PARTS & SERVICE for ST-1 Mini Conveyor Toaster
Contents
1. d 120 V PIRF4 414 BLE SUPPLIED SUPPLIED 25 INI INI IF dais 656130 4 4314 ELK CONTROL GEAR MOTOR 77 let w cl 4 1 W 14517 45120 12 PCT D pun indes H13 WHT E TRO DESEE 687968 10 14 Hr X 14520 E E 14 BLE 15P CORDSET leo wv SEALS 14630 9 214 WHI MOTOR 206 V 14695 240 V 14875 45122 127 414 WHT LOWER HEATER z 20H V 4584 208 v 14654 24 v 54573 240 V 7145 735 SUPPLIED 7188 5 WHI L SPFFO CONTRO 2 0BV 124275 114635 14 14B25 12 F1 o 14 WHT 14 SUPPLIED INFIHILTE CUN TRAN 208 V 14707 240 12550 SUPPLIER 1546G5rH SUPPLIED aUFPLICO INFINITE CON TROL l 208 34702 240 V 12355 MOTOR 208 240 V 14574 143 GLK WIRENLIT E 22171 WIRENUT 2217 NEMA 8 15 m CORDSET 208 240 25064 Merco Savory 1111 N Hadley Rd Fort Wayne In 46804 Tel 800 701 2992 Fax 219 436 0735 www mercosavory com2. Merco Savory PARTS amp SERVICE for ST 1 Mini Conveyor Toaster The ST 1 Mini Conveyor Toaster is engineered for efficient dependable service throughout 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 Merco Savory Service Representative Description Part Description Part On Off toggle switch control 20A 68117 Drive chain assy 54 links 208V 240V 12412 Energy saver switch control 14614 Rear shaft assembly 14603 Heater control 120V upper or lower 21874 Front shaft assembly 14644 Heater control 208V upper or lower 14702 Front shaft spacers 14606 Heater control 240V upper or lower 12355 Rear shaft spacers 14762 Conveyor speed control 120V 12464 Tension adjusting brackets 12508 Conveyor speed control 208V 240V 12425 Bearing retainer brackets 12381 Heater control knob 12919 Bearings 22754 Terminal block 21858 Conveyor belt assembly SS 58 links 14647 Control panel blank 14765 Gearmotor 120V 69716 Control panel decal 14763 Gearmotor 208V 240V 14674 1 adjustable legs 12668 Cooling fan motor 120V 14618 5 cord set 120V NEMA 5 15P 26047 Cooling fan motor 208V 14699 5 cord set 208V 240V NEMA 6 15P 26064 Cooling fan motor 240V 14675 Strain relief bushin
3. 2 l i LE Ter us A on T B ea mil At Walk sue ci Tae M 5 3 T P eT 4 T 1 5 AP LI 2 LE T i Lt assembly to unit Lower heating element 1 terminals Wire connectors J Conveyor Shaft Sprocket 3 5 amp 6 Remove right side panel Section A H Remove drive chain Section 1 3 Loosenset screw on hub of sprocket and slide sprocket off shaft 4 Wheninstalling new sprocket make sure set screw rests in hole of shaft 5 Replace drive chain Section 1 Conveyor Belt odes 3 4 amp 7 Remove right amp left side panels Section A Loosen but do NOT remove the bearing retainer brackets on both sides of the toaster 3 Loosen but do NOT remove the tension adjusting brackets on both sides of the toaster 4 Push front conveyor shaft towards the back of the toaster to loosen belt tension 5 Separate the conveyor belt at any link and slide out of toaster 6 When installing new conveyor belt check for proper link orientation Figure 6 7 Starting at front of toaster slide belt under front shaft and push towards rear of unit Bring belt up and over the rear shaft and pull towards front of toaster Make sure belt is resting on both belt support guides Reconnect links CAUTION Make sure belt is not installed at an angle 8 Pull forward on front conveyor shaft until excess slack is removed 9 Tighten tension adjusting brackets a
4. 414725 ST 1 TROUBLESHOOTING GUIDE Defective heat contro Defective terminal block 2 d 4 1 Defective speed control Defective speed control 1 Defective or improper electrical outlet E 3 4 Loose ar improper wiring Defective loose or improper wiring Speed control not trimmed to proper voltage Defective plug or power cord Defect in one or ore of the following Possible Causes Defective heating element s Goh peu Te pese a On Off switch bj Terminal block c Energy saver switch d Heater control switch es 1 Defective heater control switche es js 2 Defective energy saver switch 1 Defective fan motor or misaligned or bent fan 1 blade 2 Defective plug or power cord 3 Loose or improper wiring Gearmotor d S Worn shaft bearing s incorrect conveyor belt tension Incorrect alignment of drive chain motor or sprockets Worn sprockets and or drive chain Front and rear shafts are not aligned Loose sprocket s Broken drive chain Disengaged drive chain Detective rear shaft Defective or improper electrical outlet Improperly installed drive chain Defect in one or more of the following aj On Off switch b Terminal lack need control e Bearings pec Pt pn Suggested Remedy Set heater control to 9 Replace any element that does not glow after 10 minute warm up Check amp draw on affected element Check all wir
5. slide out Note proper orientation of 2 Remove the two hex head screws securing element spacers to end plate Note proper orientation of spacers 4 Replace bearings spacers and shaft Replace nuts and retainer bars conveyor belt tension adjusting brackets on front and 3 Bend the holding tabs to achieve clearance of rear shafts element 5 Replace conveyor shaft sprocket and drive chain on CAUTION Check for proper voltage amp wattage rear shaft stamped on each element before installation 6 Adjust tension of conveyor belt on front shaft to 4 Reverse this procedure to install new element remove excess slack P Power Cord M Upper Heater Element Assembly Figures 2 amp 3 Figures 3 4 8 9 amp 10 Remove right side panel Section A 1 Remove right and left side panels Remove top cover Disconnect green ground wire and the 2 wires at the and Chimney Section A large wire connectors 2 Remove the 6 sheet metal screws 3 on each side 3 Tilt toaster on back panel Squeeze strain relief securing the assembly to toaster sides bushing and pull out from toaster 3 Disconnect the 2 wires at heating element terminal 4 Reverse this procedure to install new power cord ends Refer to wiring diagram 4 Carefully lift out assembly 5 Reverse this procedure to install new assembly Refer to wiring diagram N Lower Heating Element Assembly Figures 4 8 9 amp 10 1 Remove right and left side panels Sect
6. BLOCK THE FANFROM SPINNING FREELY Energy saver toggle switch control 14614 E Heater control upper or lower 120V 21874 208V 14702 240V 12355 _ Terminal block 21859 Strain relief bushing 12599 Gearmotor 120V 5 5rpm 69716 20B8 240V 5 5rpm 14687 Bottom cover assembly G Terminal Block 2 Remove right side panel and bottom cover Remove the wires at the terminal ends noting proper wire orientation 3 Remove the 2 nuts securing the terminal block to the wall of the toaster 4 Reverse this procedure to install new terminal block Refer to wiring diagram Gearmotor and Motor Sprocket aca amp 3 Remove right side panel and bottom cover Section A 2 Loosen the 4 motor mounting screws and slide motor to achieve slack in the drive chain 3 Loosen set screw on motor sprocket and remove sprocket 4 Remove the 4 mounting screws and lift out moior 5 Disconnect 2 wire leads from motor one at the wire connector and the other at the terminal block 6 Reverse this procedure to install the new motor Refer to wiring diagram Drive Chain eee 3 5 amp 6 Remove right side panel Section Loosen but do NOT remove the 4 mounting screws Slide motor to achieve slack in drive chain and remove chain 3 When installing new chain check for proper chain orientation and tension sheet metal screws securing upper heating element 7
7. be facing towards the front of the unit This will assure proper air circulation and toaster performance Panel Removal 1 The right and left side panels are each secured to the toaster by one sheet metal screw located at the back of the unit Remove this screw and slide Figure 1 ett side panal Nat shown 14556 Eax T Sneed Contrat rob gI2AAT Control panel decal Toast receiving L 20 tray chute 14590 Gantrol panel blank shown 14765 a out the panel When replacing either panel be sure that the panel is properly positioned in the securing track 2 top cover is also held in place with one sheet metal screw Remove this screw and slide the top cover towards the back of the toaster When replacing the top cover be sure that it is properly positioned in the securing tracks 3 bottom cover is secured by two sheet metal screws Remove these screws and pull towards the front of the toaster NOTE PROPER ORIEN TATION OF THE OPEN SIDE OF THE AIR COOLING VENT This opening must always face towards the front of the unit to assure proper toaster performance Main Power On Off Switch Figures 1 amp 2 1 Remove the bottom cover 2 Disconnect the 2 wires at the on off switch terminal ends Note the correct orientation of the wires 3 Remove the rubber on off switch boot old style units and the black plastic mounting bezel 4 on off switc
8. g 000171 Fan blade 5 cw 14619 Right side panel 14554 Toast receiving tray chute 14590 Left side panel 14556 Fan motor mounting bracket 14658 Top cover 14542 Heating element 120V 825W 14648 Chimney 14539 Heating element 208V 1200W 14694 Bottom cover assembly 14732 Heating element 240V 1200W 14673 On Off energy toggle switch 18209 Lower element assembly 120V 14707 Reflector crumb tray assembly 14568 Lower element assembly 208V 14722 14T sprocket assy Drive 208 240V 13733 Lower element assembly 240V 14724 8T sprocket assembly 120V 30494 Upper element assembly 120V 14713 20T sprocket assy drive shaft 120V 14750 Upper element assembly 208V 14723 12T sprocket assembly 208V 240V 69787 Upper element assembly 240V 14725 Drive chain assembly 57 links 120V 13301 Lubricant 21720 1200 JDM 07024 ST 1 PARTS REPLACEMENT INSRUCTIONS WARNING DISCONNECT TOASTER FROM POWER SOURCE BEFORE ATTEMPTING ANY SER VICE PROCEDURES General Information The information on the following pages will describe how to replace the most common components of the ST 1 toaster Though the instructions are easy to follow the work should be done by a qualified service technician All replace ment procedures will first require the removal of one or both toaster side panels and top or bottom covers IMPORTANT When removing or replacing the bottom toaster cover it is extremely impor tant that it be positioned correctly The open side air cooling vent should
9. h can now be removed from the back of the control panel 5 Reverse this procedure to install a new switch Refer to the wiring diagram Chimney not shawn 44599 Top cover 214542 Lo P Hight sida panel 314554 E Aaflector crumb tray 14568 F Heater contro knobs 12919 C Conveyor Speed Control P C Board w 1 amp 2 Remove bottom cover 7 Pull off soeed control knob and remove the nut securing the control board panel Pull out the control from the back of the control panel Cut the wire harness tie and disconnect the 2 wire leads at the wire connectors 4 Reverse this procedure to install the new assembly D Heater Control Switches bs 1 amp 2 Remove bottom cover Pull off heater control knob to gain access to the 2 slotted screws that secure the control to the control panel Remove these 2 screws 3 Disconnect the wires from the control terminal ends noting the proper orientation of the wires 4 Install the new control securing with the 2 slotted screws 5 Re attach wires to the terminal ends Refer to the wiring diagram E Energy Saver Switch m 1 amp 2 Remove bottom cover 5 On the front of the control panel unscrew the rubber switch boot and remove the black plastic mounting bezel securing the switch to the panel In order to gain easier access to the back of the switch remove the upper heater control but do not disconnect the wires Figure 2 Conveyor speed contr
10. ing Replace terminal block Adjust trim pot on speed control to desired low setting Check that control varies the voltage Replace speed control Check voltage at receptacle Be sure it conforms to specitications on toaster data plate Replace plug and or power cord Check all wiring Check all components in order Replace as needed Replace switch es Replace switch Check that fan blade spins freely Replace blade motor as needed Check voltage at receptacle Be sure it conforms to specifications on toaster data plate Replace plug or power cord Check all wiring Check that all components of drive chain assembly are properly installed Check all components in order Replace as needed Replace bearing s Adjust conveyor belt tension Adjust alignment Replace worn sprockets or drive chain Adjust shaft alignment Tighten sprockets Replace drive chain Adjust drive chain Check drive sprockets are secure 18 1 2 14 ge y 15 172 H 314mm 3 17 122 14630 9 4 4 WHT 445mm 14748 1a Hid WHT SUPPLIED a Pd 17618 127 414 WHT UPPER HEATER LOWER HEATER 120 W 14648 120 VW 146468 TERMINAL MOTOR JUUL BLOCK UU y 21608 12626 147 22133 18 14625 12 14633 144 lo 414 r 59560 6 SPEED CONTROL hia ELK INFINITE T 120v 12464 CONTROL
11. ion A Figure 4 reetal screws eC et i s Tahir Berrien assembly 1o une Beer ir hack lensign achusting bracket awe ratasrer 231 T lope F 12658 Drive Chain Orientation 1 4 slack Disconnecting wires at heating elements Checking drive chain tension using pliers to prevent twisting of terminals INCORRECT CORRECT Heating Element Terminals Correct alignment of moter and shaft sprockets Figure 7 Tension adjusting bracket 12508 Conveyor belt assembly S S 58 Links 14647 Hear shaft assembly 14603 Rear spacers 14762 Front shaft assembly 14644 Front spacers Bearings Bearing retainer bracket 14606 20754 12381 Lower Heating Element Assy 120W 14707 B08 14722 cav 14724 Problem INSUFFICIENT OR NO FROM UPPER OR LOWER ELEMENTS i CANNOT REGULATE X CONVEYOR BELT SPEED TOASTER FAILS TO HEAT i HEAT STAYS HIGH CANNOT BE REGULATED TOASTER BECOMES EXCESSIVELY HOT AND SHUTS DOWN CONVEYOR BELT FAILS TO RUN CONVEYOR BELT DOES NOT RUN SMOOTHLY AND OR 15 EXCESSIVELY NOISY GEARMOTOR RUNS BUT CONVEYOR BELT SLIPS OR DOES NOT RUN Individual Heating Elements 120 625W 14645 Soa 1200 414604 q1200VV 14673 Tabs Upper Heating Element Assy 120W 14713 2OBWV 14722 240V
12. nd bearing retainer brackets on both sides of toaster Figure 3 Upper healing element tarminals 14T sprocket assy 208 240V 139733 56 links 14697 208 240V 54 links 12412 120V EC dar m COT Drive chain assembly aT Sprocket Assembly 120V 830484 127 Sprocket 208 240V 468787 un um w motor mounting adjusting 5 Cordset 120V NEMA 5 15P 20047 screws Coraset 206 240V NEMA 6 15P 26064 L Front and Rear Shafts and Bearings 2 Disconnect wires from both upper and lower heating Figures 3 4 5 amp 6 element terminal ends 1 Remove right and left side panels Section A Atleft side of toaster bend the 2 protruding tabs to 2 To remove front shaft and front shaft bearings achieve clearance through slots Remove bearing retainers on both sides of toaster 4 Slide out assembly from right side of toaster Loosen conveyor belt tension adjusting brackets on Reverse this procedure to install new assembly both sides of toaster Bearings with shaft will now Refer to wiring diagram slide out Note proper orientation of spacers 3 To remove rear shaft and rear shaft bearings O Individual Heating Element Remove drive chain Section 1 and conveyor shaft 4 8 9 10 sprocket Section J Remove rear bearing retainer Remove heating element assembly Sections M or brackets from both sides of toaster Bearings with N Shaft will now
13. ol 1209 412464 208 240V 12455 Oni Off toggle switch control 20 68117 Fan motor 120V 14618 20BV 14699 240V 14675 Fan blade 5 CW 14619 Fan shroud 814591 Fan motor mounting bracket Net shown 1465658 Mot shown 14641 4 Disconnect the wires from the energy save switch terminal ends noting the proper wire orientation 5 Install the new switch to the back of the control panel and secure with the black plastic mounting bezel and rubber boot 6 Re attach wires to the terminal ends Refer to wiring diagram 7 Replace the upper heater control switch F Fan Fan Housing Fan Motor one 2 Remove the bottom cover Rotate Fan Blades which will expose 2 nuts securing the fan housing to the motor Remove these two nuts to remove the housing Toremove the fan motor but do NOT remove the 2 motor mounting bracket nuts Slide the motor until clearance is achieved 4 QCutthe wire harness ties to gain access to the wire connector Disconnect the 2 wire leads from the motor one at the wire connector and one at the terminal block 5 Insert the new motor into the motor mounting bracket and tighten the 2 motor mounting bracket nuts 6 Re attach the two wire leads one at the wire connector and one at the terminal block Refer to wiring diagram 7 Install fan housing and secure with the 2 nuts 8 IMPORTANT BE SURE TO RE TIE THE WIRE HARNESS SO THAT THE WIRES DO NOT
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