Marshall Air F12G Service Manual

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This document contains the installation and

operating instructions for:

MODELS: F12G AUTOBROIL™&

F12G DUAL BELT AUTOBROIL™

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

INSTRUCTIONS TO PURCHASER:

1. ANSI Z83.11 STANDARDS REQUIRE THAT YOU POST IN A PROMINENT LOCATION THE PROCEDURES TO FOLLOW IN THE EVENT THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED FROM THE LOCAL GAS SUPPLIER.

2. THIS MANUAL NEEDS TO BE RETAINED FOR FUTURE REFERENCE.

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

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MODEL: F12G

TABLE OF CONTENTS

I. MACHINE SETTINGS (Quick Reference)..................................................................... 2

II. MACHINE INSTALLATION............................................................................................. 3

III. OPERATING INSTRUCTIONS ...................................................................................... 6

IV. SCHEDULED MAINTENANCE...................................................................................... 7

V. PREVENTIVE MAINTENANCE...................................................................................... 8

VI. TROUBLESHOOTING................................................................................................... 9-11

VII. ASSEMBLY & DISASSEMBLY INSTRUCTIONS ......................................................... 12

VIII. REPLACEMENT PARTS............................................................................................... 13-16

Pre-lnstallation ....................................................................................................... 3

Appliance Location................................................................................................. 3

Electrical Information............................................................................................. 4

Gas Piping To Appliance ....................................................................................... 4

Pre-Operation Check............................................................................................. 4

Lighting Instructions................................................................................................ 5

Shut-Off Instructions.............................................................................................. 5

Performance Criteria.............................................................................................. 5-6

BROILER LIMITED WARRANTY.................................................................................... i

BROILER WARRANTY PROCEDURES........................................................................ ii

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ILLUSTRATIONS

F12G Broiler Overall Dimensions............................................................................. FIGURE 1

Gas Components & Conveyor Drive (Rod Style)..................................................... FIGURE 2

Conveyor Drive (Mesh Style).................................................................................... FIGURE 2A

Conveyor Travel (Rod Style)..................................................................................... FIGURES

Conveyor Belt (Mesh Style)...................................................................................... FIGURE 3A

Bearing, Sprocket and Motor.................................................................................... FIGURE 4

Control Cabinet Front................................................................................................ FIGURES

Control Cabinet Components................................................................................... FIGURES

Circuit Board - Speed Control................................................................................... FIGURE 7

Thermocouple Location............................................................................................ FIGURES

Burner Assembly....................................................................................................... FIGURE 9

Tunnel Assembly....................................................................................................... FIGURE 10

Gas Piping ................................................................................................................. FIGURE 11

Gas Restraining Device............................................................................................. FIGURE 12

Hang-On Parts........................................................................................................... FIGURE 13

Lower Shield Removal.............................................................................................. FIGURE 14

Gas Line Illustration................................................................................................... FIGURE 15

Circuit Board Asby with Mount.................................................................................. FIGURE 16

Schematic.................................................................................................................. 111831

Schematic.................................................................................................................. 114464

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I. MACHINE SETTINGS

AUTOBROIL™

F12G

SERIAL NUMBER: ________________________________________________________________________________

TYPE OF GAS: ___________________________________________________________________________________

HIGH LOW

GAS PRESSURE: ________ ________

CONVEYOR SPEED SETTINGS: ___________________________

TEMPERATURE SETTING: ___________________________

START-UP TECHNICIAN: _________________________________________________________________________

START-UP DATE: ________________________________________________________________________________

COMMENTS: ___________________________________________________________________________________

_______________________________________________________________________________________

________________________________________________________________________________________

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II. MACHINE INSTALLATION

PRE-INSTALLATION

1. After uncrating the Autobroil™ unit, inspect for shipping damage. Check that all control knobs are intact on the electrical cabinet front. Contact the factory if there are obvious problems. Set the Autobroil™ in place and use the plastic wrapping to protect it from the debris and trash of building construction. DO NOT remove plug from gas inlet pipe. Leave this for the Qualified Service Company. Check that machine has not been dented or damaged by the carrier. If damaged, notify your freight carrier immediately to file a concealed damage claim, following the instructions attached to the outside of the shipping crate. Your warranty will not cover freight damage.

2. Installation must be performed by a Qualified Service Company. The term "Qualified Service Company" means any individual, firm, corporation or company which either is engaged in and is responsible for the installation or replacement of gas piping on the outlet side of the meter, or the service regulator when a meter is not provided, or the connection, installation or repair of gas appliances, who is experienced in such work, familiar with all precautions required, and has complied with all the requirements of the authority having jurisdiction.

3. A remote gas shut-off valve must be provided and interlocked to exhaust system when in operation.

4. Because this unit is power fan exhausted, it is necessary to provide adequate make up air equal to the amount removed. In addition to this, any other exhausts, flues, or air removal systems must be taken into consideration. Examples of this are heat removal fans or hot water heater flues.

5. The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system attest pressures in excess of 1/2 psig (3.45 kPa).

6. The appliance must be isolated from the gas supply piping system by closing its individual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.45 kPa).

APPLIANCE LOCATION

1. Position Autobroil™ to properly align with exhaust hood. Note name plate clearance.

2. The hood/ventilator for the appliance should be located in accordance with the National Fire Protection Association Standard #96, "Removal of Smoke and Grease-Laden Vapors from Commercial Cooking Equipment" and any local applicable requirements.

3. For proper installation, the minimum clearance from combustible construction is 9" from sides and 9" from back.

4. Adequate clearance should be maintained to allow easy access to loading and unloading areas of the machine.

5. For servicing, unit must be moved 2' clear from all construction.

CAUTION: KEEP THE APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

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ELECTRICAL INFORMATION

1. The appliance is cord connected and requires a 120 volt, AC, 60 HZ, Single Phase, 3 wire w/ground 15 AMP circuit. Appliance must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code ANSI/NFPA No. 70-1987, latest edition.

2. There is a Wiring Diagram located in the Owner's Manual and under the cover of the electrical control cabinet.

GAS PIPING TO APPLIANCE

1. Installation of this appliance must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI #Z-223.1, latest edition.

2. In Canada, this appliance is to be installed in accordance with Standard CGA B149.1 or B149.2 Installation Codes for gas burning appliances and equipment and any local applicable requirements.

3. The appliance is supplied with a 1/2" male pipe thread. The installer must make the pipe connection to the unit in accordance with the "National Fuel Gas Code," ANSI Z-223.1, latest edition. The gas line connected to the 1/2" male pipe thread cannot be less than a 1/2" pipe. The gas pressure and gas volume required by this appliance is shown on Page 7. Gas piping from source to broiler must be adequate to satisfy these requirements when all other gas appliances in the restaurant are operating at maximum demand. A 1/2" X 3/4" bushing is provided with machine to accommodate 3/4" feed line.

4. A flexible AGA approved gas line is available. Instructions are (1) the installation shall be made with a connector that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69, latest edition, and a quickdisconnect device that complies with the Standard for Quick-Disconnect Devices for Use With Gas Fuel, ANSI Z21.41, latest edition, and (2) adequate means must be provided to limit the movement of the appliance without depending on the connector and the quick-disconnect device or its associated piping to limit the appliance movement (see Figure 12 for details and Page 14, Item 4).

5. See Page 4, Items 5 and 6, for instructions on gas supply line pressure testing.

CAUTION: DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.

PRE-OPERATION CHECK

Before lighting and operating your Autobroil™, make a quick check of critical items as follows:

1. Remove protective paper from outside covers and trays.

2. Remove side panel and check to see that all parts are in place and that none are damaged.

3. Start the conveyor chain and check for proper operation. The conveyor chain should run free and not be catching or hanging up on anything.

4. The speed of the conveyor chain should be modulated from seven (7) minutes to thirty (30) seconds, and back again without the chain stopping.

5. Check that gas pressure at appliance is correct (see Performance Criteria) (Page 7).

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LIGHTING INSTRUCTIONS

1. Turn exhaust system on.

2. Make sure filters are in place in the hood.

3. Turn conveyor chain on.

4. Remove side covers.

5. Turn gas cock in gas line on.

6. Turn knob on gas valve to on (see Figure 11).

7. Turn on heat switch. Ignition is electronic.

8. If pilot flame or burners fail to light turn heat switch off and wait five minutes before attempting to relight.

SHUT-OFF INSTRUCTIONS

1. Turn heat switch off.

2. Turn conveyor switch off.

3. Turn ventilator off.

PROLONGED POWER FAILURE: NO ATTEMPT SHOULD BE MADE TO OPERATE THE APPLIANCE DURING POWER FAILURE.

PERFORMANCE CRITERIA - NATURAL GAS

1. The manifold pressure for each burner and appliance inlet pressure and gas amount is listed below:

TYPE OF GAS - Natural

PRESSURE AT THE APPLIANCE - 5.5 -10.0 IWC for Natural

MANIFOLD PRESSURE - Low 2.0 IWC; High 5.0 IWC for Natural

TOTAL GAS AMOUNT - 50,000 BTUH @ 100% High Fire

Manifold pressure is measured by a pressure gauge on the outlet side of the gas valve. With the unit on for at least fifteen minutes and the broiler temperature controller set at 600°F, the pressure should be at 2.0 IWC. Now set the broiler temperature controller to high and note that high fire pressure is 5.0 IWC. These valves are factory set. If high pressure settings do not come up to specification, check for at least 5.5" line supply pressure. Refer to Figure 11 - information is shown on gas pressure high and low range adjustment.

2. The burners in the appliance are a special infrared type. All of the air for combustion must be injected through the Venturis. This makes orifice design and alignment very critical. The orifice design, in combination with the correct natural or propane gas pressure will result in adequate air aspiration and mixing. There are no air shutters. No air adjustment is needed.

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CAUTION: DO NOT STACK BOXES OR IN ANY WAY BLOCK AREA IN IMMEDIATE VICINITY OF VENTURIS

3. Pilot burner adjustment may be made by turning the pilot adjusting screw counter-clockwise to increase, or clockwise to decrease flame size. Pilot adjusting screw is on gas valve (see Figure 11).

4. All burners will be bright orange when burning properly and with the temperature control set to cause 5.0 IWC (i.e., high fire) gas pressure on the pressure gauge. A dull red is normal once the set temperature is achieved. "Popping" or burning back at the orifice of the burner is a result of the burner grid being loose or broken, or a faulty gasket under the burner grid.

OR IN ANY OTHER WAY OBSTRUCT FLOW OF COMBUSTION AIR. THE TOP OF THE OVEN IS VERY HOT.

- FIRE WARNING –

FLAMES WILL EXIT FLUE AREA AND COOKING CHAMBER ENDS DURING COOKING

NOTE: IF BURNER IS CRACKED OR BROKEN, OR IF A GASKET IS LEAKING, THE BURNER MUST BE

REPAIRED (see Figure 9).

III. OPERATING INSTRUCTIONS

1. After the power has been turned on, cycle the conveyor ON switch and observe that conveyor is moving and not catching or hanging up on anything. The speed of the conveyor chain should be modulated from low to high, and back again without the chain stopping. Leave the heat switch OFF.

2. The conveyor time selector controls for each conveyor can be set from 30 seconds to 7 minutes 59 seconds. This is the time your food is in the oven as measured from the leading edge of the food starting IN the oven to the leading edge starting OUT of the oven.

3. When the conveyor switch is turned on the temperature display indicates the temperature of the burners. The display will read the approximate room temperature if the heat ON switch has not yet been turned ON.

LIGHTING INSTRUCTIONS

1. Turn exhaust system on.

2. Make sure filters are in place in the hood.

3. Turn conveyor chain on.

4. Remove side covers.

5. Turn gas cock in gas line on.

6. Turn knob on gas valve to on (see Figure 11).

7. Turn on heat switch. Ignition is electronic.

8. If pilot flame or burners fail to light turn heat switch off and wait five minutes before attempting to re-light.

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SHUT-OFF INSTRUCTIONS

1. Turn heat switch off.

2. Turn conveyor switch off.

3. Turn ventilator off.

4. With the heat switch ON, the display will indicate the temperature of the burners. The "SET" temperature is that which is displayed by the pointer of the large knob. The ACTUAL temperature is shown in the window. Allow 20 minutes for warm up in the morning. Your Operations Department has established speed settings for each conveyor, and generally these should not be touched unless authorized by Operations. The combination of cooking time and temperatures have been made to produce your food correctly.

5. The selectors for temperature and time may be adjusted should menu changes take place. CAUTION:

ONLY AUTHORIZED PERSONNEL SHOULD HAVE ACCESS TO THE ADJUSTABLE CONTROLS

PROLONGED POWER FAILURE: NO ATTEMPT SHOULD BE MADE TO OPERATE THE APPLIANCE DURING POWER FAILURE.

IV. SCHEDULED MAINTENANCE

DAILY CLEANING PROCEDURES CAUTION: DO NOT USE OVEN CLEANER ON THIS APPLIANCE. Under no circumstances should oven

cleaner ever be used on this appliance. IT WILL EAT HOLES IN THE ALUMINUM GAS VALVES AND GAS LINES, CAUSTIC FUMES WILL CAUSE ELECTRICAL COMPONENT DAMAGE, AND WILL CAUSE MANY OTHER PROBLEMS IF USED TO CLEAN THIS BROILER.

WARNING: THE REVERBERATING SCREEN (LOCATED UNDER THE TOP BURNERS), IS MADE FROM

INCONEL METAL MESH. THIS MATERIAL DETERIORATES WITH USE. INSPECT SCREEN DAILY AND REPLACE IF SCREEN IS SEVERELY CORRODED. FAILURE TO DO SO CAN RESULT IN METAL PARTICLES BEING SERVED TO YOUR CUSTOMERS.

CAUTION: Do not touch the broiler section immediately after appliance shut-down. The temperature inside

enclosures is in excess of 500°, which eliminates the need to clean any parts inside the enclosures for sanitary purposes. Any grease that may build up on the exterior of the enclosures should be cleaned off with a damp cloth and a minimum amount of detergent. * Never use a large amount of water on the enclosure!!

CAUTION: KEEP THE APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

1. Remove the following items and wash with hot soapy water.

Load Tray - Figure 2 Exit End Tray - Figure 2

2. Wipe conveyors with damp cloth as they cool.

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3. Remove grease residue from any part of remaining broiler structure where visible. Use a damp cloth with detergent and a putty knife for best results.

4. After cleaning all removable parts as noted, allow to dry and reassemble.

QUARTERLY CLEANING PROCEDURES

1. Remove lower burners from both broiler tunnels if examination reveals debris on the burner face.

2. Open conveyors and lay chain aside. Refer to Figure 3 for proper conveyor reassembly.

3. Remove upper burners and screens.

4. By reaching in through openings in upper broiler section, scrape any residue from tops of burner shields.

5. Remove ash and debris from lower broiler section and vacuum inside of broiler tunnel.

6. Reinstall burner screens, burners and conveyor (see Figure 3).

7. Clean gas orifices:

• Orifices are passageways directing gas flow into burner. Uneven gas flow or air to gas ratio is caused by dirty or damaged orifices.

• Orifices are made of brass. Use special care in cleaning—don't gouge or make gas holes bigger.

• To reach orifices, remove burners.

• Use a pipe cleaner dipped in rubbing alcohol to clean orifices. Swab until clean; free of carbon build-up. Do not use drill bit; this damages orifice.

EVERY TWELVE MONTHS

1. Lubricate roller chain very lightly with SAE 30 oil.

2. Remove all motor brushes and replace if less than 1/4" is left (see Figure 4).

3. INVENTORY THE SPARE PARTS KIT AND ORDER MISSING PARTS AS NEEDED. KEEP A COMPLETE

SET OF PARTS ON HAND AT ALL TIMES.

V. PREVENTIVE MAINTENANCE

1. In addition to daily cleaning, there is little preventive maintenance necessary on the Autobroil™. Bearings are high temperature, long-life bearings that need no lubrication. They are shown in Figure 4. After several years of continuous use, it may be necessary to replace the bearings. They should be replaced with bearings obtained from the Factory only, since they are special high temperature type bearings.

2. The drive motors shown in Figure 4 are a DC type motor that employs motor brushes. These brushes should be

checked for wear on a yearly basis. Replace the brushes when they have worn in length to 1/4" or less.

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3. Inspect the roller chain in Figure 2 for slack. There should be at least 1/2" slack on a cold machine or chain will be too tight when the machine heats. Remove any excessive slack by loosening the screws holding the motor in place and sliding the motor to one side to tighten the chain. If no adjustment remains, then shorten the roller chain. Lubricate the roller chains with a few drops of oil as needed.

4. Inspect conveyor for excessive slack. Figure 2 shows the automatic adjustment spring. After all of the adjustment has been used, remove a conveyor link (see Figure 3).

VI. TROUBLESHOOTING

This section contains a list of imagined problems with your Autobroil™ oven. By locating the problem in this section, you may be able to make a quick repair. ALL ELECTRICAL TROUBLE SHOOTING INVOLVING ACCESS INTO THE

MOTORS OR ELECTRICAL ENCLOSURES MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN. ALL ITEMS MARKED WITH ASTERISKS SHOULD BE PERFORMED BY SERVICE AGENCY QUALIFIED TO PERFORM SERVICE ON GAS FIRED APPLIANCES.

1. BURNER BACKFIRES

Flashback, blue flame at entrance to burner makes motor-boating sound like a blow torch. IMPORTANT: if burner backfires, turn it off. Continued operation will cause damage to the entire burner.

POSSIBLE CAUSE:

* A) Burner overtired - manifold pressure too high. Check high and low pressure at the gauge to give

pressure values shown on Page 7. Wait 5 minutes and relight. Flashback will not occur immediately unless a large opening in or around the burner grid is evident. Wait an hour after relighting to check if

problem is solved.

B) Burner grid or burner gasket failure. Replace burner grid or gasket (Figure 9).

2. FLAMES VISIBLE AT UPPER BROILER SECTION FLUE

POSSIBLE CAUSE:

* A) Low gas pressure. Check that gas pressure is not less than 3.0 IWC on natural and 6.0 IWC on

propane.

3. PILOT FLAME GOES OUT

POSSIBLE CAUSE:

* A) Increase size of pilot by adjusting gas quantity. This is accomplished by turning the screw in the top

of valve (see Figure 11).

* B) Remove pilot orifice and clean.

4. PILOT DOES NOT LIGHT

POSSIBLE CAUSE:

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* A) Pilot flame too small. Adjust gas control valve to give a larger pilot flame (see Figure 11).

* B) Low gas pressure. Increase gas pressure to appliance. * C) Pilot orifice clogged. Dislodge debris or replace orifice.

5. BURNER WILL NOT LIGHT AT ALL

POSSIBLE CAUSE:

* A) Orifice. Check that orifice is not plugged. (If it is necessary to change the orifices, new ones must be

B) Check that flame runner is properly mounted and no parts are clogged.

* C) Check that flame runs up arm and turns into upper broiler section.

D) Pilot. Pilot must light and stay lit in order for burner to light. Check pilot problem list.

6. CONVEYOR CHAIN WILL NOT MOVE

POSSIBLE CAUSE:

A) UNPLUG UNIT FROM ELECTRICAL OUTLET.

* B) Check 1 amp fuse on the speed control circuit board.

* C) Check 5 amp fuse (inside control cabinet).

* D) Check on/off switch to make sure power is flowing through the switch.

E) Check for object caught in conveyor, causing a jam.

F) Check to see if motor shaft is moving. If so, then sprocket needs to be tightened on motor or conveyor

ordered from the factory.)

shaft.

G) Check pick-up on end of motor shaft to see if it is in place and if wires are intact (see Figure 4). H) Locate plug in motor cord and disconnect motor electrically. Remove pick-up by snapping black cap

7. NO SPEED CONTROL ON CONVEYORS

POSSIBLE CAUSE:

A) If conveyor runs full speed (30 second cook time) all the time, change the pick-up as described

off of end of blue pick-up and remove screw. To loosen screw it is necessary to grip motor shaft on rear of motor with a 1/4" wrench so the shaft does not turn when applying pressure to screw. Attach pick-up to new motor and with new motor plugged to cord (but not mounted) see if motor runs. If so, then install new motor. If not, then change circuit board.

in Item 6H.

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* B) Connect the wires from the board of the conveyor with no control onto a spare circuit board. If

* C) If connecting the wires into the spare board does make it work, then the circuit board has failed.

8. REPEATED MECHANICAL BINDING

POSSIBLE CAUSE:

A) Check for excessive conveyor slack. See Page 10, Item 4 under Preventive Maintenance.

B) Check to see that chain is not on backwards. See proper chain installation on Figure 3.

there is still no control, the speed selector for that conveyor has failed.

C) Inspect chain closely for bent or warped links that may be hanging up and causing a

D) Visually inspect the motor drive chain assembly for smooth rotation of chain and make

E) Make sure the axle assembly is clean and free of grease and food residue to allow smooth

F) Check the axle assembly to make certain all set collars, bearings, etc. are properly

G) Disassemble conveyor axle assembly and check condition of green bearings for excessive wear.

9. FOOD IS COOKED INCONSISTENTLY

A) Check for correct conveyor speed and temperature. B) Check for gas pressure at gauge. It should average around 3" pressure under no load.

C) Make sure both top and bottom burners are glowing dull red at low temperature settings and bright

D) Check that high and low gas pressures are as shown on Page 7 when temperature controller is

E) Check that food is being held at consistent temperature. (Food will be inconsistent if some is partially

binding condition. Also check that the chain links are not climbing out of the sprockets as the conveyor rotates.

certain there is no binding or worn components. Check for proper slack per Item 3 bottom of Page

10.

movement of the conveyor.

positioned and secure.

orange at high temperature settings.

set at High and Low settings.

frozen and some is properly thawed.)

** INSTRUCTIONS MARKED WITH ASTERISKS SHOULD BE PERFORMED BY A QUALIFIED SERVICE

COMPANY.

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1. TUNNEL DISASSEMBLY In order to perform regular maintenance and accomplish repairs as needed, the broiler sections are assembled

as shown in Figure 10. These items are as follows:

A) Burner (four required - two on upper and two on lower section) B) Upper Tunnel Assembly C) Upper Burner Screens and Brackets

D) Lower Tunnel Assembly E) Orifice F) Burner Shield

2. BURNER REMOVAL Access to remove the bottom burners is gained by removing the front and rear center sideskins. The burner is

removed by unlocking the locking mechanism on the end of the burner as shown in Figure 2 (Item #109003).

3. GRID REPLACEMENT The burner grid (Figure 9) may be replaced by removing the six screws from both sides of the burner housing.

The assembly will then slip out. Remove all old gasketing and replace it as shown. Compress the assembly into the burner housing with hand pressure all around the outside of the burner housing. Next, place the assembly on a flat strong surface, such as a cement floor, and push the burner housing down to drive the grid frame into the housing. Insert new screws and tighten the screws in a staggered sequence. Do not over tighten screws. While pushing on the back of the burner housing with one hand, drive the screws in until the head of the screw comes in contact with the burner housing. These screws will keep the frame tight against the gasket, and yet will not bend the grid which causes cracked ceramics.

VII. ASSEMBLY & DISASSEMBLY INSTRUCTIONS

NOTE: IT IS IMPORTANT THAT THE NEW GASKET BE HELD IN PLACE WHILE ATTACHING NEW GRID. THIS IS

4. GAS LINE RESTRAINING DEVICE (Figure 12)

5. THERMOCOUPLE

EASILY ACCOMPLISHED BY RUBBING A SMALL AMOUNT OF PETROLEUM JELLY ALONG THE INSIDE UP OF THE BURNER HOUSING.

The restraining device is a separate line and should be no less than 6" away from the gas connector and in a parallel position. The following instructions refer to Figure 12. By using the adjusting clips (1) alter the length of the cable (2) so that the overall length (3) is 3" to 6" shorter than the length of the gas connector including the fitting. Then attach staple (4) to an existing wall or other architecturally sound surface. Attach scissor hook (5) to staple and secure with cotter pin. Finally attach spring hook (6) to gas appliance. Make certain that the overall length is 3" to 6" shorter than the gas connector at this point.

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When replacing the thermocouple which attaches to the temperature controller (see Figure 8).

WARNING: THIS APPLIANCE IS NOT CAPABLE OF BEING SAFELY PLACED INTO OPERATION DURING

WARNING: NOTE HOW ALL ELECTRICAL WIRING HAS BEEN ROUTED AND IS TIED IN PLACE. THIS IS

A POWER FAILURE AND NO ATTEMPT TO OPERATE IT SHOULD BE MADE.

VERY IMPORTANT TO PREVENT ELECTRICAL INTERFERENCE GENERATED IN THE SPARK PLUG WIRE FROM TRAVELING THROUGH OTHER WIRES INTO THE MOTOR SPEED CONTROLS AND DAMAGING THESE CONTROLS. SERVICE TECHNICIANS MUST ROUTE AND TIE WIRING BACK THE WAY IT WAS FROM THE FACTORY WHENEVER CHANGING OUT COMPONENTS.

VIII. REPLACEMENT PARTS

When ordering parts, make sure to specify the machine model number, type of gas and serial number as shown by the label attached to the right side cover.

PARTS DESCRIPTION LOCATION

101096 Burner Grid Figure 9 101978 Burner Gasket Figure 9 102650 Burner Grid Assembly Figure 9 105408 End Panel Figure 2 105418 Drive Shaft Figure 2 105419 Side Skin Center (Fits Either Side) Figure 2, 15 105446 Tray Loading F12 Standard Not Shown 108352 Burner Housing Figure 9 108407 Burner Screen Figure 10 108554 Burner- Complete Figure 9,10 108604 Burner Shield - Lower Figure 8,10, 14 108747 Idler Mesh Not Shown 108749 Bearing Mount Assembly Figure 2,4 108768 Drive Sprocket 1/2" Figure 2A 109003 Burner Lock Asby (Rear) Figure 2 109516 Bearing Retainer Assembly Figure 4 111826 Chain Guard Cover Figure 2, 13

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111827 Side Skin End Figure 2, 13 111830 Tray - Load Short Figure 2 111833 Exit End Tray Figure 2 111887 Flame Runner Assembly - Upper Figure 2 111891 Aluminum Tube - Flame Runner Figure 2 111892 Aluminum Tube - Pilot Figure 2 111897 Conveyor Support Assembly (One Support) Figure 2 111984 Burner Screen Retainer Figure 10 111987 Thermocouple Fitting Figure 8 111988 Conveyor Idler Assembly Not Shown 112075 Cord 9' W/90E Plug Not Shown 112090 Restrictor Disk, Carry-Over Tube For Part #112182 Figure 10 112182 Lower Carry-Over Tube, LP, Old Style Figure 10 112183 Carry-over Tube, Nat, Old Style Not Shown 113744 Sprocket Conveyor Drive -1/2" Bore Figure 2,4 113753 Carry-Over Tube - Lower Figure 10 115676 Grease Drain Figure 13 115678 Grease Cup Figure 13 115711 Grease Pan Short Figure 13 115712 Grease Pan Long Figure 13 116976 Loading Tray System Figure 13 118503 Complete Chain 2 FT. - 26 Links Figure 2 118941 Exiting End Tray Figure 13 118942 End Tray Insert Figure 13 120070 Burner Wire Mesh Figure 14 120116 Sprocket Drive 3516 x 1/2" Figure 2 130657 Kit, Motor Reversing N/A 131172 Circuit Board w/mount Figure 6, 7

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132933 Burner Lock Asby (Front) Figure 2 500001 Burner Screw Figure 9 500002 Idler Bearing on Take-up Shaft - Rod or Mesh Figure 2 500025 Conveyor Belt - Rod Figure 2,3 500035 Roller Chain #35 Figure 2 500067 Fuse Block Figure 6 500070 Gas Gauge (Natural) Figure 11,15 500071 Gas Gauge (LP) Figure 11 500083 Roller Chain Half Link Not Shown 500092 Roller Chain Master Link Not Shown 500104 Orifice #53 - Lower Burner (Natural) Not Shown 500107 Orifice Fitting 3307 1/4" FPT Figure 15 500117 Set Collar 1/2" ID-Plated Figure 2 500263 Leg - 4.0" Figure 2 500340 Terminal Strip Figure 6 500392 Jumper Figure 6 500469 Orifice #54 - Upper Burner (Natural) Not Shown 500926 Orifice #77 - Flame Runner (LP) Not Shown 500935 Fuse Non 5 Amp (In Control Cabinet) Figure 6 500940 Drive Motor Figure 2,4 500941 Motor Brush for Motor A29894G" Figure 2,4 500957 Switch, Heat & Conveyor Figure 5,7 500961 Bearing Figure 4 500965 Keylock Figure 5 500989 Conveyor Belt-Mesh 12" Figure 2A,3A 501024 Orifice #63 (LP) - Upper & Lower Burner Not Shown 501225 Conveyor Belt Space Clip for 6" Mesh Figure 3A 501239 Conveyor Belt - Mesh 6" Figure 3A

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501614 Ignition Module Figure 6 501671 Key Figure 5 501709 Orifice - Pilot Burner (Natural) Not Shown 501710 Orifice - Pilot Burner (LP) Not Shown 501718 Orifice #70 - Flame Runner (Natural) Figure 2 501723 Igniter Pilot Burner (Natural) Figure 2 501747 Transformer 24V Figure 6 501762 Igniter Pilot Burner (LP) Figure 2 501806 Fuse AGC 1 Amp (On Circuit Board) Figure 6,7 501991 Pick-up Figure 4 502127 Conveyor Belt Space Clip for 12" Mesh Figure 3A 502188 Gas Valve (Natural) Figure 11,15 502189 Ignition Cable #36 Figure 2 502191 Temperature Controller Figure 5 502193 Gas Valve Modulating (Natural) Figure 11,15 502196 Sprocket - Drive 3515 X 1/2" (Broiler Motor) Figure 2 502197 Thermocouple Figure 8 502199 Conveyor Tensioner Spring Figure 2 502202 Gas Valve (LP) Figure 11,15 502203 Gas Valve Modulating (LP) Figure 11,15 502213 Leg - 2.5" Figure 2 502261 Corrugated Gas Tube - Top or Bottom Burner Figure 15

502263 Corrugated Gas Tube - Burner Main Feed Figure 10

502349 Gas Flex-Tube (1/2") x 36" Figure 15

502631 Gas Flex-Tube (5/8") x 12" Figure 15

503287 Motor Brush for Motor A type 24Y2FETM-D4" Not Shown

503383 Tee: 3/8" FL x 3/8" FL x 1/2" FL Figure 15

503529 Jumper, Circuit Board (2) Pin Figure 16

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PERFORMANCE CRITERIA - PROPANE GAS

1. The manifold pressure for each burner and appliance inlet pressure and gas amount is listed below:

TYPE OF GAS - Propane

PRESSURE AT THE APPLIANCE - 11.0 IWC for Propane

MANIFOLD PRESSURE - Low 4.5 IWC; High 9.5 IWC for Propane

w/units before S/N :10972304 Low 5.5; High 9.5 IWC for Propane

TOTAL GAS AMOUNT - 46,000 BTUH @ 100% High Fire

Manifold pressure is measured by a pressure gauge on the outlet side of the gas valve. With the unit on for at least fifteen minutes and the broiler temperature controller set at 600 F, the pressure should be at 4.5 IWC. Now set the broiler temperature controller to high and note that high fire pressure is 9.5 IWC. These valves are factory set. If high pressure settings do not come up to specification, check for at least 11" line supply pressure. Refer to Figure 11 - information is shown on gas pressure high and low range adjustment.

CAUTION: DO NOT STACK BOXES OR IN ANY WAY BLOCK AREA IN IMMEDIATE VICINITY OF

VENTURIS OR IN ANY OTHER WAY OBSTRUCT FLOW OF COMBUSTION AIR. THE TOP OF THE OVEN IS VERY HOT.

--FIRE WARNING --

FLAMES WILL EXIT FLUE AREA AND COOKING CHAMBER ENDS DURING COOKING

3. Pilot burner adjustment may be made by turning the pilot adjusting screw counter-clockwise to

increase, or clockwise to decrease flame size. Pilot adjusting screw is on gas valve (see Figure 11).

4. All burners will be bright orange when burning properly and with the temperature control set to cause 11 IWC (i.e., high fire) gas pressure on the pressure gauge. A dull red is normal once the set temperature is achieved. "Popping" or burning back at the orifice of the burner is a result of the burner grid being loose or broken, or a faulty gasket under the burner grid.

NOTE: IF BURNER IS CRACKED OR BROKEN, OR IF A GASKET IS LEAKING, THE BURNER MUST BE

REPAIRED (see Figure 9).

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BROILER LIMITED WARRANTY

MARSHALL AIR SYSTEMS, INC., ("Marshall") warrants to the first purchaser ("Purchaser") all new equipment of its manufacture to be free of defects in material and factory workmanship for a period of one year* from date of shipment provided that (i) the equipment is installed in the Continental United States, Canada or Hawaii and operated according to the Owner's Manual while located at the original address of installation, (ii) the warranty registration card has been completed and returned to the factory within fifteen (15) days after installation, and (iii) a post-installation start-up has been performed by an authorized service representative (portable equipment not applicable). Marshall's obligation under this warranty is limited to the repair or replacement at its option of any defective part. Under certain circumstances, Marshall will reimburse Purchaser for limited labor costs in replacing parts during a period of not more than ninety (90) days after date of shipment, provided that Labor Reimbursement instructions are followed and items i, ii, and iii above are completed. See special provision for portable equipment. It is understood that Marshall's obligation with respect to equipment located outside the Continental United States, Canada or Hawaii is limited to replacement parts only.

*The following broiler parts have a six month part warranty:

• Burner Shields and Screens

• Burner Grids

• Burner Gaskets

• Electric Broiler Elements

• Flame Runners

Because Marshall does not and cannot control Purchaser's installation, use, and maintenance of equipment manufactured by Marshall, this warranty DOES NOT COVER:

Any equipment calibration;

Any component disassembled in the field;

Damage due to improper cleaning and/or abuse, i.e. burner rotation, grease accumulation in electrical components or plugs (hosing or "watering down" equipment will cause electrical failures not covered by warranty);

Blown fuses or bulbs, motor brushes and Teflon components;

Any replacement parts used on the equipment which are not purchased from Marshall;

Accessory components not installed or manufactured by Marshall.

Shipping damage must be reported to the carrier and is not covered under this warranty. Marshall will not be liable for damage as a result of improper installation, misuse, abuse, alteration of original design, incorrect voltage, unauthorized service, breakage of fragile items, or any other damage caused by an act out of Marshall's control.

The effect of corrosion, fire, and normal wear on the equipment or component parts is not covered by this warranty. This warranty does not cover cooking performance, smoke capture or holding temperatures which is a function of food types, textures, temperatures, equipment line ups and other variables chosen by the Purchaser and over which Marshall has no control. This warranty does not apply to damage caused by accident or to damage caused by the negligence of Purchaser or the employees of Purchaser or to damage caused by lightning generated electrical current or any other Act of God whatsoever. This warranty does not apply to any equipment bearing a serial number which has been tampered with or altered. Marshall reserves the right to accept or reject any such claim in whole or in part. Marshall will not accept the return of any product without prior written approval from Marshall, and all such approved returns shall be made at Purchaser's sole expense.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, OR PATENT OR OTHER INTELLECTUAL PROPERTY RIGHT INFRINGEMENT, AND EXCEPT FOR THE EXPRESS WARRANTY CONTAINED HEREIN, THE EQUIPMENT IS SOLD "AS IS." REMEDIES UNDER THIS WARRANTY AND UNDER ANY WARRANTY THAT MAY SURVIVE THE DISCLAIMER OF WARRANTIES ARE LIMITED EXCLUSIVELY TO THOSE REMEDIES DESCRIBED ABOVE. NO OTHER REMEDY IS AVAILABLE UNDER THIS WARRANTY OR ANY OTHER WARRANTY. NEITHER THIS WARRANTY NOR ANY OTHER WARRANTY COVERS, AND MARSHALL WILL NOT BE RESPONSIBLE FOR, ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO THE COST OF DISASSEMBLY AND SHIPMENT OF THE EQUIPMENT, PRODUCTION OR PRODUCT LOSSES, INJURY TO OTHER PROPERTY, OR LOST PROFITS RESULTING FROM THE USE OF OR INABILITY TO USE THE PRODUCTS OR FROM THE PRODUCTS BEING INCORPORATED IN OR BECOMING A COMPONENT OF ANY OTHER PRODUCT OR GOODS, OR OTHER LOSSES. WHERE, DUE TO OPERATION OF LAW, CONSEQUENTIAL AND INCIDENTAL DAMAGES CANNOT BE EXCLUDED, THEY ARE EXPRESSLY LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THE EQUIPMENT.

FOR INTERNATIONAL INSTALLATIONS -- PLEASE CONTACT YOUR LOCAL MARSHALL AIR SYSTEMS RECOGNIZED DISTRIBUTOR.

LIMITED. BRL. DOC

Page 21

BROILER WARRANTY PROCEDURES

RETURN GOODS AUTHORIZATION FOR PARTS - FACTORY DIRECT

For prompt warranty parts replacement and RGA processing, please call Marshall's Customer Service Department at 800-722-3474 or 704-525-6230 for assistance. In all cases, a Return Goods Authorization (RGA) number must be issued by Marshall Air Systems, Inc. Unauthorized returns will not be processed.

Option #1: Purchaser to return part prepaid to Factory, Marshall to repair or replace at own

expense if defective, and ship part back to Purchaser prepaid.

Option #2: Marshall to furnish replacement part freight prepaid with or without requesting return of

the defective part.

WARRANTY LABOR REIMBURSEMENT AND/OR PARTS REPLACEMENT THROUGH RECOGNIZED MAINTENANCE & REPAIR CENTERS

Normally, labor will be covered under the start up fee. In the unlikely event this does not apply, consult Marshall Air Systems, Inc. To be reimbursed for warranty labor costs, authorization must be given by Marshall Air Systems, Inc. Unauthorized work will not be reimbursed. Work must be performed by a Marshall Air Systems Recognized Service Agency within the service time allowance guidelines and must be submitted along with failed parts (if applicable) to Marshall Air Systems (freight prepaid) within 30 days of the work being performed. Travel is covered, but must not exceed 50 miles or 1 hour, whichever is greater. Call Marshall's Service Department at 800-722-3474 or 704-525-6230 with any questions. Service is to be performed by recognized service agencies during normal working hours. Owner to pay for all other charges including excessive travel or overtime charges. DIAGNOSTIC LABOR CHARGES ARE INCLUDED IN SERVICE TIME ALLOWANCE GUIDELINES. All portable equipment (under 90 pounds) shall be delivered by Purchaser, at his/her expense, to the nearest authorized service agency for in-shop repair or at purchaser's discretion he/she will pay all travel time and mileage expenses for portable equipment.

NON-WARRANTY RETURNS:

All items returned for customer convenience are subject to a 20% restocking fee. In the event of an error by Marshall Air Systems, Inc., a Returned Goods Authorization will be issued for full credit.

FOR INTERNATIONAL INSTALLATIONS -- PLEASE CONTACT YOUR LOCAL MARSHALL AIR SYSTEMS RECOGNIZED DISTRIBUTOR.

PROCEDUR.BRL DOC

Page 22