Pitco 12MCD Installation Manual

Installation, Operation, and Maintenance Manual

For McDonald's Gas Fryer

Counter Top Models

12MCD

NOTICES

There are three different types of notices that you should be familiar with, a NOTICE, CAUTION, and
WARNING. A NOTICE is a special note used to call attention to a particularly important point. CAUTION
is used to point out a procedure or operation which may cause equipment damage. The WARNING notice is
the most important of the three because it warns of an operation that may cause personal injury. Please
familiarize yourself with your new cooker before operating it and heed the notices throughout this manual.
The WARNINGS are listed below and on the following page for your review prior to operating the unit.

FOR YOUR SAFETY

DO NOT store or use gasoline or other flammable vapors or

liquids in the vicinity of this or any other appliance.

WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury
or death. Read the installation, operating and maintenance
thoroughly before installing or servicing this equipment

TO THE PURCHASER

POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE
FOLLOWED IN THE EVENT THAT AN OPERATOR SMELLS
GAS. OBTAIN THIS INFORMATION FROM YOUR LOCAL
GAS SUPPLIER.

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE

SAFETY SAFETY SAFETY SAFETY SAFETY

There is an open flame inside the fryer. The unit may get hot enough to set near by
materials on fire. Keep the area around the fryer free from combustibles.

DO NOT supply the fryer with a gas that is not indicated on the data plate. If you need
to convert the fryer to another type of fuel, contact your dealer.

DO NOT use an open flame to check for gas leaks!

Wait 5 minutes before attempting to relight the pilot to allow for any gas in the fryer to
dissipate.

Never melt blocks of shortening on top of the burner tubes. This will cause a fire, and
void your warranty.

Water and shortening DO NOT mix. Keep liquids away from hot shortening.
Dropping liquid frozen food into the hot shortenin g will cause violent boiling.

At operating temperature the shortening temperature will be greater than 300°F.
Extreme care should be exercise when working with hot shortening to avoid
personnel injury.

Ensure that the fryer can get enough air to keep the flame burning correctly. If the
flame is starved for air it can give off a dangerous carbon monoxide gas. Carbon
Monoxide is a clear odorless gas that can cause suffocation.

SAFETY SAFETY SAFETY SAFETY SAFETY

Table of Contents

......................................…………..

Section Title

Safety Notice

List of Tables and Figures …………………………………………………………………….

Chapter I: General Information and Installation......................................................……………......... 1-1

1.1 INTRODUCTION..................................................................................................…………. 1-1

1.2 CHECKING YOUR NEW FRYER .......................................................................………… 1-2

1.2.1 Check Your Order ............................................................................................………….. 1-2

1.2.2 Heat Deflector Installation ...............................................................................………….. 1-2

1.3 INSTALLATION..................................................................................................………….. 1-3

1.3.1 Installation Clearances......................................................................................………….. 1-3

1.3.2 Gas Connection.................................................................................................………….. 1-3

1.3.2.1 Fuel Types ..................................................................................................…………… 1-4

1.3.2.2 Fuel Supply Line Leak and Pressure Testing.............................................……………. 1-4

1.3.2.3 Gas Line Connection....................................................................................…………. 1-4

1.3.3 Ventilation and Fire Safety Systems .................................................................………….. 1-5

1.4 INITIAL ADJUSTMENTS..............................................

1.4.1 Visual Checks.....................................................................................................………….. 1-6

1.4.2 Burner Ignition Systems.....................................................................................………….. 1-7

1.4.2.1 Lighting the Pilot Light................................................................................………….. 1-7

1.4.2.2 Pilot Flame Adjustment................................................................................………….. 1-8

1.4.3 Main Burner System...........................................................................................………….. 1-9

1.4.3.1 Gas Line Requirements ...............................................................................………….. 1-10

1.4.3.2 Burner Adjustment ......................................................................................………….. 1-10

1.4.4 Initial Cleaning..................................................................................................………….. 1-11

1.4.5 Thermostat Calibration......................................................................................………….. 1-12

Page

i -ii

iii

1-6

Chapter 2: Operating Instructions……………………………………………………………………… 2-1

2.1 FILLING THE FRYER.............................................................................................………….. 2-1

2.1.1 Filling the Fryer With Liquid Shortening ...........................................................………….. 2-1

2.1.2 Filling the Fryer With Solid Shortening..............................................................………….. 2-1

2.2 OPERATING INSTRUCTIONS ..............................................................................………….. 2-2

2.2.1 Fryer Start-Up......................................................................................................………….. 2-2

2.2.2 Fryer Shutdown...................................................................................................………….. 2-2

2.3 DAILY CLEANING.................................................................................................………….. 2-3

i

Table of Contents (Continued)

Section Title

CHAPTER 3: Maintenance, Adjustments, and Service...........………………….................................... 3-1

3.1 WEEKLY FRYER CLEANING (BOIL OUT)....................................................................... 3-1

3.2 FLUE AND BAFFLE INSPECTION ...................................................................................... 3-2

3.3 SERVICE ............................................................................................................................... 3-2

3.3.2 Replacement Procedures.................................................................................................... 3-2

3.3.1.1 Main Burner Removal and Replacement...................................................................... 3-2

3.3.1.2 Changing the Main Burner Orifice.............................................................................. 3-2

3.3.1.3 Replacing the Heat Baffles .......................................................................................... 3-3

3.3.1.4 Pilot Burner Removal and Replacement..................................................................... 3-3

3.3.1.5 Pilot Orifice Replacem ent ........................................................................................... 3-3

3.3.1.6 Thermopile Replacement............................................................................................ 3-3

3.3.1.7 Temperature Control Board Replacement................................................................... 3-4

3.3.1.8 Limit Control Replacement.......................................................................................... 3-4

3.3.1.9 Thermostat Probe Replacement.................................................................................... 3-5

3.4 TROUBLESHOOTING.......................................................................................................... 3-6

3.4.1 Troubleshooting Fryers With Unitrol Valves.................................................................... 3-7

3.4.2 Troubleshooting Pilot Lights............................................................................................. 3-8

3.4.3 Troubleshooting Thermostat Systems ............................................................................... 3-9

Page

CHAPTER 4: Parts ......................................................................................................………………...... 4-1

ALPHABETICAL PART LIST ..........................................................………………............ 4-4

NUMERICAL PART LIST.......................................................………….............................. 4-5

ii

List of Tables and Figures

Table Title Page

1-1 Fryer Specification ................................................................................................................ 1-1

1-2 Ventilation and Fire Safety References................................................................…………. 1-5

4-1 Counter Top 12 Exploded View (Index)...............................................................………… 4-3

Figure Title Page

1-2 Main Burner Conditions........................................................................................………… 1-9

1-3 Gas Valve Showing Location of Pressure Regulator and Pilot Adjusters ............……….. 1-10

1-4 Air Collar .............................................................................................................…………. 1-11

4-1 Counter TOD 12 Exploded View...........................................................................………….. 4-2

iii

Chapter 1: General Information and Installation

The frying system you have selected for your establishment has been designed by Pitco Frialator to
meet the requirements of the McDonald's organization. This unit will give you many years of
reliable service if you follow the simple operation and maintenance procedures in this manual. This
manual contains the general installation, operation, and maintenance procedures for the
McDonald's counter top models.

1.1 INTRODUCTION

All models come standard with manual pilot light systems and built in safety devices. To find out
which model you have. look at the identification plate inside the door. This plate has a lot of useful
information, but to identify which fryer you have, look at the model number block. The model
number identifies which fryer and what features you have.

Table 1-1 Fryer Specifications

Specification Description

Domestic Units
(USA)

International Units

(Metric)
Hourly Gas Input 65,000 BTUs 16,380 KCal
Number of Heat Tubes 3 3
Hourly French Fry Production 45 Lbs. 20.4 Kgs.
Minimum Fat Capacity 30 Lbs. 13.61 Kgs.
Frying Area 12" x 12" 30.5x30.5cm
Frying Depth 3-5/8" 9.2cm
Drain Valve Size 1" NPT 2.54 cm
Shipping Weight 114 Lbs. 52.7 Kgs.
Gas Connection Size 1/2" 1.27cm

1-1

1.2 CHECKING YOUR NEW FRYER
Your new fryer has been carefully packed. Every effort has been made to ensure that your fryer will be

delivered to you in perfect condition. As you unpack your new fryer, inspect each of the pieces for damage. If
something is damaged, DO NOT sign the bill of lading. Contact the shipper immediately, the shipper is only
responsible for 15 days after delivery. Check the packing list enclosed with your fryer to ensure that you have
received all of the parts to the fryer. If you are missing any parts, contact the dealer from whom the fryer was
purchased.

1.2.1 Check Your Order

The crate containing the fryer unit will also contain the following:

(1) Flue Heat Deflector per fryer (1) Brush
(1) Fry Basket Hanger per fryer (2) Pitco Cleaner Sample
(1) Drain Clean Out Rod (1) Drain Extension

1.2.2 Heat Deflector Installation
If the fryer requires a heat deflector, you will find a removable label at the rear top edge of the unit. This label

has instructions for positioning and installation of the heat deflector. Refer to the label and the instructions
below to install the deflector.

a. Remove the two self -drilling screws from the top, back area of the cooker.

b. Position the heat deflector so that the angled portion of the deflector is facing toward the front of

the fryer. Secure the heat deflector to the back of the unit using the sheet metal screws previously
removed.

DO NOT obstruct the flow of combustion/ventilation or air openings around the fryer
as this may cause the build up of dangerous gases. Adequate clearance around the
fryer is necessary for servicing and proper burner operation. Ensure that you meet the
minimum clearances specified in the installation instructions.

c. When properly installed the angled section of the heat deflector will extend over the flue opening

to redirect the heat. It SHOULD NOT cover the flue opening. Nothing should block the flue
opening as this will cause the fryer to overheat and produce dangerous gases.

1-2

6" 0"

1.3 INSTALLATION

The fryer must be secured to the counter top to prevent movement. Accidental
movement of the fryer during operation may cause oil to splash out of the fryer. Hot
oil WILL cause severe bums.

Although it is possible for you to install and set up your new fryer, it is STRONGLY recommended that you
have it done by qualified professionals. The professionals that install your new fryer will know the local
building codes and ensure that your installation is safe.

1.3.1 Installation Clearances
The fryer needs clearance around it for proper operation. Adequate clearances allow for servicing and proper

burner operation. The clearances shown below are for cooker installation in combustible and non­combustible construction.

Back 6" 0"
Sides

Combustible
Constructio n

Non-Combustible
Construction

1.3.2 Gas Connection
Your fryer will give you peak performance when the gas supply line is of sufficient size to provide the

correct gas flow. The gas line must be installed to meet the local building codes or National Fuel Gas Code
(NFPA 54-1984) and ANSI Z223. 1 -1988. In Canada, install the fryer in accordance with CAN-CGA 1-B

149.1, .2 and local codes. Gas line sizing requirements can be determined by your local gas company by
referring to Nationa l Fuel Gas Code, Appendix C, Table C-4 (natural gas) and Table C-16 (propane). The gas
line needs to be large enough to supply the necessary amount of fuel to all appliances without losing pressure
to any appliance. Other factors that are used to determine the piping requirements are BTU requirements of
the appliances being connected and the length of pipe between the meter and the appliances.

NEVER supply the fryer with a gas that is not indicated on the data plate. Using the
incorrect gas type will caus e improper operation. If you need to convert the fryer to
another type of fuel, contact your dealer.

1-3

1.3.2.1 Fuel Types - Each fryer is equipped to work with one type of fuel. The type of fuel with which the
appliance is intended to operate is stamped on the data plate attached to the inside of the door.

DO NOT use an open flame to check for gas leaks!

1.3.2.2 Fuel Supply Line Leak and Pressure Testing - The fuel supply system must be tested before the
fryer is used. If the fuel line is going to be tested at a pressure greater than (>)1/2 PSIG (3.45 kPa),
make sure that the fryer is disconnected from the fuel line. If the fuel line is to be tested at a
pressure equal to or less than ([) 1/2 PSIG (3.45 kPa), the fryer can be connected but the unit's gas
valve must be shut. Test all gas line connections for leaks with a solution of soap and water when
pressure is applied.

1.3.2.3 Gas Line Connection - Connect the fryer to the gas supply line with a connector that complies with
the Standard for Connectors for Movable Gas Appliances (ANSI Z21.69/ CAN-CGA-6.16).

NOTICE

NEVER use an adaptor to make a smaller gas supply line fit the cooker connection.
This may not allow proper gas flow for optimum burner operation, resulting in poor
cooker performance. NEVER supply the cooker with any fuel other than the type
indicated on the data plate. Using the inc orrect gas type will cause improper
operation.

1-4

1.3.3 Ventilation and Fire Safety Systems
Your new fryer must have proper ventilation to function safely and properly. Exhaust gas temperatures can

reach as high as 1200°F. Therefore, it is very important to install a fire safety system. Your ventilation
system should be designed to allow for easy cleaning. Frequent cleaning of the ventilation system and the
fryer will reduce the chances of fire. Table 1-2 provides a list of reference documents that provide guidance
on ventilation and fire safety systems. This table is not necessarily complete. Additional information can be
obtained from the American Gas Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

Table 1 -2 Ventilation and Fire Safety References

Topic

Underwriters Laboratory
Document

National Fuel Gas Code
Document

Grease Extractor ANSI/UL710-1981 ANSI/NFPA 96-1987
Ventilation Hood ANSI/UL 705-1984 ANSI/NFPA96-1987
Filter Unit ANSI/UL 586-1985 ANSI/NFPA 96-198 7

Types of Fire Extingushers
and Detection Equip ment

ANSI/UL 900-1987

CO2 ANSI/UL 154-1983 ANSI/NFPA 12-1989
Dry Chemical ANSI/UL 299-1984 ANSI/NFPA 17-1985
Water ANSI/UL 626-1984 ANSI/NFPA 13-1989
Foam

Sprinklers ANSI/UL 199-1982

ANSI/NFPA 11-1988
ANSI/NFPA 13-1989

ANSI/NFPA 13-1989

Smoke Detectors ANSI/UL 268-1981 ANSI/NFPA 72B-1986
Fire Detection Thermostats ANSI/UL 521-1987 ANSI/NFPA 72B-1986

Excessive ventilation causes drafts, which will interfere with the proper operation of the pilot and the burner.
Leave at least 18 inches of open space between the fryer's flue vent opening and the intake of the exhaust
hood.

1-5

CAUTION

•

Manometer (low pressure gage)

• Digital Thermo

meter (Temperature probe)

• DC Millivolt Meter

Ensure that your ventilation system does not cause a down draft at the fryer's flue
opening. Down drafts will not allow the fryer to exhaust properly and will cause
overheating which may cause permanent damage. The Heat deflector DOES NOT
stop down drafts. Damage caused by down drafts will not be covered under
equipment warranty. NEVER allow anything to obstruct the flow of combustibles or
ventilation exiting from the fryer flue. DO NOT put anything on top of the flue area.

NOTICE

NEVER connect the blower directly to the flue openings. The direct flow of air will
cause poor temperature recovery, poor ignition, inefficient operation of the fryer, and
could extinguish the pilot.

1.4 INITIAL ADJUSTMENTS
After your fryer has been installed as described in section 1.3, it needs to be adjusted to ensure that it will

perform as designed. These adjustments must be performed by a qualified person. To perform these
adjustment the following tools will be needed:

1.4.1 Visual Checks

Before you begin filling and adjusting the fryer, perform the following visual checks:

a. After the fryer is in its permanent location, check the levelness. Any additional

leveling that is necessary must be performed before using the fryer

b. Check the temperature bulbs (thermostat/high-limit), located in the

fryer tank to ensure that the mounting screws are tight. The figure
shows the probe location. Look down inside the fryer tank to see the
probes.

1-6

1.4.2 Burner Ignition Systems
The counter top fryer has a standing manual pilot system. Follow the procedures in this section to light and

adjust the pilot system.

CAUTION

Before going any further, fill the fryer with WATER. Water is used for the
installation adjustments because the temperature will never exceed 212°F (100°C)
thereby allowing plenty of adjustment time. Never let the water level go below the
MIN LEVEL mark on the rear of the tank.

There is an open flame inside the fryer. The unit may get hot enough to set near by
materials on fire. Keep the area around the fryer free from combustibles.

1.4.2.1 Lighting the Pilot Light

Wait 5 minutes before attempting to relight the pilot to allow for any gas in the fryer to
dissipate.

a. Open the gas supply valves to the fryer.

b. Open the fryer's door to gain access to the controls. Ensure that the thermostat control knob is in

the OFF position.

c. Turn the Unitrol valve knob to the PILOT position and push in on the knob. Hold the

knob in for approximately one minute to purge the air from the line. Hold a flame
to the pilot burner until the pilot ignites. This may take a little while the first time you
light the fryer because of air in the lines. Once lit, hold the knob in for approximately
60 seconds then release. The air only needs to be purged from the line the first time the pilot is lit or
after the gas line has been disconnected.

d. If the pilot goes out wait 5 minutes and repeat step c. If after three tries the pilot will not remain

lit, refer to the operator troubleshooting section of this manual.

e. Turn the Unitrol gas valve knob counterclockwise to the ON position.

f. Turn the fryer thermostat knob to the desired temperature.

1-7

g. The main burner will light and be controlled by the thermostat. The pilot burner will remain lit

regardless of the thermostat setting.

1.4.2.2 Pilot Flame Adjustment - The pilot flame should be adjusted to produce the proper millivolt output

from the pilot sensing device. There are two types of pilot sensing devices thermopile or
thermocouple. Millivolt output for the thermopile should be between 300 and 500 millivolts.
Figure 1-1 shows the pilot assembly with examples of the incorrect and correct pilot size. Example
A illustrates a pilot flame size that is too small to produce sufficient millivolt output. Example B is
the correct size for proper millivolt output.

Figure 1-1 Pilot Assembly, Flame Adjustment

a. This test requires a DC millivolt meter set to a scale of 0-l000mv.

b. Locate the thermopile wires at the Hi-limit.

c. Using the positive (+) test probe, touch the probe to one of the High Limit wire terminals.

d. Connect the negative (-) test probe to pilot bracket. If the reading on the meter, when the pilot is

lit, is 400 ± 50mv the pilot flame does not need adjustment. If the voltage is not correct proceed
to step e.

e. Remove the pilot flame adjustment cover.

f. Turning the flame adjusting screw (figure 1-3) clockwise lowers the flame and the millivolt

output. Turning the screw counterclockwise increases flame size and millivolt output.

g. Rotate the screw in the direction to achieve a reading of 400 ±50 mv for thermopiles.

NOTICE

Allow 3 to 5 minutes between flame adjus tments to allow the reading to settle.

h. Replace the pilot flame adjusting screw cover.

1-8

1.4.3 Main Burner System
The main burner receives gas from the main gas supply through the thermostatically controlled valve. When

the thermostat is turned up the gas control valve opens. After the burner system is operating, perform the
burner adjustments in the following procedure. Figure 1-2 illustrates the different conditions possible for the
main burner.

The tubes and baffles are badly
carbonized. Check vent and
adjust if necessary. Check for
heat tube or flue blockage.

INSUFFICIENT FLOW

Have gas company check
incoming gas pressure. Adjust
manifold pressure as described in

1.4.3.2.

The flame seems to "lift off the
face of the burner. To correct
adjust main burner as described
in 1.4.3.2.

EXCESSIVE FLOW

A soft, steady blue flame should
enter the heat tube without
touching the front outside rim
of the tube.

INSUFFICIENT GAS PRESSURE

NORMAL FLOW

Figure 1-2 Main Burner Conditions

1-9

1.4.3.1 Gas Line Requirements - A properly installed gas supply system will deliver 5.0" - 6.0" w.c.
natural gas (11.0" - 12.0" w.c. LP) to all appliances connected to the line, operating at full demand.

1.4.3.2 Burner Adjustment - The burners must be adjusted to deliver optimum flame. Adjust the burner
flame using the following procedure.

a. Ensure that the main gas valve is shut off, remove the manifold pressure tap plug and connect an

accurate pressure gage (range of 0-16" w.c. in 0.1" increments) or manometer.

Figure 1-3 Gas Valve Showing Location of Pressure Regulator and Pilot Adjusters

b. Turn on all appliances connected to the gas supply line and light their main burners. The pressure

reading of the installed pressure gage should not drop from the required installation pressure. Any
loss of pressure indicates inadequate supply line installation which will cause poor performance of
all appliances during peak usage.

c. The installed pressure gage reading should be the same, ±0.1", as that marked on the data plate

inside the door. If the pressure is correct go to step f, if not, adjust the pressure.

d. To adjust the pressure, remove the regulator adjustment screw cover (see Figure 1-3). Use a flat

tip screwdriver to adjust the screw until the proper pressure is reached. Turning the screw
clockwise will increase the pressure, counterclockwise will decrease the pressure.

e. When the pressure is correct, install the regulator adjustment screw cover.

f. To remove the pressure gage, turn off fryer and shut the main gas valve. Remove the gage

1-10

and install the pressure tap plug using some pipe sealing compound.

Figure 1-4 Air Collar

g. Now that the pressure is set for proper operation, set the main burner flame. Unlock the air

collars by loosening the set screw for the collars. Open the main gas valve, light the pilot, and
turn thermostat to light the main burners.

h. Adjust the shape and size by raising or lowering the air collars to achieve a soft blue flame with

well defined inner cones as seen on figure 1-2.

i. When the flames have been properly adjusted, lock the collars in place with the set screw

provided.

1.4.4 Initial Cleaning
When the fryer is shipped, many of its parts are covered with a thin coat of cooking oil for protection. Before

the fryer is ready for cooking it must be cleaned. This will remove the oil coating and any foreign matter that
may have accumulated during storage and shipment. Perform the cleaning as described below. During
cleaning

a. Fill the fryer with water. Turn the fryer on and set the thermostat to 200°F.

b. Allow the fryer to heat for 15 minutes. Add Pitco fryer cleaner directly to the water, stirring with

the fryer cleaning brush to ensure cleaner has dissolved thoroughly.

NOTICE

Do not leave the fryer unattended during cleaning. Never let the water level go below
the "Min Level" mark on the back of the tank.

1-11

c. Using the fryer cleaning brush, scrub the inside of the fryer to remove protective coating.

d. When cleaning is complete, turn the thermostat to OFF and turn gas valve knob to the Pilot position.

Drain the water into a container suitable for hot water and dispose of it.

e. When the tank has cooled, rinse it thoroughly with cool water. Continue to rinse the tank until the

cleaner has been rinsed, thoroughly from the tank.

f. Using a clean dry cloth, wipe out all of the water. Be very thorough removing the water, because any

residual water will cause hot oil to splatter out of the fryer.

CAUTION

Mild steel tanks must be wiped down/coated with oil to keep the tank from rusting.

g. Now that the tank is clean, you are ready to fill and operate the fryer. Refer to 2.1 for instructions on

adding shortening to the fryer.

1.4.5 Thermostat Calibration
Filling the fryer with oil is described in 2.1. To perform the calibration check detailed below you will need a

digital thermometer.

NOTE

The thermostat calibration should be checked only. If the setting is off a few degrees
perform the steps that follow. If the dial setting is off a significant amount call a
qualified technician for warranty service.

a. Place the tip of the thermometer in the shortening approximately 1" above the temperature

sensors.

b. Set the thermostat at 325°F and wait for the temperature reading on the thermometer to rise. As

the temperature rises toward 325°F watch the thermometer closely.

c. If the shortening temperature reaches 350°F and the burners DO NOT turn off, turn the

thermostat down. Keep lowering the thermostat setting until the burners go out.

CAUTION

If the burners do not turn off at the lowest thermostat setting, the thermostat could be
defective. Contact your ASA P representative.

1-12

d. Let the fryer cycle 4 to 6 times before checking the temperature. Compare the thermometer

temperature against the thermostat setting. If the values are more than 5°F apart continue with
calibration, if they are not go to i.

e. Loosen the set screw that holds the thermostat knob to its shaft.

f. Rotate the thermostat dial without moving the shaft to the temperature indicated on the

thermometer. Tighten the set screw on the thermostat dial to lock the dial on place.

g. Adjust the thermostat to a new setting and allow the fryer to cycle 4 to 6 times at the new

temperature. Check the thermometer temperature against the thermostat dial, if it greater than
5°F away from the dial setting, perform the above procedure again. If the temperature is ±5°F of
the thermostat dial setting, the thermostat is set correctly.

h. When the calibration is correct, remove the thermometer and replace the tube screen.

1-13

Chapter 2: Operating Instructions

This chapter describes how to operate your fryer to obtain the best performance. Included in this chapter are
filling, operating, and cleaning instructions for gas fryers.

2.1 FILLING THE FRYER
Both liquid and solid shortening can be used in the fryer, but liquid is preferred. You can melt solid shortening

but you must carefully follow the instruction in section 2.1.2.

2.1.1 Filling the Fryer With Liquid Shortening

a. Make sure the drain valve is completely closed.

b. Fill the fryer with oil to the "Oil Level" line marked

on the back of the kettle.

2.1.2 Filling the Fryer With Solid Shortening

Never melt blocks of solid shortening on top of the burner tubes. This will
cause a fire, and will void your warranty.

a. Make sure the drain valve is completely closed.

b. Remove the screen covering the tubes.

c. Cut the shortening into cubes no larger than 1".

ALWAYS pack the shortening below, between, and
on top of the burner tubes. DO NOT leave any large
air gaps. Use care when packing the solid shortening
in the kettle. DO NOT bend or break the temperature
sensor probes. If these are damaged the fryer will not
function properly.

c. Once the fryer is packed with shortening, the

shortening must be melted. Place the switch, located
above the thermostat knob, in the MELT ON position. The fryer will automatically melt the
shortening using short, controlled, bursts of heat. The melt cycle will continue until cooking
temperature has been reached.

2-1

2.2 OPERATING INSTRUCTIONS
To ensure the food always comes out the very best, follow the preparation instructions for the food you are

cooking. Using the best shortening makes the best fried foods. The best shortening will last longer than lower
grade shortening and save you money. When not in use the shortening should be cooled and covered to
prevent contamination.

Water and shortening DO NOT mix. Keep liquids away from hot shortening.
Dropping liquid frozen food into the hot shortening will cause vio lent boiling.

2.2.1 Fryer Start -Up

DO NOT START FRYER WITHOUT FILLING WITH OIL!

a. Light the pilot light as described in section 1.4.2.
b. Turn the temperature control knob (thermostat) to the desired temperature setting. This knob is

located behind the front doors or on the front control panel.

c. Turn the fryer ON by pressing the ON side of the ON/OFF/TEST switch. The POWER ON light

and the HEATING light will come on. The HEATING light cycles with the main burners.

d. Place the melt option switch in the MELT ON position. If the oil temperature is less than 150°F,

the burners will turn on for 4 seconds and remain off for 30 seconds. This will heat the shortening
slowly to 150°F (65°C). At 150°F (65°C) the burners will remain on constantly until the
shortening reaches the thermostat setting.

e. The Melt Cycle switch can be left ON after reaching normal temperature. The fryer is now at

normal operating temperature and ready for use.

2.2.2 Fryer Shut-Down

There are two shutdown modes of fryer operation, STANDBY and COMPLETE. The standby mode
removes the ability for the fryer's main burners to cycle. Complete shutdown turns off the gas supply to the
fryer. Shut down the fryer by:

STANDBY Turn the thermostat to OFF. Depress and turn the gas valve cloc kwise to

the PILOT position. The cooker is now in Standby and can remain this way
for only brief periods of time. NEVER leave the cooker in standby
overnight.

2-2

a. Wipe up any shortening that spills onto the exterior of the fryer. This should be done with a

COMPLETE To completely shut down the cooker, turn the gas valve counter clock-

wise to the OFF position and turn the power switch OFF. The fryer is
now completely shut down and can be cleaned.

2.3 DAILY CLEANING
Your fryer should be cleaned every day to maintain peak performance and appearance. Perform the

procedures below every day.

clean soft cloth while the oil is still warm.

b. Use warm water with a mild detergent to clean surfaces. Be careful not to get water in the

shortening and to remove any detergent from the fry tank.
c. Use a non-abrasive scouring powder or pad to clean stains if necessary.
d. Perform the weekly boil out cleaning of your fryer described in section 3.1.

2-3

Chapter 3: Maintenance, Adjustments, and Service

This chapter provides you with the information and procedures necessary to perform basic fryer maintenance
and adjustments. If after performing maintenance on your fryer it does not perform properly, contact your
authorized service center.

3.1 WEEKLY FRYER CLEANING (BOIL OUT)
The fryer should be thoroughly cleaned once a week. This cleaning should include a complete draining of

the fryer and a boil out.

a. You will need a container large enough to hold 1-1/2 times the oil in one tank. This container

should also be able to withstand temperatures in excess of 350°F (177°C).

CAUTION

Completely shut down the fryer before draining the oil and replacing with water. If
possible, allow the oil to cool to less than 130°F (54.4°C).

At operating temperatures, the shortening in the fryer may be hotter than 375°F
(190°C). This hot, melted shortening can cause severe bums. Do not let hot
shortening touch your skin or clothing. Always wear insulated oil-proof gloves and
eye protection when working with hot oil

b. Drain the oil from the fryer and discard or save for reuse. Remove the tube screens. Close the

drain valve and fill the tank with warm water and non-caustic detergent. For best results use
Pitco Fryer Cleaner part number P6071397 (sample packet included with the fryer).

c. Restart your fryer as described in 2.2 and set the thermostat to 200°F and bring the water to a

slow boil. DO NOT allow water to boil because excessive foaming will occur.

d. Allow the fryer to soak for 20 minutes to soften shortening deposits. Use fryer brush to remove

any residue from tank, tubes, and side walls. Perform the daily cleaning procedure described in
section 2.3.

e. Drain the hot water into a container and dispose of the oil in an ecologically sound manner. Rinse

the tank with clean warm water.

f. Wipe the tank dry with clean cloth wipes taking care to remove ALL of the water. Close the drain

valve and remove the large container.

g. Replace the tube screens and refer to section 2.1 to refill the fryer.

3-1

3.2 FLUE AND BAFFLE INSPECTION
It is recommended that once every six months with the cooker cooled down you examine the flue area and

the burner tube baffles. Check for corrosion or blockage of the flue and erosion of the baffles. Ensure that the
cooker is shutdown and cooled to room temperature. Do not turn it on during the examination. Examination
of the flue area during cooking may cause bodily injury.

3.3 SERVICE
This section is provided to aid you in the event of fryer or filter troubles. If these troubleshooting procedures

do not correct your problem contact a qualified technician or the factory. The troubleshooting procedures are
in a flowchart format.

3.3.1 Replacement Procedures
These procedures are provided to the qualified technician as a guid e to removal and replacement of various

fryer components. If a test is required to verify component operation after installation, it will be referenced.

To prevent bums, always ensure the fryer is completely SHUT DOWN and COOLED
down before working on the fryer. Do not break any fryer gas connections while the
unit is connected to a gas supply line.

3.3.1.1 Main Burner Removal and Replacement
a. Loosen the set screw in the base of the burner casing.

b. Unscrew and remove the two hex head screws at the top of the burner.

c. Loosen the set screw. Lift the burner and air collar up to clear the top of the burner

fitting. Remove the burner from the fryer.

d. To reinstall the burner, reverse the procedure.

3.3.1.2 Changing the Main Burner Orifice

a. Unscrew the orifice with a 3/8" wrench and remove the orifice.

d. Insert the new orifice and tighten with the 3/8" wrench. Ensure the orifice is tight enough to

prevent gas leakage around the orifice.

3-2

3.3.1.3 Replacing the Heat Baffles

a. Remove the Main Burner as described in 3.3.1.1.

b. The heat baffles are located inside the heat tubes. They are attached to the rear of the baffle

supported by tack welds. Using a chisel, break away the baffle support and remove the old
baffles. Be careful not to puncture the heat tubes because this will require complete tank
replacement.

c. Insert the new baffles in the tubes in the original position.

d. Install the main burners.

3.3.1.4 Pilot Burner Removal and Replacement

a. Unscrew the tubing nut from the pilot tubing connection at the gas valve. Disconnect the

thermopile from the connection on the gas valve.

b. Unscrew and remove the two screws that attach the pilot assembly to the fryer tank. Lif t the

entire pilot assembly out of the fryer.

c. To replace the pilot assembly, reverse the procedure.

3.3.1.5 Pilot Orifice Replacement

a. Remove the pilot assembly as described in 3.3.1.4.

b. Unscrew the tubing nut from the pilot tubing connection at base of the pilot burner. The pilot

orifice is located inside the tubing connection.

c. Remove the orifice and replace with the new orifice. Ensure the orifice is tight enough to-prevent

gas leakage around the orifice.

d. Replace the tubing in the pilot tubing connection and tighten the tubing nut tight enough to

prevent gas leakage.

e. Replace the pilot assembly and adjust the pilot flame as described in 1.4.2.

3.3.1.6 Thermopile Replacement

a. Remove the pilot assembly as described in 3.3.1.4.

b. Unscrew and remove the thermopile from the pilot assembly.

c. Unscrew the thermopile from the gas valve magnet.

3-3

d. Screw the new thermopile into the pilot assembly and the gas valve magnet.

e. Replace the pilot assembly and adjust the pilot flame as described in 1.4.2.

f. Ensure that all nuts and screws are tight.

3.3.1.7 Temperature Control Board Replacement

a. Disconnect the power from the fryer.

b. Shut the gas supply valve to the fryer.

c. Turn the unit 180° so that the back of the fryer is toward you.

d. Remove the four hex head slotted screws from the entrance box at the bottom of the unit.

Remove the box and set it down gently.

e. Disconnect the white nine socket jack and the four socket jack. The box should now be free.

f. Disconnect all 11 spade terminations from the temperature control board.
g. Remove the two hex nuts fastening the board to the box. Remove the defective board and

discard.

h. Install the new temperature control board by refastening the hex nuts and reconnecting the spade

termination. Refer to the schematic for the proper connection.

i. Reconnect the white nine socket jack and the four socket jack. Refasten the entire box to the fryer.

3.3.1.8 High Limit Control Replacement - The High Limit control includes a temperature sensor inside the
fryer tank, control unit inside the fryer cabinet, and connecting capillary tubing.

CAUTION

The High Limit control capillary tubing is very delicate. Be VERY CAREFUL when
working with the capillary tubing. If the tubing is kinked or broken the High Limit
control is no longer usable.

a. Drain the oil from the fryer and remove the heat tube screens.

b. The High Limit control probe (heat sensor) is clamped to the right hand heat tube inside the tank.

Unscrew and remove the two screws in the probe clamp.

3-4

c. Remove the probe from the clamp and gently straighten the capillary tubing. Unscrew the small

hex nut inside the cabinet at the bottom of the tank for the High Limit control. Make sure the
capillary tube is free.

d. Unscrew the large connector nut from the tank and pull the probe and capillary tubes through the

opening.

e. Remove the two mounting screws from the High Limit control bracket and remove the High

Limit control unit. Disconnect the wires from the High Limit body.

f. Reverse the procedure to install the new High Limit control.
g. Use pipe joint compound on the large fitting before installing to prevent oil leakage. DO NOT use

joint compound on the small nut.

3.3.1.9 Thermostat Probe Replacement

a. Drain the oil from the fryer and remove the heat tube screen. The thermostat probe (heat sensor)

is clamped to the left hand heat tube inside the tank. Unscrew and remove the two screws in the
thermostat probe clamp.

b. Remove the thermostat probe from the clamp. Unscrew the small hex nut in side the cabinet

under the tank for the thermostat control.

c. Unscrew the large connector nut from the tank and pull the thermostat probe through the

opening.

d. Unplug the electrical connection.

e. Install the new thermostat in reverse order.

f. Use pipe joint compound on the large fitting before installing to prevent oil leakage. DO NOT

use joint compound on the small nut.

g. Perform the calibration procedures detailed in section 1.4.5.

3-5

3.4 TROUBLESHOOTING

This section is provided to aid you in the event of fryer troubles. If these troubleshooting procedures do not
correct the problem contact a qualified technician or the factory. The troubleshooting procedures are in
flowchart format.

3.4.1 Troubleshooting Fryers With Unitrol Valves

3-6

3-7

3.4.2 Troubleshooting Pilot Lights

3-8

3.4.3 Troubleshooting Thermostat System

3-9

Chapter 4: Parts

This chapter contains listings of the components used in the different models of McDonald's fryer. These
components are listed in two places, with the illustration and in ordered part lists. The illustrations in this
chapter are provided to show relative location of component of the fryer. With each illustration there is a
table of components in numerical order by illustration number. The illustration has numbered lines pointing
to components which are listed in the table.

At the end of this chapter there are alphabetical and numerical listings of all parts used in the fryer. The
alphabetical part list is arranged in alphabetical order according to the part name. Each part name also has the
Pitco Frialator part number. The numerical list is in Pitco Frialator part number order. A brief description of
each component is provided for each part.

4-1

Figure 4-1 Counter Top 12 Exploded View

4-2

Table 4-1 Counter Top 12 Exploded View (Index)

Index

Number

1 Cabinet, Weldment 8 Door Assembly 12 MCD
2 Tank Weldment SS 8A Handle, Chrome

2A Baffle, Removable 6,12 8B Plug, Hole 1/2" Chrome

3 Flue Weldment 9 Probe, Thermistor Gas
4 Front Panel 12A Gas 10 Piping, Pilot 12C Nat
5 Entrance Box, Assembly 10A Thermopile CP2 24"

5A

5B Transformer, 40 VA 120/208/240 to 24 12 Burner, Pitco 4"

6 Auxiliary Box, Assembly 13 Valve, Ball 1" Plated
6A Fuse, 1 Amp Slow Blow Glass 14 Piping Collar Air
6B Potentiometer, 0-900 ohm 15 Top Door Hinge
6C Switch, Toggle (ON-OFF-ON) DPDT 16 Hinge, Door Bottom Weldment
6D Knob, Thermostat McDonald's 17 Cabinet, Bracket Magnet Catch

Control, Temperature 24 VAC GO
On-8, Off-22

Description

Index

Number

11 Switch, Hi Limit

Description

7 Piping, Supply Gas 12C Nat 18 Magnet
7A Valve, Gas 1/2" Thermopile Nat 19 Cabinet, Bracket Magnet Catch
7B Orifice #45

20

Hanger, Basket 12 SS

* For complete part information, refer to the part lists later in this chapter.

4-3

ALPHABETICAL PART LIST

Part Description

AIR COLLAR A8001001
AUXILIARY BOX, ASSEMBLY B4301901
BAFFLE, REMOVABLE 6,12 B1002704
BURNER, PITCO 4" P6071050
CABINET, BRACKET MAGNET CATCH A1815501
CABINET, BRACKET MAGNET CATCH A1817902
CABINET, WELDMENT B1813801
CONTROL, TEMPERATURE 24 VAC GO ON-8, OFF-22 PP10561
DOOR ASSEMBLY 12 MCD B2301801
ENTRANCE BOX, ASSEMBLY B2907501
FLUE WELDMENT B3501211
FRONT PANEL 12A GAS B7200802
FUSE, 2 AMP SLOW BLOW GLASS P5045700
FUSE HOLDER P5045794
HANDLE, CHROME P6071516
HANGER, BASKET 12 SS A 1102904

Pitco Frialator

Part Number

HINGE, DOOR BOTTOM WELDMENT B3800501
KNOB, THERMOSTAT MCDONALD'S P6071265
MAGNET P6071300
ORIFICE #45 P6071345
PIPING, PILOT 12C NAT B7550207
PIPING, SUPPLY GAS 12C NAT B8012104
PLUG, HOLE 1/2" CHROME P6071493
POTENTIOMETER, 0-900 OHM P5046582
PROBE, THERMISTOR GAS B6700601
SWITCH, HI LIMIT PP10084
SWITCH, TOGGLE (ON-OFF-ON) DPDT P5047165
TANK WELDMENT SS B3312602
THERMOPILE CP2 24" P5047541
TRANSFORMER, 40 VA 120/208/240 TO 24 PP10210
VALVE, BALL 1" PLATED P6071769
VALVE, GAS 1/2" THERMOPILE NAT P5045638
VALVE, GAS 1/2" THERMOPILE LP P5045639

4-4

NUMERICAL PART LIST

Pitco Frialator

Part Number

A1102904 HANGER, BASKET 12 SS
A1815501 CABINET, BRACKET MAGNET CATCH

Al817902 CABINET, BRACKET MAGNET CATCH
A8001001 AIR COLLAR
B1002704 BAFFLE, REMOVABLE 6,12
B1813801 CABINET, WELDMENT
B2301801 DOOR ASSEMBLY 12 MCD
B2907501 ENTRANCE BOX, ASSEMBLY
B3312602 TANK WELDMENT SS
B3501211 FLUE WELDMENT
B3800501 HINGE, DOOR BOTTOM WELDMENT
B4301901 AUXILIARY BOX, ASSEMBLY
B6700601 PROBE, THERMISTOR GAS
B7200802 FRONT PANEL 12A GAS
B7550207 PIPING, PILOT 12C NAT
B8012104 PIPING, SUPPLY GAS 12C NAT
P5045638 VALVE, GAS 1/2" THERMOPILE NAT

Part Description

P5045639 VALVE, GAS 1/2" THERMOPILE LP
P5045700 FUSE, 2 AMP SLOW BLOW GLASS
P5045794 FUSE HOLDER
P5046582 POTENTIOMETER, 0-900 OHM
P5047165 SWITCH, TOGGLE (ON-OFF-ON) DPDT
P5047541 THERMOPILE CP2 24"
P6071050 BURNER, PITCO 4"
P6071265 KNOB, THERMOSTAT MCDONALD'S
P6071300 MAGNET
P6071345 ORIFICE #45
P6071493 PLUG, HOLE 1/2" CHROME
P6071516 HANDLE, CHROME
P6071769 VALVE, BALL 1" PLATED

PP10084 SWITCH, HI LIMIT

PP10210 TRANSFORMER, 40 VA 120/208/240 TO 24

PP10561 CONTROL, TEMPERATURE 24 VAC GO ON-8, OFF-22

4-5