Service Manual 3/10 - Whaley Food Service
Contents
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4. uoneje1sui juawdinba Jo ay woy ead 8uo polad 10 eq 2 5 sued zuawasejdal pue sjessaA 2524 7 8 4 ueu 18410 syanpoud AINVYUVM IO HISNHI suonipuoo pue eui o 128fqns diusueunpoM 10 erj91eui 128J8p 01884 01 VEEL eunr Jaye paesu syonpoud sued Dureey pue sjasseA ejsed R 18 1 saaw 18 nduio3 794007 w 8piS do suiejs s ejseg dsuy daay suiajs s 18414 819544 Duneey mau je jauo1sn Jaseyoind ay o syueem Buneay jo Buneay SNOISNTOXY ALNVIDIVM AALIWIT OOVIIND 40 C A SERVICE INFORMATION If you have a service related question call 1 800 KEATING Please state the nature of the call it will ensure speaking with the appropriate person Have your serial and model number available when ordering parts KEATING OF CHICAGO INC 8901 West 50th Street McCook Illinois 60525 6001 Phone 708 246 3000 FAX 708 246 3100 Toll Free 1 800 KEATING In U S and Canada www keatingofchicago com As continuous product improvement occurs specifications may be changed without notice KEATING LIMITED WARRANTY CARD PLEASE COMPLETE AND MAIL AT ONCE WARRANTY IS NOT IN EFFECT UNTIL CARD IS RETURNED WARRANTY CARD IS ALSO A
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8. COOKER LIFT ARM ROD U BOLT WITH MOUNTING PLATE SCREW 10 24 X 3 8 SERRATED FLANGE LOCK WASHER 0 190 ID X 0 5630 D X 0 047 THK NICKEL MANUAL TOP SIDE COOKER GAS SPRING ROD NUT 1 4 20 HEX NICKEL PLATED 3 8 2 1 2 CLEVIS PIN COTTER KEYS S S 1 4 20 X 3 THREADED ROD 1 4 STAR WASHER 1 4 20 ACORN NUT WELDMENT HANDLE GEAR GAPPING SYSTEM d gt gt oa oo BR BR PO NM DM AH A N N A AHA O N A AB ABA NN F N PART NUMBER 016659 1 800 KEATING 015164 028181 015164 017316 1 800 KEATING 012118 012119 015046 015173 014247 028622 028486 028487 028501 028491 028488 030241 028461 028464 028518 028519 028521 028522 028490 028500 052114 052266 052251 054444 015262 052269 052287 030269 015414 032328 052117 052286 032327 013217 016383 015164 015166 014226 017046 015227 033828 TOP SIDE COOKER CONTROL PANEL ITEM N M DESCRIPTION THERMOSTAT THERMOSTAT KNOB THERMOSTAT DIAL PLATE HI LIMIT CONTROL HI LIMIT MOUNTING BRACKET CONTACTOR 50A 3 POLE ROCKER SWITCH LIGHTED ON OFF INSTRUCTION PLATE ON OFF SWITCH PLATE INDICATING LIGHT ELEMENT ON RED 250V INSTRUCTION PLATE ELEMENT ON LIGHT PLATE TERMINAL BLOCK 3 POLE COVER without SERIAL PLATE CORD WITHOUT PLUG 12 3 SJO PANEL TRAY QTY
9. head is equipped with a 9 2 74m neoprene covered 12 gauge 4mm 2 three wire with ground electrical cord No plug is provided Each cooking head is rated 4000W 18 amps single phase at 220 Volts 4 37kW 19 amps single phase at 230 Volts and is designed to be connected to its own 208 240V single phase electrical supply For proper connecting and grounding procedure see local codes the National Electrical Code ANSI NFPA 70 latest edition or Canadian Electrical Code CAN C22 1 latest edition as applicable A WARNING THIS APPLIANCE MUST BE EARTHED OPERATING A CAUTION Food will cook much faster with a Top Side Cooker than with a griddle alone Watch food while cooking or use timers to ensure food will not be overcooked A WARNING OPERATION OF THE TOP SIDE COOKER SHOULD BE LIMITED TO PERSONNEL THOROUGHLY TRAINED IN OPERATING PROCEDURES COOKING 1 Turn ON OFF switch to ON position 2 Set thermostat to desired temperature Red ELEMENT ON light will illuminate when the element is on Figure 3 1 Top Side Cooker Control Panel pre 2005 model Maximum thermostat setting 554 F 290 C 2005 current model NOTE The green Power light will be illuminated as long as there is power to the Top Side Cooker COOKING HEIGHT ADJUSTMENT Keating s Top Side Cooker has been designed to allow you infinite height adjustments from 1 8 to 11 2 approximately 3mm to 38mm An ad
10. steel control panel e Stainless steel head cover e MIRACLEAN cooking surface e Proprietary USDA and UL listed polymer cooking sheets e Electronic thermostat e Infinitely adjustable cooking height from 1 8 to 11 2 3mm to 38mm STANDARD ACCESSORIES e Proprietary USDA and UL listed polymer cooking sheets 1 NOTE Keating of Chicago Inc manufacturer reserves the right to change specifications at any time COOKING HEAD SPECIFICATIONS Each Top Side cooking head is designed to be connected to a 208 220 or 240 volt single phase line HEIGHT WIDTH WATTS AMPS 10 1 2 267mm STANDARD TOP SIDE COOKERS e Sizes 1 to 6 heads e Mounting Can be mounted to any standard MIRACLEAN gas or electric 30 762mm deep griddle 24 deep plate 610mm up to 72 wide up to 6 heads maximum e Cooking Surface 10 2 267mm wide x 20 508mm deep per cooking head e Number of heads One head can be used for every 12 305mm of plate width Each Top Side cooking head will be positioned over a griddle thermostat to ensure peak efficiency e ETL and ETL Sanitation listed SAFETY PRECAUTIONS A WARNING THIS SYMBOL WARNS YOU THAT SERIOUS BURNS OR OTHER INJURIES MAY RESULT IF SAFETY INSTRUCTIONS ARE NOT FOLLOWED e DO NOT SUBMERGE THE TOP SIDE COOKING HEAD IN WATER e CLEANING CHEMICALS OR UTENSILS USED FOR CLEANING GRIDDLES WILL DAMAGE OR DESTROY THE POLYMER COOKING SH
11. EET e NEVER USE A WATER JET TO CLEAN Il INSTALLATION This Top Side Cooker MUST be installed on a Keating griddle only Failure to do so voids the warranty The Top Side Cooker must be installed inspected calibrated and serviced by qualified certified and or licensed service personnel Contact your dealer for assistance DAMAGE DURING SHIPMENT The Top Side Cooker has been assembled tested and inspected at the factory Upon arrival the complete Top Side Cooker should be thoroughly checked any damage that may have occurred during shipment What to do if equipment arrives damaged VISIBLE LOSS OR DAMAGE Be certain to note this on the freight or express receipt and have it signed by the delivery person FILE CLAIM FOR DAMAGES IMMEDIATELY Regardless of extent of damage CONCEALED LOSS OR DAMAGE If the damage is noticed when the equipment is unpacked notify the freight company immediately and file a concealed damage claim This MUST be done immediately Be sure to retain the shipping container for inspection Keating does not assume responsibility for loss OR damage incurred in transit INSTALLATION On new installations your Top Side Cooker has already been factory installed tested leveled and inspected When installing onto existing MIRACLEAN griddle use the specific instructions included with the Top Side Cooker ELECTRICAL CONNECTION Each Keating Top Side Cooking
12. SERVICE MANUAL KEATING OF CHICAGO INC Sewing Those Whe Sewe The Very Best TOP SIDE COOKER manufactured years 1998 2004 Keating Of Chicago Inc 1 800 KEATING www keatingofchicago com KEEP THIS MANUAL FOR TRAINING NEW PERSONNEL TABLE CONTENTS SECTION I INTRODUCTION General tsk ed bee 1 Standard Features 1 Standard Accessories 1 Cooking Head Specifications 1 Safety Precautions 1 SECTION II INSTALLATION Damage During Shipment 1 Installation 1 Conditioning the Cooking Head 2 Electrical Connection 2 SECTION OPERATING Cooking SR M a lab ke EN 2 Cooking Height Adjustment 2 s rne RR RD EM 2 Cleaning Procedures 2 3 Cleaning the Cooking Head 3 SECTION IV MAINTENANCE Warranty Repairs 3 Preventive Maintenance 3 4 Installing a Cooking Sheet 4 Handling Cooking Sheets 4 Leveling of Cooking Head 4 5 SECTION V SERVICE DIAGNOSIS Trouble Shooting Chart 5 Thermostat Replacement Instructions 6 7 SECTION VI PARTS LIST Ordering Pa
13. Top Side Cooker on a regular basis The control panel should be cleaned of any greasy residue with a damp cotton cloth Remove any residue from the ON OFF switch and the thermostat knob Wipe down the cabinet sides and back on a regular basis INSTALLING A COOKING SHEET 1 Raise Top Side Cooking head completely 2 Lay the 20 x 24 508mm x 610mm cooking sheet on the griddle plate with 20 508mm dimension front to back 3 Lower the Top Side Cooker head onto the cooking sheet ensuring that the sheet is centered under the head the front edge of the sheet is even with the front edge of the head and the sides of the sheet are parallel to the side of the head 4 Fold both edges of the cooking sheet over the head While gently pulling the right side of the sheet to remove any slack firmly push the cooking sheet mounting clip onto the right side mounting rib on top of the head 5 Repeat process on the left side 6 Reverse the process to remove the cooking sheet TIPS ON PROPER HANDLING AND USE OF COOKING SHEETS To ensure long life of your Keating cooking sheets please follow the tips below Cooking sheets should never e Be folded or creased e Be touched with sharp objects e Come in contact with griddle scrapers or abrasive pads e Be placed under other equipment or objects Cooking sheets should always e Be wiped with a damp soft cotton cloth after each run to remove any product residue
14. VAILABLE TO COMPLETE ON LINE AT YOUR CONVENIENCE COMPANY ADDRESS CITY STATE ZIP DEALER DATE OF PURCHASE INVOICE NUMBER SERIAL NUMBER FRYER FILTER SYSTEM GRIDDLE REMARKS TOP SIDE COOKER HOT PLATE LPASTA PLUS I HAVE READ THE INSTALLATION AND OPERATION INSTRUCTIONS SIGNED DATE Sewing Those Whe Sewe The Very 13
15. e Be cleaned after the griddle is shut down for the day The time to change a Cooking Sheet is when e Product starts sticking to the sheet e Too much carbon build up causes a product appearance cooking or taste problem e The head surface is cool e f the sheet is torn or ripped A WARNING THE TOP SIDE COOKING HEAD AND GRIDDLE PLATE ARE HOT USE PROPER CARE WHEN CHANGING THE COOKING SHEETS LEVELING OF COOKING HEAD S The cooking head s were leveled at the factory NOTE For best results level griddle before checking Adjust legs to level griddle REMOVING OF COOKING HEAD NOTE To identify parts refer to Figure 6 1 on page 6 1 Turn off griddle and disconnect Top Side Cooker electric power 2 Remove the cooking sheet by lifting off cooking sheet mounting clips 3 Place a layer of soft cloth and then a layer of cardboard onto griddle plate under cooking head to protect MIRACLEAN surface 4 Raise cooking head completely to release tension on cooking head support pin Remove support pin and its cotter pin and carefully lower cooking head to protected griddle surface A WARNING The cooking head is not supported after the cooking head support pin has been removed If dropped the weight of the cooking head when unsupported will cause damage to the griddle surface or injury to personnel 5 Do not turn the support pin in either direction 6 To reattach the cooking head to the ram
16. ide view of a cooking had and how the surface can be damaged Proper use of the utensils supplied with your MIRACLEAN Griddle will prevent surface damage Surface Damage CHROMIUM PLATE GLOSE NICKS SPACED NICKS IV MAINTENANCE WARRANTY REPAIRS Keating s warranty begins with the date of installation In the event your Keating Top Side Cooker needs repair under warranty other than routine maintenance or cleaning you are requested to contact KEATING OF CHICAGO INC at 1 800 KEATING before calling a local service company NOTE The cooking sheets are not covered under warranty PREVENTIVE MAINTENANCE Preventive maintenance should be done in daily weekly monthly and yearly intervals as necessary Following preventive maintenance procedures will help keep your Top Side Cooker working efficiently Proper care and servicing will lead to years of quality performance PREVENTIVE MAINTENANCE CHART OPERATOR OWNER SECTION e Clean all cooking sheets II e Clean all MIRACLEAN cooking surfaces e Clean all surfaces of Weekly Top Side Cooker e Verify thermostat settings e Review cooking procedures e Check Cooking Sheets replace if necessary Monthly Yearly QUALIFIED SERVICE PERSONNEL ONLY e Thoroughly check and test Top Side Cooker e Calibrate controls High production facilities should be checked more often Proper care should be taken to fully clean the
17. justing knob allows fast and precise height adjustment Clockwise movement of the knob will increase the spacing counter clockwise movement will decrease the spacing Each turn of the adjusting knob represents 1 8 approximately 3mm movement Experimentation will give you the best cooking height for each type of food product The cooking head should contact the product firmly to ensure optimum heat distribution without flattening the product SHUTDOWN Turn ON OFF switch to OFF position CLEANING PROCEDURES A Keating Cooking Sheets e Clean cooking sheets with a damp soft cloth after each run of product a Turkish towel works best A WARNING THE COOKING HEAD WILL BE HOT USE PROPER CARE WHEN CLEANING THE COOKING SHEETS End of day cleaning Before the griddle is turned off for the day the cooking sheets should be cleaned as described below Wear heat resistant gloves for maximum safety during the entire cleaning procedure 1 At the end of the day wipe the cooking sheet in place with a damp soft cloth Continue wiping until the surface of the cooking sheet is free of any residue 2 Remove the cooking sheet from the cooking head Clean the cooking head and the griddle surfaces 3 Wash the cooking sheet with a mild detergent in warm water and dry thoroughly 4 After the cleaning is complete reverse the cooking sheet and reattach it to the cooking head B Cooking Sheet Clips To remove the stainless s
18. lift arm raise cooking head completely and replace cooking head support pin Insert a new stainless steel cotter pin to secure support pin holding support pin to keep it from spinning 7 Replace cooking sheet See Installing a Cooking Sheet V SERVICE DIAGNOSIS A properly adjusted Keating Top Side Cooker with no load will cycle ON approximately every 5 2 to 6 minutes Each cycle will last 40 seconds ensuring that the temperature setting is held within a narrow range A Trouble Shooting The following diagnosis is only to be used as a guide to qualified service personnel Keating recommends that you use a qualified service company A WARNING Disconnect power before service PROBLEM POWER ON light does not come on ELEMENT ON light does not come on and cooking head will not heat ELEMENT ON light does not come on but cooking head does heat ELEMENT ON light flashes once whenever power is turned on ELEMENT ON light comes on but cooking head will not heat Temperature of cooking head is erratic PROBABLE CAUSE No electricity to Top Side Cooker b ON OFF switch is faulty a Connections to thermostat are loose or thermostat is faulty Connections to thermostat temperature probe are loose or probe is faulty Hi Limit has tripped or Hi Limit is faulty Connections to Hi Limit are loose or Hi Limit is faulty Connections to contacto
19. ng plates on the Keating Top Side Cooker should be in place at all times If plates are damaged or lost replace them immediately TOP SIDE COOKING HEAD Figure 6 1 38 3940 46 47 48 49 50 control box TOP SIDE COOKING HEAD FOR MANUFACTURED YEARS 4 99 2004 Figure 6 1 ITEM N DESCRIPTION THERMOSTAT TEMPERATURE PROBE KIT COOKING HEAD COMPLETE STOP CLEVIS PIN S S SWIVEL BRACKET WIRE SLEEVE INCL IN ITEM 5 SWIVEL BRACKET SWIVEL BRACKET SUPPORT CLEVIS PIN S S COOKING SHEET MOUNTING CLIP COVER COOKING SHEET SINGLE SHEET COOKING SHEET PACKAGE OF 12 MIRACLEAN COOKING FACE PLATE HEATING ELEMENT 4KW 220V NOT SHOWN HIGH LIMIT PROBE HIGH LIMIT PROBE MOUNTING PLATE KNOB COLLAR WORM GEAR 1 4 20X 1 4 ALLEN SET SCREW HOUSING COVER WORM GEAR WHEEL SPUR GEAR SHAFT REAR COVER FRONT HOUSING REAR HOUSING FRONT PLUNGER REAR PLUNGER NOT SHOWN TEFLON WASHER NOT SHOWN FIBER WASHER NOT SHOWN TOP SIDE COOKER WELD MANUAL TOP SIDE COOKER SPRING SUPPORT WELDMENT MANUAL TOP SIDE GAS SPRING LIFT MANUAL TOP SIDE COOKER GAS SPRING SCREW 5 16 18 X 3 4 HEAD ZINC PLATED TOP SIDE COOKER SUPPORT BRACE GAS TOP SIDE CONDUIT SUPPORT NUT RIVET 1 4 20 X 5 8 0 332 BODY WASHER 1 410 X 7 80D X 1 16 THK NICKEL SCREW 1 4 20 X 3 4 SERRATED FLANGE LOCK TOP SIDE
20. r are loose or contactor is faulty ON OFF switch is faulty ELEMENT ON light is faulty Thermostat temperature probe or wires have shorted out Cooker has not been reset If erratic thermostat is faulty SOLUTION Connect Top Side Cooker to an approved source of power Replace ON OFF switch Check connections and tighten where necessary If thermostat is faulty replace Check connections and tighten where necessary If probe is faulty replace it Wait until cooking head cools down If ELEMENT ON light will not come on Hi Limit is faulty replace it Check connections and tighten where necessary Check connections and tighten where necessary If contactor is faulty replace it Replace ON OFF switch Replace ELEMENT ON light Element on light is part of the thermostat Replace probe and or wires Press Reset Start switch Replace thermostat THERMOSTAT REPLACEMENT KIT PART 057138 MOUNTING AND WIRING INSTRUCTIONS New Thermostat Mounting and Wiring Instructions 1 After removing the old thermostat drill four larger holes for mounting new housing See Figure After drilling holes remove any metal filings from inside the unit 2 Feed the female ends of the four new wires from the inside to the outside of the unit through the old thermostat s mounting hole FI 3 Connect the male ends of the four new wires to the female gt ends of
21. rts 8 Warning and Operating Plates 8 Top Side Cooking Head Exploded View 8 Top Side Cooking Head Parts List 9 Control Panel Assembly 10 SECTION VII WIRING DIAGRAMS Wiring Diagrams 11 3 10 TopSide NOTICE This operating installation and service manual should given to the user The operator of the griddle should be familiar with the functions and operation of the griddle This manual must be kept in a prominent easily reachable location near the griddle Notice Keating of Chicago Inc manufacturer reserves the right to change specifications at any time FOR YOUR SAFETY AWARNING IMPROPER INSTALLATION ADJUSTMENT DO NOT STORE OR ALTERATION SERVICE OR MAINTENANCE USE GASOLINE OR CAN CAUSE PROPERTY DAMAGE INJURY OTHER FLAMMABLE VAPORS OR LIQUIDS OR DEATH READ THESE INSTALLATION IN THE VICINITY OF OPERATING AND MAINTENANCE THIS OR ANY OTHER INSTRUCTIONS THOROUGHLY BEFORE APPLIANCE INSTALLING OR SERVICING THIS EQUIPMENT A WARNING Before obtaining access to terminals all supply circuits must be disconnected IINTRODUCTION GENERAL Keating Top Side Cookers are designed to give maximum production efficiency delivering high quality food products The following design features are incorporated into Keating Top Side Cookers STANDARD FEATURES e Stainless
22. teel cooking sheet clips for cleaning simply lift them off They can be cleaned in a dishwasher C Cooking Head The MIRACLEANG surface is very durable and with proper care following the procedures below will last many years 1 Scrape MIRACLEAN surface from front to back with the Keating griddle scraper with Cooking Sheets removed 2 Clean and polish surface wit Keating Klenzer on a damp soft cotton cloth Wipe off excess Klenzer NOTE Keating Klenzer MSDS Sheet available online at www keatingofchicago com A WARNING BECAUSE OF THE SUPERIOR MIRACLEANG SURFACE THE ONLY TOOLS YOU WILL EVER NEED TO CLEAN THE TOP SIDE COOKING HEAD ARE A DAMP SOFT COTTON CLOTH AND A KEATING SCRAPER e NEVER USE A GRIDDLE STONE BRICK GRIDDLE SCREEN OR HARSH CHEMICALS TO CLEAN THE MIRACLEAN SURFACE e DAMAGE DONE TO THE MIRACLEAN SURFACE BY GRIDDLE STONE BRICK SCREEN OR HARSH CHEMICALS WILL VOID THE WARRANT Y e THE DAMAGE DONE TO THE MIRACLEAN SURFACE IS IRREPARABLE e NEVER USE ICE TO COOL THE MIRACLEANG SURFACE AS IT MAY WARP THE MIRACLEANG SURFACE e USE ONLY KEATING SUPPLIED CLEANING TOOLS AND KLENZER e USE ONLY A KEATING STEEL SPATULA A CAUTION Do not hack chop or hit the surface You will dent the steel plate under the trivalent chrome It is even possible to hack two nicks close together and actually tear the MIRACLEAN surface as the chromium will not stretch Below is a sketch showing a s
23. the wires that came off the old thermostat L1 L2 wid rharmostat X p 250 DRE TUR COM and N O Mounting Hole 4 places 4 Feed the new sensor wire through the old thermostat s ELEMENT Figure A mounting hole Location of old thermostat mounting hole and where new holes 5 Remove the two spade connectors that are attached should be drilled the unit thermostat s sensor wire 6 Strip 3 8 of insulation from each of the four ends of the thermostat s sensor wires 7 Place tubing on both leads of the thermostat s sensor wire ra 8 Attach the two pairs of thermostat wires using butt connectors See Figure C wiring diagram on reverse 9 Shrink the tubing over the butt connectors on the thermostat s sensor wire 10 Mount new housing to the control panel 11 Connect all six wires to the new thermostat See Figure C lt 7 wiring diagram on reverse V 12 Place the new thermostat in the housing and tighten the four screws See Figure B f ls vest New thermostat Operating Instructions Operating l FIL When the thermostat is powered up the display will show the set operating temperature To change the operating t temperature push and hold the SET button L and turn the adjustment knob until the desired temperature uq m is displayed Release the button to lock in the set
24. ting Side view Figure B Temperature offset E New Thermostat Housing and Control Panel To change the offset power off the unit Push and hold the PUSH TO SET button re apply power to the unit while still holding the button down Turn the adjustment knob to the desired amount of offset release the button to lock in the setting Adjust the setting to a positive number if the cooker s temperature is higher than the set temperature Adjust the setting to a negative number if the cooker s temperature is lower than the set temperature Existing Wiring TERMINAL x old unit New Unit a REDI wiring wiring Thermostat as ae Seas x W Wires s TC S2 RED RED TC TC S1 BLACK COM N 0 New Thermostat Part 056840 BLACK Rear View NA A BLACK t2 RED L1 L1 Figure C Wiring Diagram Wiring Diagram VI EXPLODED VIEW amp PARTS LIST ORDERING PARTS Parts may be ordered by part number by calling 1 800 KEATING or your local service company You may also order online at Keating s part store www keatingofchicago com Refer to the Keating Top Side Cooker Limited Warranty for complete service and ordering information The model serial plate for each cooking head is located on the the control panel assembly The serial and model numbers are necessary when ordering WARNING AND OPERATING PLATES All warning and operati
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