inside the cabinet. If the front cover is not accessible, the pump must be removed from the pump motor (disconnect input/output plumbing from the pump prior to removing it). Remove three setscrews to disengage the pump from the motor.

3. Prior to reassembly, the inside housing must be clean and free of any sediment or debris. If not,

the gears will bind again after reassembly.

Remove these bolts to

remove pump cover.

NOTE: The pump cover in

current production units is held in place by four (4) bolts.

Remove debris or hardened

shortening to free gears.

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1.8.5 Improper Filtration Function (cont.)

Incorrectly sized or installed paper will allow food particles and sediment to pass through and clog the suction tube on the bottom of the filter carriage. Particles large enough to block the suction tube may indicate that the crumb tray is not being used.

Pan blockage can also occur if shortening is left in the pan and allowed to solidify. Heater strips (if equipped) on the oil return plumbing are designed to prevent solidification of shortening left in the plumbing. Heater strips will not melt or prevent solidification of shortening in the pan.

Remove blockage by forcing it out with an auger or drain snake. DO NOT use compressed air or other pressurized gases to force out the blockage.

The SUFF/UFF filtration systems use microswitches attached to handles for each vat. They are wired in parallel and provide the 24 VAC required to activate the pump relay coil when the handles are moved to the ON position. The activated pump relay coil pulls the pump motor switch in, supplying power to the pump motor.

Filter systems equipped with oil-return heater tape are wired into the 120 VAC source, and remain energized as long as the unit is plugged in and power remains constant. Heater tape should receive constant power all day and all night; it should not be connected to a power supply that is turned off at night.

1.8.6 Frypot Leakage

Frypot leaks are almost always due to improperly sealed high-limit, thermostats/temperature probe and drain fittings. When installed or replaced, each of these components must be sealed with Loctite PST567 sealant or equivalent to prevent leakage. In very rare cases, a leak may develop along one of the welded edges of the frypot, or where the tube is welded to the frypot. When this occurs, the frypot must be replaced.

If the sides or ends of the frypot are coated with oil, the most likely cause is spillage over the top of the frypot rather than leakage.

Frypot locations (indicated by arrows) where potential leaks could occur.

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1.8.7 Improper Basket Lift Function Bell-Crank Basket Lifts

Most High Efficiency Decathlon Series gas fryers are equipped with a bell-crank style basket lift. A cam and a bell crank are connected to the basket lift arm by a flat metal link. The cam is attached to a drive motor. The motor rotates the cam, raising or lowering the lift arm linked to the bell crank. A roller-activated microswitch is used to limit travel. When the roller in the microswitch is in contact with the cam, the motor is energized. As the cam rotates, the roller loses contact with the cam and the motor power circuit is broken, de-energizing the motor.

Timing circuitry in the controller initiates and stops basket lift operation. When the product button is pressed, the timing circuitry activates a coil in the basket lift relay to supply power to the motor. The microswitch stops the motor at the lift’s lower travel limit and the switch contacts are reversed. At the end of the programmed cooking time, the timing circuit activates the coil once more and the lift rises until the microswitch again loses contact with the cam, opening the motor power circuit and stopping the motor.

Problems with the bell-crank basket lift system can be grouped into two categories:

• binds and jams or

• motor and gear wear.

Binds and jams. Noisy, jerky, or erratic lift movement is usually due to lack of lubrication. Apply a light coat of Lubriplate or similar lightweight white grease to the connection points to correct the problem.

Motor Problems. If power is reaching the motor but the motor fails to run, the motor is burned out and must be replaced.

Back view of bell-crank basket lift.

Bell-crank basket-lift arms.

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1.9 Troubleshooting Guides

The following troubleshooting guides are intended to assist service technicians in quickly isolating the probable causes of equipment malfunctions by following a logical, step-by-step process.

PROBLEM

Burner will not ignite.

Light in ON/OFF switch

is not illuminated.

A. ON/OFF switch is off. A. Turn ON/OFF switch on.

PROBABLE CAUSES CORRECTIVE ACTION

ON/OFF switch is on,

ut the switch light is not

illuminated.

ON/OFF switch is on and

the switch light is

illuminated, but there is

no output to gas valve.

No burner flame.

A. No voltage at switch. A. Ensure line voltage is present at the

switch.

A. Drain microswitch circuit (filter-

equipped units) is open.

B. Voltage is present at ON/OFF switch,

but continuity of the switch in ON position is not "0.”

C. Continuity of thermostat is not "0" (oil

temperature is at least 15°F below electronic thermostat setting).

D. Gas valve is suspect. D. Go to "No burner flame" section. C. Gas valve is known to be good, but

there is not 24 VAC (120VAC on systems so equipped) at the gas valve terminals.

A. Ensure drain valve is fully closed and

microswitch is functioning. Replace microswitch if defective.

B. ON/OFF switch is defective. Replace

switch with a known working switch.

C. Thermostat(s) is/are defe ctive.

Replace defective thermostat with a known working thermostat.

D. Inspect electronic sensor (while still in

frypot) for damage. Replace if bent, dented, or cracked. Inspect leads for fraying, burning, breaks, and/or kinks. If found, remove and replace thermostat(s). Remove leads from terminal block, allow oil to cool 15°F (8°C) below thermostat setting, and check continuity. If continuity is not "0,” then thermostat has failed. Replace thermostat(s).

Fluctuating or erratic

lighting of burner flame.

Electronic/operating

thermostat will not adjust

to correct temperature.

A. Incoming gas supply pressures are not

within range [Natural- 6-14" W.C. (1.49-3.49 kPa); Propane- 11-14" W.C. (2.74-3.49 kPa)]

B. Air in gas supply lines (new

installation).

A. Electronic/operating thermostat is out

of calibration.

A. Inspect gas supply to fryer. Repair

and/or replace faulty components (defective supply shut-off valves, incorrect piping size, etc.)

B. Allow unit to cy cle on and off for

approximately 30 minutes to force air from gas manifold and lines.

A. Calibrate electronic/operating

thermostat. Replace if calibration is not possible.

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1.10 Wiring Diagrams

Note: The diagrams in this section depict wiring as of the date of manual publication. It may not reflect design changes made to the equipment after publication. Refer to the wiring diagram affixed to the unit when actually troubleshooting this equipment.

1.10.1 Controller Dean Common Cabinet

805-1545 B

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1.10.2 Wingstreet Common Cabinet

805-1599 B

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1.10.3 BK1814 Main Wiring Diagram prior after Sep. 2010

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1.10.4 BK1814 Main Wiring Diagram prior to Sep. 2010

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1.10.5 BK1814 RAM Wiring Diagram

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1.10.6 Filter Box

CHAPTER 1: SERVICE PROCEDURES

1-43

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.7 Thermatron Controller

1-44

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.8 FAST Controller prior to Feb 09

1-45

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.9 FAST Controller Non-CE after Feb 09

1-46

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.10 FAST Controller CE after Feb 09

1-47

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.11 FAST Controller India

1-48

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.12 KFC-1 Controller

1-49

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CHAPTER 1: SERVICE PROCEDURES

1.10.13 CM4S Controller

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.14 3000 Controller

1-51

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.10.15 Constant Pilot, FAST Ready

1-52

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 1: SERVICE PROCEDURES

1.11 Probe Resistance Charts

Thermatron Probe Resistance Chart

° Celsius ° Fahrenheit Ohms (±3%)

21 70 108130 27 80 84606 32 90 66721 38 100 53020 43 110 42452 49 120 34206 54 130 27735 60 140 22641 66 150 18588 71 160 15349 77 170 12741 82 180 10635 88 190 8925 93 200 7527

99 210 6391 104 220 5470 110 230 4705 116 240 4030 121 250 3441 127 260 2967 132 270 2583 138 280 2255 143 290 1977 149 300 1729 154 310 1496 160 320 1320 166 330 1170 171 340 1051 177 350 942 182 360 840 188 370 750 193 380 676 199 390 605 204 400 541

Controller Probe Resistance Chart

° Celsius ° Fahrenheit

21 70 1080 27 80 1101 32 90 1122 38 100 1143 43 110 1164 49 120 1185 54 130 1206 60 140 1226 66 150 1247 71 160 1268 77 170 1289 82 180 1309 88 190 1330 93 200 1350

99 210 1371 104 220 1391 110 230 1412 116 240 1432 121 250 1453 127 260 1473 132 270 1493 138 280 1514 143 290 1534 149 300 1554 154 310 1574 160 320 1594 166 330 1614 171 340 1634 177 350 1654 182 360 1674 188 370 1694 193 380 1714 199 390 1734 204 400 1754

Ohms (±3%)

1-53

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1 High Efficiency Common Cabinet Decathlon (HDC) Primary Components

2.1.1 Decathlon HD50 Primary Components

2-1

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

Each section is labeled by size (e.g., D50) and parts are not interchangeable between different sized fryers. The parts in this manual are for use on Common Cabinet style fryer.

If you have any questions, call the Frymaster and Dean 24-Hour Service Hotline, 1-800-551-8633.

2.1.1 Decathlon HD50 Primary Components

ITEM PART # DESCRIPTION

1 826-3009 Frypot - S/S (Use 108-3638 for Energy Star Frypot Assy. )

2 3

* 810-0705 * 810-0703

4 230-4900 Diffuser Assembly (Use 230-6887 for Energy Star)

5 6 810-3356 Burner, High Efficiency 7 220-5287 Bracket, Burner Mounting

8 200-9063 Shield, Burner Heat (Use 220-9949 for Energy Star)

9 10 231-2060 Side Panel, Left Side 11 232-2060 Side Panel, Right Side 12

* *

* 13 14

106-5433 x1 (Single)

106-5956 x3 (3-battery) 106-6333 x4 (4-battery) 106-7631 x5 (5-battery)

230-1848 x1 (Single) 230-1812 x2 (2-battery) 230-1841 x3 (3-battery) 230-1875 x4 (4-battery)

230-2434 x5 (5-battery) 16 106-7542SP Door Assembly (Left or Right) 17

* 810-2346 Magnetic Catch, Door * 230-4998 Hinge, One-piece

210-1595 Single (SCFHD50, 823-4075 with deflector)

210-3131 Double (SCFHD50, 823-4074 with deflector) 19 810-0356 Caster, Plate-mount, 5" without Brake

* 826-1117 Caster Kit, Plate-mount, 5" without Brake (includes mounting hardware)

20 810-0357 Caster, Plate-mount, 5" with Brake

* 826-1118 Caster Kit, Plate-mount, 5" with Brake (includes mounting hardware) * 810-0944 Caster, Plate-mount, 3" with Brake * 810-1494 Caster, Plate-mount, 4" without Brake * 106-7649 Cordset, 10' Power

21 810-2411 Leg, Single Bolt Mount (black)

* 810-3169 Leg Package, 4 Bolt Mount (4 per set)

22 823-3248 Leg Support Assembly

* Not illustrated.

►►► See Orifices, Section 2.2

See Additional Components and Controllers, Section 2.3

⁄

Tube, Tube,

" x 23" Pilot Gas Supply (one-piece gasline)

⁄

" x 17½" Pilot Gas Supply (one-piece gasline)

►►► See Drain Components, Section 2.4

See Additional Components and Controllers, Section 2.3

Cabinet Back

220-1847 x1 (Single)

220-1806 220-1838

x2 (2-battery) x3 (3-battery)

823-5932 Joiner Strip

Top Cap

106-5955 x2 (2-battery)

Flue Cap

210-8077 Handle, Door

Basket Lifts

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.2 Decathlon HD60/63 Primary Components

2-3

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.2 Decathlon HD60/63 Primary Components (cont.)

ITEM PART # DESCRIPTION

1 106-9632 Frypot - S/S

* 106-9634 Frypot - S/S (Single HD60 without filtration) * 823-5742SP Frypot - S/S (Single HD60 without filtration, Red Robin) * 106-9638SP Frypot - S/S (Single HD63 without filtration)

* 823-6314 Frypot - S/S (Single HD63 without filtration, Red Robin) 2 3

* 810-0705 Tube,

* 810-0703 Tube,

* 810-0703 Tube, Pilot Gas Supply, 1⁄4" x 17.50" (one-piece gasline) 4 230-1431 Diffuser Assembly 5 6 810-3356 Burner, High Efficiency 7 220-5152 Burner Bracket 8 200-8748 Shield, Burner Heat 9

* 810-0691 Vent Tube

10 231-2311SP Side Panel, Left Side 11 232-2311SP Side Panel, Right Side

* 221-2737 Side Panel, Left Side (Filter Ready)

* 222-2737 Side Panel, Right Side (Filter Ready)

* 823-5744 Side Panel, with Splash Panel (660/363/663)

220-1851 x1 (Single) 220-1828 x2 (2-battery) 220-3702 x2, without Deflector (2-battery)

220-4518 x1, without Deflector (3-battery) 13 210-3017 Joiner strip 14

106-5434 x1 (Single)

106-5953 x2 (2- and 6-battery)

106-6080 x3 (3- and 6-battery)

106-4683 x4 (4- and 6-battery) 15

230-3078 x1 (Single)

230-1833 x2 (2-battery)

230-1890 x3 (3-battery)

230-1891 x4 (4-battery)

230-1890 x3 (6-battery)

230-1891 x4 (6-battery) 16 106-4309SP Door Assembly, left or right 17 210-8077 Handle, Door

* 810-2346 Magnet, Door * 230-4998 Hinge, One-piece

* Not illustrated.

►►► See Orifices, Section 2.2

See Additional Components and Controllers, Section 2.3

⁄4" x 23" Pilot Gas Supply (one-piece gasline)

⁄4" x 17½" Pilot Gas Supply (one-piece gasline)

►►► See Drain Components, Section 2.4

See Additional Components and Controllers, Section 2.3

Cabinet Back (One-piece)

Top Cap

Flue Cap

2-4

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.2 Decathlon HD60/63 Primary Components (cont.)

ITEM PART # DESCRIPTION

210-2737SP Single (60/63/65, 823-3649 with deflector) 210-6763 Single (Church's 63, 823-6524 with deflector) 823-7219 Single (Raising Cane's) 210-6761 Double (Church's 63, 823-6523 with deflector) 210-1482 Double (Chili's, 823-4999 with deflector) 823-7152 Double (Raising Cane's)

19 810-0356 Caster, Plate-mount, 5" without Brake

* 826-1117 Caster Kit, Plate-mount, 5" without Brake (includes mounting hardware)

20 810-0357 Caster, Plate-mount, 5" with Brake

21 810-2411 Leg, Single Bolt Mount (black)

* 810-3169 Leg, 4 Bolt Mount, Package (4 per set)

22 823-3248 Leg, Single Bolt Mount, Support Assembly

* Not illustrated.

Basket Hanger

2-5

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.3 Decathlon HD/FPHD65 Primary Components

2-6

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.3 Decathlon HD/FPHD65 Primary Components (cont.)

ITEM PART # DESCRIPTION

1 106-9633 Frypot - S/S 2 3

►►►

* 810-0705

* 810-0703 4 230-1431 Diffuser Assembly 5

►►► See Drain Components, Section 2.4 6 108-2612SP Burner, High Efficiency 7 220-5152 Burner Bracket 8 200-8748 Shield, Burner Heat 9

* 810-0691 Vent Tube

221-0012 Side Panel, Left Side with Hole (unit exterior) 211-8078 Side Panel, Left Side (unit exterior) 231-2311 Side Panel, Left Side (Single 65)

222-0012 Side Panel, Right Side with Hole (unit exterior) 212-8078 Side Panel, Right Side (unit exterior) 232-2311 Side Panel, Right Side (Single 65) 823-5789 Side Panel, with Splash Panel (565)

220-2353 x2 (2-, 4-, 5-, and 6-battery) 220-0668 x3 (5-battery)

220-2354 x2 (2-, 4-, 5-, and 6-battery) 220-0667 x3 (5-battery)

220-1851 x1 (one-piece)

220-1828 x2 (one-piece) 13 230-1478 14

106-5434 x1 (Single)

106-5953 x2 (2-battery)

824-1871 x3 (3-battery)

823-5976 x4 (4-battery and 6-battery)

823-5975 x2 (5-battery and 6-battery)

823-6090 x3 (5-battery)

230-2472 x1 (HD marine edge) 15

Flue Cap

230-3078 x1 (Single)

230-1833 x2 (2-battery)

230-2323 x3 (3-battery and 5-battery)

230-2298 x2 (5-battery and 6-battery)

* 200-3649 Deflector, Flue (Single, HD, non-S/S) (use screws 809-0437) * 210-6525 Deflector, Flue (Single, Chili's, S/S) (use screws 809-0437)

* Not illustrated.

See Orifices, Section 2.2 See Additional Components and Controllers, Section 2.3

⁄

Tube, Pilot Gas Supply, Tube, Pilot Gas Supply,

" x 23" (one-piece gasline)

⁄

" x 17½" (one-piece gasline)

See Additional Components and Controllers, Section 2.3

Side Panel, Left

Side Panel, Right

Cabinet Upper Back

Cabinet Lower Back

Cabinet Full Back

Joiner Strip Top Cap

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.3 Decathlon HD/FPHD65 Primary Components (cont.)

ITEM PART # DESCRIPTION

16 106-7710 Door Assembly, left or right 17 210-8077 Handle, Door

* 810-2346 Magnet, Door * 230-4998 Hinge, Lower * 823-5137 Hinge, Upper Right * 823-5136 Hinge, Upper Left

18 823-5859 Basket Hanger, Church's (with Deflector)

* 823-5801 Basket Hanger, Chili’s Single System, 6" Splash Guard

* 823-5856 Splash Guard (2-, 4-, 5-, and 6-battery) 19 810-1494 Caster, Plate-mount 4" without Brake 20 810-2406 Caster, Plate-mount 5" without Brake

* 810-0944 Caster, Plate-mount 3" with Brake

* 807-0154 Cordset, 10’ Power 21 810-2411 Leg, Single Bolt Mount (black)

* 810-3169 Leg, 4 Bolt Mount, Package (4 per set) 22 823-3248 Leg, Single Bolt Mount Support Assembly,

* Not illustrated.

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.4 Decathlon LHDC65 Primary Components

20 13

13a

13b

13c

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.4 Decathlon LHDC65 Primary Components (cont.)

ITEM PART # DESCRIPTION

1 823-7565 Frypot - S/S Filter

* 823-7567 Frypot – S/S Non-Filter 2 3

►►►

* 810-0705

* 810-0703 4 230-1431 Diffuser Assembly 5

►►► See Drain Components, Section 2.4 6 108-2612SP Burner, High Efficiency 7 220-9905 Burner Bracket 8 200-9948 Shield, Burner Heat 9

* 810-0691 Vent Tube

221-0012 Side Panel, Left Side with Hole (unit exterior) 211-8078 Side Panel, Left Side (unit exterior) 231-2311 Side Panel, Left Side (Single 65)

222-0012 Side Panel, Right Side with Hole (unit exterior) 212-8078 Side Panel, Right Side (unit exterior) 232-2311 Side Panel, Right Side (Single 65) 823-5789 Side Panel, with Splash Panel (565)

220-9325 Single 220-9485 Double (2-, 4-, 5-, and 6-battery) 220-9849 Triple (3-, and 5-battery)

13 230-1478 Connecting without pins

* 823-5961 Connecting with pins (same as 230-1478 but with pins)

13a 823-8776 Connecting without pin and without holsters

* 823-7278 Connecting with pins and without holsters (same as 823-8776 but with pins)

13b 823-8829 Connecting with single holster on right

13c 823-7917 Connecting with double holsters

824-2317 Single 824-2318 x2 (2-battery, 5-battery and 6-battery ) 824-2319 x3 (3-battery and 5-battery) 823-2320 x4 (4-battery and 6-battery)

Flue Cap

824-2310 Single 824-2314 x2 (2-battery, 5-battery and 6-battery ) 824-2315 x3 (3-battery and 5-battery)

824-2316 X4 (4-battery and 6-battery) * 200-3649 Deflector, Flue (Single, HD, non-S/S) (use screws 809-0437) * 210-6525 Deflector, Flue (Single, Chili's, S/S) (use screws 809-0437) * 230-9973 Cover, HD65 90° Flue

* Not illustrated.

See Orifices, Section 2.2 See Additional Components and Controllers, Section 2.3

⁄

Tube, Pilot Gas Supply, Tube, Pilot Gas Supply,

" x 23" (one-piece gas line)

⁄

" x 17½" (one-piece gas line)

See Additional Components and Controllers, Section 2.3

Side Panel, Left

Side Panel, Right

Cabinet Full Back

Joiner Strip

Top Cap

2-10

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.3 Decathlon LHDC65 Primary Components (cont.)

ITEM PART # DESCRIPTION

16 106-7710 Door Assembly, left or right 17 210-8077 Handle, Door

* 810-2346 Magnet, Door * 230-4998 Hinge, Lower * 823-5137 Hinge, Upper Right * 823-5136 Hinge, Upper Left

18 823-5859 Basket Hanger, Church's (with Deflector)

* 823-5801 Basket Hanger, Chili’s Single System, 6" Splash Guard

* 823-5856 Splash Guard (2-, 4-, 5-, and 6-battery) 19 810-1494 Caster, Plate-mount 4" without Brake 20 810-2406 Caster, Plate-mount 5" without Brake

* 810-0944 Caster, Plate-mount 3" with Brake

* 807-0154 Cordset, 10’ Power 21 810-2411 Leg, Single Bolt Mount (black)

* 810-3169 Leg, 4 Bolt Mount, Package (4 per set) 22 823-3248 Leg, Single Bolt Mount Support Assembly, 23 Weldment, Vent

823-2309 823-2311 823-2312

823-2313 24 108-4284 Side Assembly, Frypot with Insulation Left 25 108-4285 Side Assembly, Frypot with Insulation Right 26 220-9906 Box, Burner Air 27 240-0319 Shutter, Burner 28 220-8858 Door, Ignitor 29 220-8865 Door, Ignitor Access 30 240-0320 Shutter, Long Burner 31 108-4062 Flue Assembly 90°

* 108-5788 Cordset, 10’ Power

* Not illustrated.

Single and 5-battery 2-battery, 5 battery and 6-battery 3-battery and 5-battery 4-battery and 6-battery

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.5 Y/KSCF/C/HC Primary Components

18b

18a

13a

13b

318

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CHAPTER 2: PARTS LIST

2.1.4 Y/KSCF/C/HC Primary Components (cont.)

ITEM PART # DESCRIPTION

1 823-6138 Frypot – S/S (YSCFHC 14)

* 106-9637 Frypot – S/S (YSCFHC 18) * 823-6367 Frypot – S/S (Y/KSCF/C/HC 18) India without hooks

* 823-7879 Frypot – S/S (Y/KSCF/C/HC 18) India with hooks 2 3

* 810-0705 Tube, Pilot Gas Supply, 1⁄4" x 23" (one-piece gasline)

* 810-0703 Tube, Pilot Gas Supply, 1⁄4" x 17½" (one-piece gasline) 4 230-4900 Diffuser Assembly (use 230-6888 for 8 row burner) (use 230-7711 for India) 5 6 810-3356 Burner, High Efficiency

* 810-2151 Burner, Left

* 810-2149 Burner, Center

* 810-2150 Burner, Right 7 220-5152 Burner Mounting (use 200-2738 for India) 8 200-8748 Heat shield 9

* 810-0691 Vent Tube

10 231-2060

11 232-2060

12 220-1828 Back Panel

13 210-1355 Joiner Strip 13a 823-6922 Joiner Strip 13b 823-7924 Joiner Strip (India slotted for hooks)

106-7984 214 106-7985 314

106-7669 218 (use 106-9625 for India) 106-9785 318

823-6292 214 823-6300 314

230-1833

823-6974 318 ( use 230-1890 for YSCFHC318G) 16 106-8511 Door, left or right 17 810-3335 Handle, Push-in

* 810-2346 Magnet, Door * 230-4998 Hinge, One Piece

18 810-2793 Basket Hanger, Double

18a 810-2794 Basket Hanger, Double Wireform 18b 230-8002 Basket Hanger, Double Keyholed (India)

230-8757 Basket Hanger, Triple Keyholed 19 810-0356 Caster, Plate-mount 5" without Brake (use 826-1138 for India) 20 810-0357 Caster, Plate-mount 5" with Brake

* 106-7649 Cordset, 10’ Power

21 810-2411 Leg, Single Bolt Mount (black)

* 810-3169 Leg, 4 Bolt Mount, Package (4 per set) (use 810-3168 for India)

22 823-3248 Leg, Single Bolt Mount Support Assembly

* Not illustrated.

►►► See Orifices, Section 2.2

See Additional Components and Controllers, Section 2.3

►►► See Drain Components, Section 2.4

See Additional Components and Controllers, Section 2.3

Side Panel, Left Side (unit exterior) (use 221-3272 for India) (use 231-8145 for SS 318G) (use 221-8141 318G Painted) Side Panel, Right Side (unit exterior) (use 222-3272 for India) (use 232-8145 for SS 318G) (use 222-8141 318G Painted)

Top Caps

Flue Caps

218 (use 823-6880 for India before Feb. 11) (use 823-7875 for India after Feb.

11)

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HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.6 BK1814 Primary Components

2-14

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.1.5 BK1814 Primary Components (cont.)

ITEM PART # DESCRIPTION

1 823-7554 Frypot (BK50)

* 823-6997 Frypot (BK60) 2 3

* 810-0703 Tube, Pilot Gas Supply, 1⁄4" x 17½" (one-piece gas line) 4 230-6887 Diffuser (Baffle) Assembly 5 6 810-3356 Burner, High Efficiency Cast 7 220-5152 Burner Mounting 8 200-8748 Heat shield 9

* 810-0691 Vent Tube

10 231-2060 Side Panel, Left Side (unit exterior)

* 231-6259 Side Panel, Left Side BK RAM Inner

11 232-2060 Side Panel, Right Side (unit exterior)

* 232-6259 Side Panel, Right Side BK RAM Inner

12 Back Panels

220-6434 60/50 BK60/50/RAM/60 (use 220-6432 for RAM/60 - RAM on right) 220-7150 50/60 BK60/RAM/50/60 (use 220-7151 for 60/RAM - RAM on left) 220-6270 BK160 220-6754 BK260 220-7268 BK60/50/60

230-6427 RAM Back Cover with cutout for receptacle 13 823-7515 Joiner Strip 14

108-0971 BK60/50 (BK1814 - 60/50/RAM/60) 108-1590 BK50/60 (BK1814 - 60/RAM/50/60) 108-0975 BK60/160 108-3606 BK260 108-1750 BK60/50/60

230-6268 BK60/50 (BK1814 - 60/50/RAM/60)

230-6431 RAM/60 (BK1814 - 60/50/RAM/60)

230-7143 60/RAM (BK1814 - 60/RAM/50/60)

230-7142 BK50/60 (BK1814 - 60/RAM/50/60)

230-8800 BK160

230-6705 BK260

230-7238 BK60/50/60 16 Door, Left or Right

106-4309 BK60

106-7542 BK50 17 210-8077 Handle

* 810-2346 Magnet, Door * 230-7192 Hinge, One Piece

18 Basket Hanger

823-7773 BK60/50 or BK50/60 (BK1814 - 60/50/RAM/60 or 60/RAM/50/60)

823-7770 BK160 or RAM/60 (BK1814 - 60/50/RAM/60)

823-7774 60/RAM (BK1814 - 60/RAM/50/60)

823-7771 BK260

823-7772 BK60/50/60 19 810-2280 Caster, Plate-mount 5" with Brake

* 106-7649 Cordset, 120V 10’ Power * 807-5003 Receptacle, RAM 15A 125V * 108-2582 Relay, Control Assy BK1814/HD50 includes 807-4114 and wire harness * 812-2185SP Relay, Time Delay

* Not illustrated.

►►► See Orifices, Section 2.2

See Additional Components and Controllers, Section 2.3

►►► See Drain Components, Section 2.4

See Additional Components and Controllers, Section 2.3

Top Caps

Flue Caps

2-15

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.2 Orifices

ITEM PART # COMPONENT

* 810-2060 2.40 mm CE

* 810-3801 2.35 mm (China)

* 810-3132 2.20 mm

* 810-2938 0-1999 ft. 2.26mm

* 810-3053 2000-3999 ft. 2.18mm

* 810-3054 4000-5999 ft. 2.10mm

* 810-2058 2.08mm used on LHDC65 #45

* 810-4285 2.06mm used on LHDC65 #46

* 810-3055 6000-7999 ft. 2.04mm

* 810-3056 8000-8999 ft. 1.98mm

* 810-3057 9000-10000 ft. 1.94mm

* 810-2939 0-1999 ft. 1.40mm

* 810-2940 0-1999 ft. 1.32mm (LP-Butane Mix)

* 810-3058 2000-3999 ft. 1.35mm

* 810-2497 1.32mm used on LHDC65 #55

* 810-3059 4000-5999 ft. 1.30mm

* 810-3060 6000-7999 ft. 1.26mm

* 810-3061 8000-8999 ft. 1.22mm

* 810-3062 9000-10000 ft. 1.20mm

* 810-0710 1.40 mm

* 810-2059 1.51 mm (100% Butane India)

* Not illustrated.

Natural Orifices

Propane Orifices

2-16

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CHAPTER 2: PARTS LIST

2.3 Additional Components and Controllers

ITEM PART # DESCRIPTION

1 826-2013 Thermostat, Sunne 2 810-2035 Knob, Thermostat 3 826-2117 Spark Module (module, 807-4383, and rajah connector, 807-4375)

* 106-7535SP Ignition Cable (for controller operated fryers)

Pilot Assemblies

106-1839SP Natural Gas, Electronic Ignition with Controller includes ignition cable Non-CE

108-2787 Natural Gas, Electronic Ignition with Controller includes ignition cable CE

106-1238SP Natural Gas, Electronic Ignition without Controller Non-CE

108-2990 Natural Gas, Electronic Ignition without Controller CE

106-6752SP Natural Gas, Trailing Pilot Non-CE

108-2785 Natural Gas, Trailing Pilot CE

106-1128SP LP Gas, Electronic Ignition with Controller includes ignition cable Non-CE

108-2768 LP Gas, Electronic Ignition with Controller includes ignition cable CE

KIT6627 LP Gas, Electronic Ignition without Controller Non-CE

108-2991 LP Gas, Electronic Ignition without Controller CE

KIT8899 LP Gas, Trailing Pilot Non-CE

108-2786 LP Gas, Trailing Pilot CE

* 807-1310 Flame Sensor * 220-4626 Air Shutter (screw, 809-0931) * 807-4199 Cable Assembly, Controller to Interface Board (SMT)

Controllers

106-7141 Controller, Compu-Fry III.5, Full-vat

826-2413 Controller, Compu-Fry III.5 (HD60, Red Robin)

826-2304 Generic Digital Controller

106-6022 Controller, Analog

826-2858 Controller, Wingstreet

108-4717 Controller, 3000 (Church’s)

108-0376 Controller, CM4-S (with bezel)

* Not illustrated.

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CHAPTER 2: PARTS LIST

2.3 Additional Components and Controllers (cont.)

ITEM PART # DESCRIPTION

826-2323 Basket Lift Timer (General Market, HD60, Red Robin)

826-2385 Basket Lift Timer (HD63, Red Robin)

108-1351 Controller, 3-Lane (Burger King)

6 826-2269 Potentiometer Kit, Dean

* 106-3729 Kit, Thermatron, 24VAC, Extended Melt Cycle * 810-0110 Knob, Thermatron Controller * 230-4625 Face Plate, 3-switch, Thermatron * 810-3141 Sound Device * 806-3660 Sound Device, High Output

7 106-5419SP Probe Assembly, Temperature (Thermatron and FAST)

* 826-2423 Probe Assembly, Temperature (Dean controller) (BK 3-Lane)

807-3552 Natural Gas, Electronic Ignition

807-3628 Propane Gas, Electronic Ignition

807-3294 Natural Gas, Constant Pilot

807-3295 Propane Gas, Constant Pilot

807-2091 G20/25 (CE only)

807-2127 G31 (CE only)

9 44970SP

810-1001 Piezo Igniter (trigger)

200-1868 Piezo Bracket

807-3540 Electrode, Piezo

807-3650 Lead Wire, Piezo 10 807-2176 Transformer, 100/120-12/24 VAC Dual Voltage

* 807-0800 Transformer, 120/24 VAC

11 807-3680 High-limit Thermostat, Manual Reset 450° F (232° C)

* 210-4628 Bracket, Frypot Sensors (requires tack welding to heat tube) * 210-4629 Bracket, Frypot Controller Probe (requires tack welding to heat tube)

12 807-1321 Fuse Holder, Buss

* 807-3843 Fuse, 3A Subminiature (250V) * 807-3592 Fuse, 2A Slow-blow (230V) * 807-3750 Fuse, 5A (120V)

826-2434 Standing Pilot (use 106-6670 for FAST)

826-2425 Basket Lift

106-9669 YUM/Wingstreet Interface Board

* 807-4199 Cable Assembly, SMT Controller to Interface Board

* 807-4597 Control Harness D-Series Wiring 14 807-0834 Relay, 12VDC 15A SPDT (basket lift) 15 807-0833 Relay, 12VDC 5A DPDT (latching)

* 807-4114 Relay, 24VAC Coil, Reset

* 106-6657 Pump Relay (includes 807-4114 and drain safety wiring)

* 807-0012 Pump Relay 18 amp 24V coil 16 807-3574 Switch, Power (green lens) 17 807-3580 Switch, Rocker, Manual Filter Power 18 807-3579 Switch, Six-terminal Boil-out 19 807-3576 Switch, Fryer Reset (momentary)

* 807-3578 Switch, 3-position, ON-OFF-ON

* 807-3575 Switch, Blank Insert

* 807-3577 Circuit Breaker, 7 amp

* 807-4112 Indicator Light, Green, 24V

* 807-4111 Indicator Light, White, 24V

* 807-3581 Indicator Light, Red, 120V

* Not illustrated.

Gas Valves

Piezo Ignition Assembly

Interface Boards

2-18

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.4 Drain System Components

2.4.1 3" Drain Manifold Components

2-19

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.4.1 3" Drain Manifold Components (cont.)

ITEM PART # DESCRIPTION

1 823-5188 Tube, 3" Filter Right, 50/60/80

823-7664 Tube, 3” Drain Middle BK50 of BK60/50/60

823-8167 Tube, 3” Drain YSCFHC318 2 823-4681 Tube, 3" Right Drain, 50/60/80 3 823-4682 Tube, 3" Center Drain, 50/60/80 4 812-1764 Tube, 3" Right Drain, KSCFH218G 5 823-6315 Tube, 3" Left, SCFC50 6 823-5911 Tube, 3" Right Drain, Wingstreet 7 812-1998 Spout, 3" 50/60/80 8 812-1901 Spout, 3" CF/BID80 9 812-2006 Spout, 3" Wingstreet

10 812-1908 Spout, 3" KSCFH218G 11 823-6100 Spout, 3" HD65 (with fitting) 12 823-5968 Spout, 3" SCFHD60/63/65 13 200-6751 Tube, 3" Joiner, SCF50 14 200-9365 Tube, 3" Joiner, Drain Filter Right 15 200-6752 Tube, 3" Joiner, SCF50 (for matching cabinet)

220-6660 Tube, 3” Joiner, Under RAM BK60/50/RAM/60, BK60/RAM/50/60 (19.00”)

16 812-1999 Tube, 3" 50/60/80, Short, End Drain

823-7662 Tube, 3” Left End BK60/50/60 (3.17”)

823-7452 Tube, 3” Left End BK60/50/RAM/60, BK260, BK50 on BK60/RAM/50/60

(4.00”) 17 812-2008 Tube, 3" Wingstreet, Short, Mid Drain 18 823-5910 Tube, 3" Wingstreet, Short, Left Drain 19 823-7633 Tube, 3” Right End BK260 20 823-7663 Spout (Dump), 3” BK60/50/60, BK60/50/RAM/60, BK260, BK60/RAM/50/60

(10.06”) 21 823-7520 Spout (Dump), 3” BK260 (13.82”) 22 823-7667 Spout (Connecting Drain), 3” BK60/RAM/50/60 23 823-7462 Spout (Connecting Drain), 3” BK60/50/RAM/60 24 823-7668 Tube, 3” Left Drop BK60/RAM/50/60 25 823-7461 Tube, 3” Right Drop BK60/50/RAM/60 26 809-0969 Clamp, T-Bolt 27 816-0729 Sleeve, Drain Connection

2-20

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.4.2 Drain Valve Assemblies

2-21

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.4.2 Drain Valve Assemblies (cont.)

ITEM PART # DESCRIPTION

A 108-1581 Valve Assy, 1 ¼” Drain (BK50 on BK1814-BK60/50/RAM/60 and BK60/RAM/50/60)

B 106-8042 Valve Assy, 1 ¼” Drain (YSCF14-Wingstreet) C 106-8172 Valve Assy, 1 ¼ “ Drain (CFHDC150) D 106-3979 Valve Assy, 1 ¼ “ Drain (CFHDC50, BK50 on BK1814-BK60/50/60)

E 108-1723 Valve Assy, 1 ½” Drain (Left BK60 on BK1814- BK60/50/RAM/60 and

BK60/RAM/50/60)

F 108-1559 Valve Assy, 1 ½” Drain (BK160) G 106-8401 Valve Assy, 1 ½” Drain (CFHD160, 118G, 60) H 106-3977 Valve Assy, 1 ½” Drain (60’s – Raising Cains, HDC60’s, HDC65’s, BK260, 60’s on

BK60/50/60, Right 60 on BK1814- BK60/50/RAM/60 and BK60/RAM/50/60

* 108-3474 Valve Assy, 1 ½” Drain (GM1814) (use 108-3475 for 1 ¼” drain GM1814)

I 108-0448 Valve Assy, 1 ½” Drain (Y/KSCF 18) 1 810-2784 Valve, 1 ¼” Full Port Drain(includes item # - O-ring) 2 823-5075 Valve , 1 ¼” W/A, Drain Wingstreet

* 810-2126 Valve, 1 ¼” Full Port Drain(includes handle) 3 810-2783 Valve, 1 ½” Full Port Drain (use 823-5053 for Y/KSCF18G) 4 810-2127 Valve, 1 ½” Full Port Drain 5 823-7426 Handle W/A, BK50 Drain Valve 6 823-6262 Handle W/A, HD50/Y/KSCF18G Drain Valve 7 823-6340 Handle W/A, CF150 Drain Valve 8 823-7632 Handle W/A, BK60 Drain Valve 9 823-6424 Handle W/A, Rotating 118G Drain Valve

10 816-0544 O-Ring Seal 11 816-0547 Cap, Vinyl Red 12 816-0549 Cap, Vinyl Blue 13 807-2104 Switch, CE Micro Roller Lever 14 106-6020 Bracket Assy 1 ¼” Drain Valve (use 108-3706 on GM1814) 15 106-8173 Bracket Assy 1 ¼” Drain Valve CF150 16 106-5511 Bracket Assy 1 ½” Drain Valve HE50 (use 108-3701 on GM1814) 17 200-6795 Strap, 1 ¼” Drain Valve Connecting 18 200-6116 Strap, Round Drain Connecting (use 220-5155 for Y/KSCF18) 19 200-8796 Bracket, Drain KSCF218 20 809-0988 Washer, 1.00 OD x .525 ID Teflon 21 816-0220 Insulation, RF Switch 22 220-0143 Guard, BID180 Microswitch Drain 23 901-2348 Cover, DV Safety Switch 24 200-1257 Retainer, Drain Valve Nut

* 812-1717SP Nipple, Drain (BK160 Non-Filter)

* Not illustrated.

2-22

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

2.5 Oil Return System

CHAPTER 2: PARTS LIST

3430

2-23

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.5 Oil Return System (cont.)

ITEM PART # DESCRIPTION

1 106-4006SP Valve Assembly, ½" Oil Return (see Section 2.6 for com ponents)

2 106-7598SP Valve, Solenoid with Female Pins 3 200-9295 Handle, Oil Return (YSCFC 14, SCFHDC 50/60, HD 65) 4 200-8929 Handle, Oil Return (YSCFC 18) 5 809-0601 Clip, Clevis (to attach handle to Item 1) 6 816-0639 Cap, Red Vinyl (grip for end of handle) 7 210-8790 Bracket, Oil Return Handle 8 810-1057 Flexline, ⅝" OD x 13.00" Long

9 810-1067 Flexline, ⅝" OD x 8.50" Long 10 810-1680 Flexline, ⅝" OD x 6.50" Long 11 810-1400 Flexline, ⅝" OD x 21.00" Long 12 810-1160 Flexline, ⅝" OD x 3.00" Long 13 810-1668 Adapter, Male, ⅝" OD x ½" 14 810-1669 Adapter, Female, ⅞" OD x ½" 15 810-3199 Fitting, ¼" NPT x ⅜", Hose Barb 16 812-1838 Tubing, ⅜" OD, 27.00" Long 17 810-1372 Fitting, ¼" NPT x ⅜" OD, 90° Tube 18 813-0022 Nipple, ½" NPT Close, Black Metal 19 813-0062 Elbow, ½", 90°, Black Metal 20 813-0298 Nipple, ½" x 2.00" NPT, Black Metal 21 813-0304 Bushing, ½" x ¼", Flush, Black Metal 22 813-0460 Nipple, ½" x 3.00" NPT, Black Metal 23 813-0530 Tee, Reducing, ½" x ¼" x ½" 24 813-0838 Nipple, ¼" NPT Close, Black Metal 25 813-0919 Elbow, ¼" Street, 90°, Stainless Steel

26 823-7800

27 813-0165 Elbow, ½" x ½" Street, 90° 28 813-0173 Union, ½" NPT, 150# 29 813-0331 Elbow with Side Outlet, ½" NPT 30 810-2492 Fitting, Straight, Quick Connect 31 810-3160 32 813-0003 Tee, ½" x ½" x ½", Black Metal 33 813-0087 Nipple, ½" x 1.50" NPT 34 813-0265 Nipple, ½" x 2.50" NPT, Black Metal 35 813-0342 Elbow, Street, 45°, ½" NPT 36 813-0515 Nipple, ½" x 12.00" NPT 37

►►►

Bracket, Disconnect (Use 823-8001 for 2-Battery) (Use 823-7997 for BK21814/HD50) (Use 823-7998 for BK units with RAM)

Adapter, ½" NPT x

See Additional Oil Return Components, Section 2.6

/16"

2-24

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.6 Additional Oil Return Components

2-25

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.6 Additional Oil Return Components (cont.)

ITEM PART # DESCRIPTION

810-3113 314/350 810-3117 214/250 810-3118 260/460/665/63/218G 810-3120 460 810-3121 360/318G 810-3734 BK1814 -60/50/60 810-3555 BK1814 – 60/50/RAM/60 or 60/RAM/50/60 810-3170 550

810-3346 4 GPM, Viking 826-1264 4 GPM, 2-piece 810-3347 8 GPM, Viking

* 807-11973 Viking Pump Seal Kit 3 816-0093 Gasket (Pump/Motor) (included with motor) 4 Motor and Gasket Kit

826-1785 100V 50/60Hz 826-1712 115V 50/60Hz

826-1270 230V 50/60Hz 5 200-8929 Handle, Oil Return (use 200-9295 BK1814) 6 809-0601 Clip, Clevis, Rod End 7 816-0638

* 816-0637 * 816-0639

8 210-8790

9 106-4006SP

10 106-3962 Bracket, ½" Switch Flush 11 220-2459 Cover, Safety Switch ½" 12 807-2103 Microswitch, Straight Lever 13 826-1366 Nut, 4-40 Keps Hex (with External Teeth) 14 810-0278 Valve, ½" Ball 15 816-0220 Insulation, Microswitch 16 900-2935 Retainer, Oil Return Valve 17 901-2772 Handle Bracket, Valve

* Not illustrated.

Pump

Oil Return Manifold

Cap, Vinyl Yellow Cap, Vinyl Blue Cap, Vinyl Red Bracket, Oil Return Handle (use 230-6575 BK60/50) (use 230-7305 for

318G)

Valve Assembly, Oil Return

/16" x 3"

2-26

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.7 Oil Disposal Plumbing (Popeye's and Church’s)

ITEM PART # DESCRIPTION

108-1121 1 810-0278 Valve 2 900-5953 Handle 3 814-0047 Sleeve

108-1117 4 810-2379 Hose, 107.5", ½" x ½" 5 813-0699 Nipple, Snaptite, ½" 6 823-7153 Handle 7 816-0631 Sleeve/Cap, Handle 8 810-0487 Coupling, Male

108-2226 9 810-0487 Coupling Male

10 810-0490 Quick Disconnect ½” Female

Valve, Oil Disposal

Oil Disposal Assembly

2-27

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

2.8 Oil Return Wand

CHAPTER 2: PARTS LIST

ITEM PART # DESCRIPTION

106-3997

Wand Valve Assembly

1 810-0278 Valve, ½" Ball 2 806-9128 Bracket, Microswitch 3 816-0220 Insulation, Microswitch 4 807-2103 Microswitch, CE Micro-roller, Straight Lever 5 900-2849 Cover, Microswitch 6 900-2839 Handle, Wand Valve 7 813-0022 Nipple, ½" x Close NPT 8 810-2283 Quick Disconnect, 1-⅜" (#VHC8-8F) 9 810-2282 Collar, Quick Disconnect, 1-⅜" Hole

106-2568SP 108-0528

Wand Hose Assembly (Generic) Wand Hose Assembly (Church's, Popeye's, Raising Cane's)

10 106-1454SP Nozzle Assembly, Hose with Handle (part of 106-2568 and 108-0528) 11 810-1434 Hose Assembly, Standard, 5 ½ feet (part of 106-2568 and 108-0528) 12 813-0165 Elbow, Street, ½" NPT, 90° (part of 106-2568) 13 813-0699 Nipple, Snaptite, ½" (#PHN8-8F) (part of 106-2568) 14 823-7153 Handle, Wash Down Hose (part of 108-0528) 15 816-0631 Cap, Red Vinyl, ½" x 3" (part of 108-0528) 16 810-0487 Coupling, Male (part of 108-0528)

* 813-0368 Nipple, ½" NPT x 16" Black Metal * 813-0345 Elbow, ½" NPT, 45° Black Metal * 813-0087 Nipple, ½" NPT x 1.5" Black Metal * 810-2043 Clamp, Pipe, ½" (Jiffy H-40) * 230-4773 Bracket, Side

* Not illustrated.

2-28

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.9 Over-the-Top Oil Return System

ITEM PART # DESCRIPTION

1 810-1669 Adapter, Female ⅞" O.D. x ½"

2 810-1680 Flexline, ⅝" I.D. x 6.50" Long

3 810-2513 Tubing, Faucet Upper 4 810-2699 Coupling, Quick Disconnect, Snaptite 5 810-2700 Nipple, Quick Disconnect, Snaptite 6 810-3234 Tubing, Faucet Rear 7 813-0093 Nipple, ½" x 4" NPT BM

2-29

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10 Filtration Components

2.10.1 Filtration Components; SCFHDC50 Series and BK1814 Fryers

ITEM PART # DESCRIPTION

1 823-6366 Basket, Crumb

823-7425 Basket, Crumb (BK1814) 2 810-3541 Ring, Hold-down 3 200-8003 Screen, Sana Grid 4 823-7294 Pan, Filter 5 813-0568 Plug, ⅛" NPT Socket-Head Pipe 6 810-2805 Caster, 2" Filter Pan 7 809-0823 Nut, Nylock, ¼-20

* 823-6603 Lid (mounted in frame) * 823-7652 Lid (mounted in frame) BK60/50/RAM/60, BK260 * 823-7418 Lid (mounted in frame) BK60/50/60 * 823-7627 Lid (mounted in frame) BK50/RAM/50/60

* Not illustrated.

2-30

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.2 Filtration Components; SCFHDC60 Series Fryers

ITEM PART # DESCRIPTION

1 823-6018 Basket, Crumb

* 823-7110 Basket, Crumb (Raising Cane's)

2 810-3540 Ring, Hold-down 3 200-5726 Screen, Sana Grid 4 823-6338 Pan, Filter 5 810-2805 Caster, 2" Filter Pan 6 809-0070 Nut, ¼-20 Hex, S/S

* 823-6403 Lid (mounted in frame)

* Not illustrated.

2-31

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.3 Filtration Components; Y/K/SCF/C/HC218 and 63 Series Fryers

ITEM PART # DESCRIPTION

1 823-6172 Basket, Crumb 2 810-3195 Ring, Hold-down 3 106-7330SP Screen Assembly, Filter 4 823-7534 Pan, Filter 5 813-0568 Plug, ⅛" NPT, Socket-Head 6 810-2805 Caster, 2" Filter Pan 7 809-0823 Nut, Nylock, ¼-20

* 823-6507 Lid (mounted in frame)

* Not illustrated.

2-32

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.4 Filtration Components; Y/KSCF/C/HC218 Export (India) Series Fryers prior to May 2010

ITEM PART # DESCRIPTION

1 823-5427 Basket, Crumb 2 823-4470 Ring, Hold-down 3 823-4471 Handle Hold Down Ring 4 106-7912SP Screen Assembly, Filter 5 108-1022SP Pan, Filter 6 813-0679 Plug, ⅛" SS NPT, Sq-Head 7 810-2805 Caster, 2" Filter Pan 8 809-0823 Nut, Nylock, ¼-20

* 813-0704 Plug, ⅜” SS Hex Head * 823-6911 Lid (mounted in frame)

* Not illustrated.

2-33

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.5 Filtration Components; Y/KSCF/C/HC218 Export (India) Series Fryers after May 2010

ITEM PART # DESCRIPTION

1 823-7904 Basket, Crumb 2 810-3195 Ring, Hold-down 3 823-7834 Lid 4 106-7330SP Screen Assembly, Filter 5 823-7534 Pan, Filter 6 813-0568 Plug, ⅛" SS NPT, Sq-Head 7 810-2805 Caster, 2" Filter Pan

* 809-0823 Nut, Nylock, ¼-20

* Not illustrated.

2-34

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.6 Filtration Components; 65 Series Fryers (Filter Paper Option)

ITEM PART # DESCRIPTION

1 823-6018 Basket, Crumb 2 810-3540 Ring, Hold-down 3 200-5726 Screen, Sana Grid 4 813-0568 Plug, ⅛" NPT, Socket-Head Pipe 5 823-6304 Pan, Filter 6 810-2805 Caster, 2" Filter Pan 7 809-0823 Nut, Nylock, ¼-20

* 823-5857 Lid (mounted in frame)

* Not Illustrated.

2-35

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.7 Filtration Components; 65 Series Fryers (Filter Leaf Option)

ITEM PART # DESCRIPTION

1 823-5851 Basket, Crumb 2 106-6466SP Filter Leaf with Suction Tube Assembly 3 106-8399 Filter Leaf (screen only) 4 823-5258SP Filter Pan 5 810-2805 Caster, 2" 6 809-0070 Nut, ¼"-20 Hex

* 823-5857 Lid (mounted in frame)

* Not Illustrated.

2-36

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.10.8 Filtration Components; 65 Series Fryers (Popeye’s / Church’s Filter Paper Option)

ITEM PART # DESCRIPTION

1 823-7769SP Filter Pan SCFHD65 2 810-2805 Caster, 2" 3 200-5726 Screen, Sana Grid UFF60 4 810-3540 Ring, Hold-down UFF60 5 823-8659 Basket, Crumb 65 6 813-0568 Pipe Plug 1/8 NPT Socket Head

2-37

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.11 Basket Lift Components

2-38

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.11 Basket Lift Components (cont.)

ITEM PART # DESCRIPTION

1 823-3625 Lift Rod 2 813-0035 Bushing, Bronze 3 200-2069 Lift Bar 4 210-2140 Bushing, ⅜" x ½" 5 824-1783 Back, Upper

* 824-0991 Back, Lower 6 823-6871 Lift Assembly, Left 7 823-6870 Lift Assembly, Right 8 106-8370 Lift Guide Assembly 9 809-0990 Nut, Low Crown, ¼" x 20"

10 810-3307 Roller 11 809-1018 Bolt, ¼" x 20" x 1" S/S 12 823-3626 Switch, Limit Cam 13 807-2104 Microswitch, Micro Roller Lever 14 807-0107 Gear Motor, 120V

1 823-6309 Lift Rod 2 813-0035 Bushing, Bronze 3 220-3060 Lift Bar 4 810-2140 Bushing, ⅜" x ½" 5 824-1834 Back 6 823-6588 Lift Assembly, Left 7 823-6589 Lift Assembly, Right 8 106-8368 Lift Guide Assembly 9 809-0990 Nut, Low Crown, ¼" x 20"

10 810-3307 Roller 11 809-1018 Bolt, ¼" x 20" x 1" S/S 12 823-6312 Switch, Limit Cam (HD63 Red Robin)

* 823-3626 Switch, Limit Cam (HD60 Red Robin)

13 807-2104 Microswitch, Micro Roller Lever 14 807-0107 Gear Motor, 120V

* 106-1870SP Lift Assembly, D60/63 Basket (Red Robin)

* 823-3625 Lift Assembly, Basket (Red Robin)

* 230-3069 Arm, Basket Lift Cam (Red Robin)

* 809-1019

*Not illustrated.

HDC50 Models (106-7702)

HDC60/63 Models (106-8058)

Bolt, ⅜" x

/16" Shoulder (Red Robin)

2-39

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

2.12 Accessories

CHAPTER 2: PARTS LIST

2-40

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

CHAPTER 2: PARTS LIST

2.12 Accessories (cont.)

ITEM PART # DESCRIPTION

1 106-1637SP Cover, Full-vat (HD50/BK50) 2 106-2585SP Cover, Split-vat (HD60)

* 106-1447SP Cover, Full-vat (HD60) * 108-1872 Cover, Full-vat (BK60) * 106-1479SP Cover, Full-vat (Raising Cane's) * 106-2897SP Cover (FPHD65/Church's) * 106-6494 Cover (HD56) * 810-0180 Handle, Vat Cover (Full- and Split-)

3 812-1226SP Drain Nipple, extension 1 ¼"

* 812-1717SP Drain Nipple, extension 1 ½" 4 803-0278 L-shaped Brush 5 803-0277 Grid Assembly

* 810-2552 Mesh grid assembly

* 810-2235 Grid assembly, rack 6 803-0197 Fryer’s Friend 7 803-0304 Basket, Twin (KFC)

* 803-0392 Basket, Twin (Raising Cane's) 8 803-0271 Basket, Twin 9 803-0099 Basket, Full

* 803-0337 Basket, 6" x 8 ¾" x 16 ¾"

10 823-3938 Crumb Scoop

106-2631SP Sediment Tray

823-3947 Chicken Crisper

* 803-0293 Gloves (pair) * *

824-2043 Workshelf, 260 (Raising Cane's)

824-2044 Workshelf, 360 (Raising Cane's) * 824-1992 Workshelf, 460 (Raising Cane's)

* Not illustrated.

2.13 Fasteners (Screws, Nuts, Bolts)

ITEM PART # DESCRIPTION

* *

809-0417 Nut, Flange ¼-20 Serrated 809-0766 Nut, Keps 10-32 SS Hex

* 826-1366 Nut, 4-40 Keps Hex (with External Teeth, pkg. of 25)

* * * * * * * *

809-0247 Nut, 8-32 Hex Keps (Zinc Plated) 809-0863

Nut, Nylock,

⁄

"-18 Hex

809-0169 Screw, #12 x ¾" Hex Washer Slotted Head

809-0428 Screw, ¼-20 x ½" Hex Head 826-1389 Screw, ¼-20 x ¾" Hex Head (pkg. of 10) 809-0918 Screw, 10-24 x ½" Slotted Head 809-0845 Screw, 10-32 x ⅜" Hex Slotted Head

809-0846 Screw, 4-40 x 1"

* 809-0918 Screw, 10-24 x ½" Round Slotted Head * * * * * *

* Not illustrated.

809-0167 Screw, Sheet Metal 10 A x ⅝" B

809-0475 Screw, #10 x ⅜" Hex Washer Head

809-1019 Screw, .375 x ½" Shoulder

826-1379 Screw, #10 x ½" Phillips Truss Head (pkg. of 10)

809-0962 Screw, 8-32 x 1-⅝" Phillips Truss Head

809-0191 Washer, ¼" Spring-lock

2-41

HIGH EFFICIENCY DECATHLON SERIES GAS FRYERS

2.14 Flexlines

CHAPTER 2: PARTS LIST

17.50 (± 1.00)

Typical Flexline

LENGTH PART NUMBER LENGTH PART NUMBER

3.0-inch 810-1160 13.0-inch 810-1057

4.5-inch 810-1339 17.5-inch 810-1369

5.0-inch 810-1159 21.0-inch 810-1400

6.5-inch 810-1680 21.5-inch 810-1068

8.5-inch 810-1067 29.5-inch 810-1069

9.5-inch 810-1043 53.5-inch 810-1056

11.5-inch 810-1055

Flexlines come with a ⅞-inch female fitting on each end. Adapters (listed below) are required to fit them to standard ½- inch NPT pipe nipples of fittings. Add ¾-inch to the overall length of the flexline for each adapter used.

1.91

1.55

810-1668

810-1669

NOTE: Be aware that these are flexible metal lines. Consequently, the length of a particular line can vary as much as ±

½ inch on shorter lines and ± 1 inch on longer lines, depending upon whether the line has been stretched or compressed in handling.

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Frymaster FPHD565 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual