Merco C-40 Service Manual
PARTS & SERVICE for C-40VS/C-40 Vertical Conveyor Toaster
The C-40VS and C-40 are high volume conveyor toasters, constructed of
brushed Stainless Steel. The C-40VS has a variable speed control enabling
the toasting of not only bread, but English Muffins, bagels, as well as buns,
with one pass through the conveyor. Standard features for both machines
include variable heat and bun-toast switch for toasting on one or both sides.
Each is available in 208V or 240V, single phase (Check data plate).
NOTICE
All repair operations described in this Manual should only
be carried out by a Savory Certified Service Technician.
05-02kdl 07015
IMPORTANT
Disconnect power before attempting service or
disassembling components.
Servicing: All electrical and drive components are
accessible for servicing by removal of the right side
panel. Remove the two screws from underside of
panel and pull handle to release.
A On/Off Switch Replacement:
1. Remove right side panel.
2. Remove two retaining screws from front panel.
3. Disconnect wiring harness from switch terminals.
4. Connect wiring harness to new switch and install
switch in panel. Refer to wiring diagram.
B Bun/Toast Switch Replacement:
1. Remove right side panel.
2. Disconnect wiring harness from switch terminals.
3. Depress two spring clips on top of switch and tilt
switch forward.
4. Insert the new switch into the panel opening,
snapping snugly into place.
5. Reconnect the wiring harness to the terminals.
Refer to wiring diagram.
C Thermostat Replacement:
(Refer to Figure #3)
1. Remove left and right side panels.
2. Remove insulation
NOTE: The wiring harness must be disconnected from
heating elements to remove insulation on right side.
Hold terminals with pliers to prevent bending. (Figure
#4)
3. Remove rear heating element. (Refer to Section D)
4. Remove wire guard. (Refer to Section O)
5. Remove two baskets from conveyor chain, then
rotate the chain so that this opening is at the
bottom directly under the thermostat bulb.
6. Pull off thermostat knob.
7. Remove the two retaining screws from front panel.
8. Remove wires from thermostat.
9. Push as much capillary tube as possible through
the plastic grommet located on the upper portion
above the shelf and pull thermostat bulb out of the
hole.
10. Feed capillary tube and bulb through plastic
grommet into the lower portion below shelf and
remove from toaster.
11. To install new thermostat, feed bulb and tube
through bottom of plastic grommet.
CAUTION: Avoid sharp bends or kinks in the capillary
tube as this will create restrictions preventing proper
thermostat operation.
12. Insert bulb into hole and through center guide.
The bulb can be seen through the openings for the
wire guard and read heater element.
13. Push bulb through hole in left side inner panel. It
can be manually guided by reaching through rear
delivery opening and up through opening in
conveyor where baskets have been removed. Bulb
should be extended about 1-1/2” from left inner
panel.
14. Attach wires to thermostat. (Refer to wiring
diagram)
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15. Install new thermostat with two screws and replace knob.
16. Position the balance of tube so it runs from bottom of
thermostat along inside of front panel. Coil excess parallel to
and under shelf. Make certain tube is away from all electrical
connections.
17. Check tube positioning before replacing panel to be sure the
tube will clear all electrical connections.
18. Replace heater element, wire guard, insulation, heater wires,
(refer to wiring diagram) and side panels.
D Heater Unit Assembly Replacement:
(Refer to Figure #5)
1. Remove right panel.
2. Holding the heater connections with pliers to
prevent bending, remove the three screws
retaining the wiring harness on the heater
connections of the unit being replaced.
(Figure #4)
3. Remove insulation.
4. Remove the two screws holding heater
element to inside panel.
5. Slide heater unit out the side.
NOTE: Because of air space required in some
heating elements they may not easily pass thru the
opening. If element does not slide out completely,
remove left side panel, insulation and wire guard.
(Refer to Section O). Use a suitable “flat” tool
such as a yardstick or 24” ruler and insert through
wire guard opening. Gently pry heating element at
curvature so it can clear opening and slide out.
(Figure #6)
Figure 6
Figure 5
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6. Slide new heater unit into place and fasten
with two screws.
7. Replace insulation.
8. Reconnect wiring harness (Refer to Wiring
Diagram). Hold heater terminals with pliers.
Be sure all connections are tight and jumper
has been installed between upper heater unit
connections.
E Individual Heater Element
Replacement:
Each heater unit is equipped with two
elements.
These may be replaced individually as
follows:
1. Remove heater unit as described in Section
D.
2. Place unit on a flat surface and remove
jumper and the two screws, nuts and
retainers.
3. Bend holding tabs away from element and lift
out at an angle that will let terminal ends clear
holes.
4. When replacing elements, make certain that
element with “raised bend” is on top and
“flat” on bottom. There should be air space
at points circled in (Figure #7). Elements
must not touch at these points.
F Motor Replacement:
(Refer to Figure 8, 9 & 9A)
1. Remove right side panel.
2. Disconnect motor lead wire from terminal block and
conveyor speed control (and or P.C. board if your unit
contains one). Or on-off switch on C-40 only units.
3. Remove two mounting bolts from under toaster that attach
motor bracket. Slip off drive chain.
4. Lift out motor and bracket assembly and remove four
screws holding motor to bracket.
5. Using 1/16” Allen wrench, loosen Allen screws and remove
clutch sprocket from motor shaft.
6. Mount clutch sprocket on new motor shaft and mount new
motor on bracket.
7. Install motor and bracket assembly attaching with the two
mounting bolts. Do not tighten bolts.
8. Mount drive chain on sprocket by sliding motor to the left
then adjust chain by sliding motor to the right (Figure #8).
Tighten bolts.
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208V-21107
240V-21109
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