Service Manual - Whaley Food Service
Contents
1. Transmission panels Assembly 2 Remove all baskets and both conveyor chains Section K iia 3 Unhook tension springs from brackets Figure 10 A Aiea 4 Remove bearing retainers and bearings Z 21354 5 Lift one end of assembly shaft and remove carrier chain f2. Merco Savory PARTS amp SERVICE MANUAL for C 20VS Vertical Conveyor Toaster The C 20VS is a high volume vertical conveyor bread and bun toaster constructed of durable and lustrous stainless steel This toaster is available in both 208V and 240V models 120 V Models are available for shipboard use only Refer to the chart on page 7 for parts that apply exclusively to 120V shipboard toasters The C 20VS has a variable conveyor speed control which allows the toasting of not only bread but English muffins bagels and buns with only one pass through the conveyor Standard features include variable heat and bun toast switch for selecting one or two sided toasting The C 20VS is engineered for efficient dependable service through out the years Like any piece of fine equipment with moving parts and broad temperature ranges physical wear takes its toll When this happens the information found in this manual will prove very helpful Although the instructions are easy to follow all repair procedures should be carried out by a qualified Savory Service Representative 07012 1200 JDM CAUTION S 8 Remove wires from thermostat so Unplug unit and allow to cool before attempting any Push as much capillary tube as possible through the plastic service procedures in this manual grommet located on the upper portion above the shelf and pull thermostat bulb out of hole 10 Feed capillary tube and bulb through plastic grommet
3. 21650 a a a a f mine i mot Coupling Bearing Right Side G Raisiner Bo 1 See Section D follow steps 1 2 and 3 2 Remove two lock nuts holding bearing retainer and remove Gars retainer Guard Wire Me ore sm 3 Remove old bearing em Z id 4 Install new bearing and seat in opening 5 Replace retainer nuts insulation and heater wiring Retainer Domed 21183 Coupling Bearing Left Side l R 421282 i S 1 Remove left side panel and insulation o Bracket Retainer Flat E Tension Spring 2 Remove two lock nuts holding bearing retainer and remove ge obey 4 E eE retainer S T 3 Remove old bearing Oe 4 Install new bearing and seat in opening Leg Adj Plastic 5 Replace retainer and lock nuts 12668 Tension Assembly Bearing Right or Left 1 Remove right side panel 2 Remove one end of tension spring from tension bracket Transmission Bearing Right Side 1 See Section I Follow steps 1 2 and 3 2 Remove two lock nuts holding bearing retainer and remove retainer 3 Remove old bearing 4 Install new bearing and seat in opening 5 Replace retainer and lock nuts Figure 12 6 See Section Follow steps 4 5 and 6 Master Link Transmission Bearing Left side 1 Remove left side panel 2 Remove the two lock nuts holding bearing retainer and remove retainer 3 Remove old bearing 4 Install new bearing and seat in opening 5 Replace retainer nuts and side panel K Conveyor Cha
4. expand toasting chamber Figure 18 This will allow enough clearance for coupling assembly to be lifted from toaster 10 To install new assembly spread inner walls as in Step 9 for clearance 11 Check bearing for wear or binding Replace if necessary be a a gt 0 Wire Guard Replacement Figure 18 1 Remove left side panel and insulation Remove the three nuts holding end plate and remove plate Figure 19 Slide out wire guard 4 Insert new guard into track NOTE Use rear track for toasting buns or bread Use forward track for toasting bread only 5 Replace end plate nuts insulation and side panel Removal of coupling assembly al P P C Board Assembly Replacement Refer to Figure 20 NOTICE PROCEED WITH THE BELOW LISTED STEPS ONLY IF YOUR UNIT CONTAINS THE P C BOARD ASSEMBLY Remove right side panel Loosen set screw and remove speed control knob Remove nut securing potentiometer Disconnect wires from P C Board and remove screws nuts and washers holding guard to toaster frame Remove board and potentiometer 6 Install new board assembly reversing above procedure lS E w Figure 17 Exploded view of upper toaster Guard Wire HOTTIE Piate Enid 51171 Figure 20 PARTS FOR C 20VS 120V MODELS For Shipboard Use ONLY DESCRIPTION PART TEE LNH ot Ly DDA HOR Ep REAR RIT H E CET METAR VOR AT 6 Ln pan ra pa pn cee AC RC ae ea eee L
5. from under toaster Slip off drive chain Lift out motor and bracket assembly and remove four screws holding motor to bracket Using 1 16 Allen wrench loosen Allen screws and remove clutch sprocket from motor shaft Mount clutch sprocket on new motor shaft and mount new on bracket Install new motor and bracket assembly attaching with the two mounting bolts Do not tighten bolts Mount drive chain on sprocket by sliding motor to the left Slide motor to the right and tighten bolts Figure 8 Check sprocket alignment Figure 9 10 Reconnect wire and replace side panel Refer to wiring diagram Figure 5 Left Side Wire Guard Opening R Figure 6 Heating Element Unit There must be air space at circled areas Element Only 208V 21103 240V 21105 Nut Lock 10 32 Figure 7 Retainer Domed 21183 Jumper gp 213506 Grommet Plastic 41052 Heater Unit Front amp Rear 208V 2 1208 me DAV H 21 240 etainer Bearing 21584 K Hubbed Sprocket 32T 21319 Wire Harness Kit 27833 AS Sprocket Clutch 16T Gear Motor 208 240V 50 60 Hz 22743 G Drive Chain Replacement a 3 Remove two lock nuts holding bearing retainer and 1 Remove right side panel remove retainer Loosen motor mounting bolts and slide motor to lef to 4 Remove tension bracket and old bearing _ T 5 Install new bearing and seat in opening Figure 10 Replace tension bracket retainer lock nuts and spr
6. EE E H TEE R TEA TERMINAL T LC NM H a Fit K a ft oot wan ar SATEH Laa TOS RIR R asad NE UTE a ss onead L 5 anean ey i a TT H Wiring Diagram C 20VS ES Merco Savory 1111 N Hadley Rd Fort Wayne In 46804 Tel 800 701 2992 Fax 260 436 0735 www mercosavory com
7. ent 12 Install bearings retainers and lock nuts 7 aa lt a R S l a l l d 13 Replace three screws into front reflector EONS OH ve ODay aaae 14 Replace conveyor chains springs to tension brackets front bearings Section I and J baffle inner top assembly insulation and case top Be sure 3 Slide assembly shaft to right side and lift left end of shaft out case top is seated properly in retaining channels of bearing hole and LUNS shaft i l 15 Replace side insulation wiring side panels and baskets NOTE Free wheeling left sprocket is mounted with hub side inward 4 Inspect shaft bearing for wear or binding Replace if Figure 15 Coupling necessary pease 5 Replace new assembly in reverse order of above 21189 IERT SL Check conveyor chain line up section K 7 Check drive chain tension Section G Chain Carrier 21353 M Tension Assembly Replacement 1 Remove receiving tray delivery chute left and right side
8. in Replacement 1 Remove toast receiving tray delivery chute left and right side panels 2 Remove the two screws in upper edge of front opening that hold the front baffle Slide baffle toward back of machine to remove Figure 11 3 Remove baskets by slightly spreading chains sliding basket to one side and lifting out Figure 13 4 Release the tension spring from spring bracket on both sides Master Link of tension bracket on both sides of tension assembly Clip 5 Locate master link link without extended pins Figure 12 Remove clips on master link figure 13 and remove Pull chain from bottom 6 With extended pins facing inward drape new chain over top of the coupling assembly Make sure links of chain are meshed over sprocket teeth Drop remainder of chain behind sprocket and from bottom opening lift it across transmission assembly Master Link and tension assembly sprockets Visually check for fit over j sprocket teeth and bring two ends of chain together Install master link and clips Repeat procedure for other chain IMPORTANT Align right and left side master links to insure proper alignment of baskets Figure 14 7 Replace baskets spring on tension brackets front baffle receiving tray delivery chute and left and right side panels Figure 14 Proper alignment of right and left master links Figure 11 Conveyor Chain Baffle Master Links Baffle 8 21453 gt 9 L Transmission Assembly Replacem
9. ing N 3 Lift off old chain and position new chain over sprockets j NOTE If tension bracket has two anchor holes for Check orientation Figure 9 spring use hole closest to front toaster 4 Slide motor to right to remove chain slack and tighten motor mounting bolts 5 Check chain tension Figure 8 Too tight will result in premature ware of chain sprocket and bearing and may bind drive components Too loose will result in chain slipping or falling off sprockets Drive Chain Orientation Orientation H Clutch Sprocket Replacements 1 Remove right side panel Loosen motor mounting bolts and slide motor to left Remove drive chain 3 Loosen Allen screws on clutch sprocket and remove sprocket from motor shaft 4 Install new sprocket on motor shaft and tighten screws Check sprocket alignment Figure 9 5 Position chain on sprocket and slide motor to right to remove slack Tighten mounting bolts Check chain orientation and tension Figures 8 amp 9 Replace right side panel Hubbed Sprocket Replacement Remove right side panel Loosen motor mounting bolts and slide motor to left Remove drive chain and loosen Allen screws on hub of sprocket and slide off shaft 4 Install new sprocket and align set screws with indents in transmission shaft 5 Replace drive chain and slide motor to right and tighten Figure 8 Replace side panel WNP Figure 10 Nut 10 32 m Sorew 21228 J Bearing Replacement
10. into A On Off Switch Replacement Remove right side panel figures 1 amp 2 Remove two retaining screws from front panel Disconnect wiring harness from switch terminals Connect wiring harness to new switch and install switch in panel Refer to wiring diagram i a B Bun Toast Switch Replacement Remove right side panel Figures amp 2 2 Disconnect wiring harness from switch terminals 3 Press two spring clips on top of switch and tilt forward 4 Insert new switch into panel bd m C Thermostat Replacement p lt 2 Remove insulation NOTE The wiring harness must be disconnected from the heating elements to remove insulation on the right side Hold terminals with pliers 7 to prevent bending Figure 4 3 Remove rear heating element assembly Section D 4 Remove wire guard Section O 5 Remove two baskets from conveyor chain rotate the chain so that this opening is at bottom directly under thermostat bulb 6 Remove thermostat knob 7 Remove the two retaining screws from front panel Remove left and right side panels Figures amp 2 on the lower portion below the shelf and remove Figure 3 Thermostat Installation Connect wiring harness to new switch To Install New Thermostat Refer to wiring diagram I 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 Thermos
11. rom sprocket Move chain to one side repeat for opposite end i of shaft Bezet 7 E Chan Drive 6 Slide shaft to one side and lift opposite end out of bearing 21191 aiaa hole Lift assembly out and under to clear carrier chains 7 Reverse above procedure to install new assembly NOTE Free wheeling left sprocket is mounted with hubside inward 8 Inspect bearing for wear or binding Replace if necessary 9 Install bearing spring brackets and retainers Attach springs to bracket 10 Check for chain alignment Figure 14 11 Install baskets left and right side panels N Coupling Assembly Replacement Figure 16 See Section K Follow steps 1 through 5 Upper inside Remove insulation Section D corner of toaster Remove wire guard Section O Locate the four screws on the upper inside corners of the sides that hold the case top in place Figure 16 Loosen screws and top A rubber mallet or similar soft tool may be helpful with a tight fitting top Figure 17 5 Remove insulation 6 Remove the twelve screws holding the inner top panel assembly in place and lift off Figure 17 7 Remove coupling assembly bearing from both sides Section J 8 Remove the three screws from the left inside panel that attach to the front reflector Circled in Figure 17 9 Standing at right side of machine gently push on left inner wall to
12. tat operation Insert bulb into hole and through center guide The bulb can be seen through the openings for the wire guard and rear heater element 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 extend about 1 1 2 from left inner panel gt Insuiation Top Gage Top A aiaa Figure 2 21202 Figure 1 ne ee ee Nat Shown Panel Right amp Left LKR aE G r 21036 aid x Cord Sat 30 Amp Nut Acorn 942994 21412 mc rey 21415 Chute Toast 21252 Shown in Rear Delivery Position 14 Attach wires to thermostat Refer to wiring diagram 15 Install new thermostat with two screws and replace knob 16 Position balance of tube so it runs from bottom of thermostat along inside of front panel Coil excess parallel to and under shelf Make sure tube 1s away from all electrical connections 17 Replace heater element wire guard insulation heater wires and side panel Refer to wiring diagram D Heater Unit Assembly Replace ment 1 Remove right side panel Figure 7 2 Holding the heater connections with pliers to prevent bending remove three screws holding wiring harness on 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 o
13. ut the side NOTE Because of air space required in some heating elements they may not easily pass through the opening If element does not slide out completely remove left side panel insulation and wire guard Section O Use a suitable flat tool such as a yardstick or ruler and insert through wire guard opening Gently pry heating element at curvature so it can clear opening and slide out figure 5 6 Slide new heater unit into place and fasten 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 Replace ment Each heater unit 1s equipped with two elements These may be replaced individually as follows 1 Remove heater unit Section D 2 Place heater unit on a flat surface and remove jumper and two screws nuts and retainers 3 Bend holding tabs away from elements and lift out at an angle that will let terminal ends clear holes 4 When replacing elements make sure element with raised bend on top and flat on bottom There should be air space at points circled in Figure 6 Elements must not touch at these points F Motor Replacement l 2 Remove right side panel Disconnect lead wire from terminal block and conveyor speed control and or P C board if contained in your unit Remove two mounting bolts
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