User manual TOASTMASTER TMDC36

Medium Duty Counterline INSTALLATION - OPERATION - MAINTENANCE Griddle Models TMDG-24, TMDG-36 (shown) and TMDG-48 Charbroiler Models TMDC-24, TMDC-36 (shown) and TMDC-48 Open Top Models TMDO-12, TMDO-24 and TMDO-36 (shown) Middleby Philippines Corporation ~ 113 Technology Ave., Laguna Technopark Inc., Binan, Laguna, Philippines 4024 Phone (632) 5208170 - Fax (632) 5208191 - www.middleby.com MANUAL MDC 0804-MDO-MDC SAFETY PRECAUTIONS Before installing and operating this equipment, be sure everyone involved in its operation is fully trained and aware of precautions. Accidents and problems can be caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or to the equipment. DANGER WARNING CAUTION NOTICE This symbol warns of immediate hazards that will result in serve injury or death. This symbol refers to a potential hazard or unsafe practice that could result in injury or death. This symbol refers to a potential hazard or unsafe practice that could result in injury, product damage, or property damage. This symbol refers to information that needs special attention or must be fully understood, even though not dangerous. WARNING FIRE HAZARD FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Keep area around appliances free and clear of combustibles. Purchaser of equipment must post in a prominent location, detailed instructions to be followed in the event the operator smells gas. Obtain the instructions from the local gas supplier. WARNING Asphyxiation can result from improper ventilation. Do not obstruct the flow of combustion and ventilation air to and from your cooking equipment. NOTICE Be sure this Operator's Manual and important papers are given to the proper authority to retain for future reference. Toastmaster ® PAGE 2 MEDIUM DUTY COUNTERLINE TABLE OF CONTENTS Congratulations! You have purchased one of the finest pieces of commercial cooking equipment on the market. You will find that your new equipment, like all Toastmaster equipment, has been designed and manufactured to meet the toughest standards in the industry. Each piece of toastmaster equipment is carefully engineered and designs are verified through laboratory tests and field installations. With proper care and field maintenance you will experience years of reliable, trouble-free operation. For best results, read this manual carefully. RETAIN THIS MANUAL FOR FUTURE REFERENCE. Table of Contents Specifications Installation Operation Cleaning Adjustments Troubleshooting Parts 4 9 12 14 16 18 21 Read these instructions carefully before attempting installation. Installation and initial startup should be performed by a qualified installer. Unless the installation instructions for this product are followed by a qualified service technician (a person experienced in and knowledgeable with the installation of commercial gas an/or electric cooking equipment) then the terms and conditions on the Manufacturer's Limited Warranty will be rendered void and no warranty of any kind shall apply. In the event you have questions concerning the installation, use, care, or service of the product, write to: MIDDLEBY COOKING SYSTEM ~ Philippine Factory : 113 Technology Ave., Laguna Technopark, Binan Laguna, Philippines, 4024 * Tel. Nos. (632) 520-8170 to 79 Fax No.: (632) 520-8191 USA Factory : 1400 Toastmaster Drive, Elgin, IL 60120 Tel. (847) 741-3300 The serial plate is located on the interior side of the valve panel, as shown below: Figure 1 Serial plate is located on the outer left side and upper right side of front panel PAGE3 Toastmaster ® SPECIFICATIONS MEDIUM DUTY COUNTERLINE SPECIFICATIONS NOTICE Installation must comply with National Fuel Gas Code, ANSI Z223.1, Natural Gas Installation Code, CAN/CGA-B149.1, or the Propane Instalation Code, CAN/CGA-B149.2, as applicable. Local codes regarding installation vary greatly from one area to another. The National Fire Protection Association, Inc. states in its NFPA 96 latest edition that local codes are the "authority" having jurisdiction" when it comes to installation requirements for equipment. Therefore, installations should comply with all locals codes. Toastmaster reserves the right to change specifications and product design without notice. Such revisions do not entitle the buyer to corresponding changes, additions, or replacements for previously purchased equipment. This product is intented for commercial use only, not for household use. GAS SUPPLY The Serial Plate is located on the interior side of the valve panel (see Figure 1 on page 3). It indicates the type of gas the unit is equipped to burn. All Toastmaster equipment is adjusted at the factory. Check type of gas on serial plate. These models are design-certified for operation on natural or propane gases. The unit is shipped configured for natural gas. A kit for conversion to using propane gas is included (see instructions in kit or page 9 of this manual). This appliance should be connected ONLY to the type of gas for which it is configured. An adequate gas supply is imperative. Undersized or low pressure lines will restrict the volume of gas required for satisfactory performance. Fluctuations of more than 25% on natural gas or 10% on propane gas will create problems and affect burner operating characteristics. A 1/8" pressure tap is located on the manifold to measure the manifold pressure. An adequate gas supply line to the unit should be no smaller than the inside diameter of the pipe from the unit to which it is connected. Purge the supply line to clean out dust, dirt, or other foreign matter before connecting the line to the unit. All pipe joints and connections must be tested thoroughly for gas leaks. Use only soapy water for testing on all gases. NEVER use an open flame to check for gas leaks. All connections must be checked for leaks after the unit has been put into operation. Test pressure should not exceed 14" W.C. CAUTION THIS APPLIANCE AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE DISCONNECTED FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF 1/2 PSIG (3.45 kPa). THIS APPLIANCE MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS INDIVIDUAL MANUAL SHUTOFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES EQUAL TO OR LESS THAN 1/2 PSIG (3.45 kPa). SPECIFICATIONS Toastmaster ® PAGE 4 MEDIUM DUTY COUNTERLINE CLEARANCES WARNING SPECIFICATIONS There must be adequate clearance between units and adjacent construction. Clearance must also be provided for servicing and for operation. Minimum Clearances from COMBUSTABLE construction: Griddle Models Sides Back Bottom 4" 4" 4" Open Top Models 6" 6" 6" Minimum Clearances from NON-COMBUSTABLE construction: Griddle Models Sides Back Bottom 0" 0" 4" Charbroiler Models 4" 4" 4" Open Top Models 0" 0" 4" VENTILATION WARNING Improper ventilation can result in personal injury or death. Ventillation which fails to propely remove flue products can cause headaches, nausea, or could result in death. All units must be installed in such a manner that the flow of combustion and ventilation air are not obstructed. Provisions for adequate air supply must be provided. Do not obstruct the front of the unit at the top by the control panel as combustion air enters these areas. NOTICE Proper ventillation is the owner's responsibility. Any problem due to improper ventilation will not be covered by the warranty. SPECIFICATIONS All units must be installed in such a manner that the flow of combustion and ventillation air are not obstructed. Provisions for an adequate air supply must be provided. Do not obstruct the front or rear of the unit, as combustion air enters through this area. Be sure to inspect and clean the ventillation system according to the ventillation equipment manufacturer's instruction. In case of unsatisfactory performance on any appliance, check the appliance with the hood exhaust fan in the "OFF" position. Do this only long enough to check equipment performance. Then turn the fan back on and left it run to remove any exhaust that may have accumulated during the test. PAGE 5 Toastmaster ® SPECIFICATIONS Figure 2 MEDIUM DUTY COUNTERLINE DIMENSIONS OF GRIDDLE Model TMDG-24 TMDG-36 TMDG-48 "A" (Width) 24" 36" 48" Number and Size of Burners 2@30,000 3@30,000 4@30,000 Total BTU 60,000 90,000 120,000 SPECIFICATIONS PAGE 6 Toastmaster ® MEDIUM DUTY COUNTERLINE Figure 3 SPECIFICATIONS DIMENSIONS OF CHARBROILER MODELS Model TMDC-24 TMDC-36 TMDC-48 "A" (Width) 24" 36" 48" Number and Size of Burners 2@30,000 3@30,000 4@30,000 Total BTU 60,000 90,000 120,000 SPECIFICATIONS PAGE 7 Toastmaster ® SPECIFICATIONS Figure 4 MEDIUM DUTY COUNTERLINE DIMENSIONS OF OPEN TOP MODELS Model TMDO-12 TMDO-24 TMDO-36 "A" (Width) 12.25" 24.375" 36.50" Number and Size of Burners 2@20,000 4@20,000 6@20,000 Total BTU 40,000 80,000 120,000 SPECIFICATIONS Toastmaster ® PAGE 8 MEDIUM DUTY COUNTERLINE Installation INSTALLATION NOTICE Installation must comply with National Fuel Gas Code, ANSI Z223.1, Natural Gas Installation Code, CAN/CGA-B149.1, or the Propane Instalation Code, CAN/CGA-B149.2, as applicable. These installation procedures must be followed by qualified personnel or warranty will be void. Local codes regarding installation vary greatly from one area to another. The National Fire Protection Association, Inc. states in its NFPA 96 latest edition that local codes are the "authority having jurisdiction" when it comes to installation requirements for equipment. Therefore, installations should comply with all locals codes. Step 1: Unpack IMMEDIATELY INSPECT FOR SHIPPING DAMAGE All containers should be examined for damage before and during unloading. The freight carrier has assumed responsibility for its safe transit and delivery. If damaged equipment is received, either apparent or concealed, a claim must be made with the delivering carrier. Apparent damage or loss must be noted on the freight bill at the time of delivery. The freight bill must then be signed by the carrier representative (Driver). If the bill is not signed, the carrier may refuse the claim. The carrier can supply the necessary forms. A request for inspection must be made to the carrier within 15 days if there is concealed damage or loss that is not apparent until after the equipment is uncrated. The carrier should arrange an inspection. Be certain to hold all contents plus all packing material. 1. 2. Uncrate carefully. Report any hidden damage to the freight carrier IMMEDIATELY. Do not remove any tags or labels until unit is installed and working properly. Step 2: Convert Unit to Use Propane Gas (if necessary) Each unit is shipped equipped with fixed orifice hoods appropriate for use with natural gas. If propane gas will be used, convert the unit for use with propane gas by the following procedure: 1. 2. Remove the front panel by removing the knobs and screws on the front. For charbroiler and open top models, remove the grates and burners to access the orifices from above. For griddle models, slide the burner toward the rear of the unit to access the orifices (see diagram on page 22), OR remove the griddle plate to access the orifices by removing two nuts at the rear of the unit. Remove the natural gas orifices and install the furnished propane orifices. Re-install the burners. Re-install the front panel. Remove the hex-threaded plug from the pressure regulator. Inside is a removable insert. Pull the insert out, turn it around, and put it back in so that the end with the letters "LP" is now facing you. Re-attach the hex-threaded plug. The pressure regulator is now set for 10" (25.4cm) water column. Check the pressure. Toastmaster ® 3. INSTALLATION 4. 5. 6. 7. PAGE 9 INSTALLATION MEDIUM DUTY COUNTERLINE Provided orifices are size #45 for natural gas and #55 for propane gas. For special gas mixtures, and for altitudes above 2,000 feet, consult factory for appropriate orifice sizes. Step 3: Connect Gas Supply All units are shipped from the factory equipped for use with natural gas. If the unit is to be used with propane gas, the orifices must be replaced and the pressure regulator converted (see Step 2 on previous page). If this equipment is being installed at over 2,000 feet altitude and that information was not specified when ordered, contact the appropriate authorized Toastmaster Service Representative of the Toastmaster Service Department. Failure to install with proper orifice sizing in poor performance and may void the warranty. The Serial Plate is located on the interior side of the valve panel (see Figure 1 on page 3). It indicates the type of gas the unit is equipped to burn. All Toastmaster equipment is adjusted at the factory. Check type of gas on serial plate. These models are design-certified for operation on natural or propane gases. For natural gas, the convertible regulator is set to deliver a 4"W.C. pressure to the manifold. For propane gas, it is set to deliver 10" W.C. If applicable, the vent line from the gas appliance pressure regulator shall be installed to the outdoors in accordance with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1, Natural Gas Installation Code, CAN/CGA-B149.1, or the Propane Installation Code, CAN/CGAB149.2, as applicable. This appliance should be connected ONLY to the type of gas for which it is equipped. An adequate gas supply is imperative. Undersized or low pressure lines will restrict the volume of gas required for satisfactory performance. Fluctuations of more than 25% on natural gas or 10% on propane gas will create problems and affect burner operating characteristics. A 1/8" pressure tap is located on the manifold to measure pressure. An adequate gas supply line to the unit should be no smaller than the I.D. of the pipe from the unit to which it is connected. Purge the supply line to clean out dust, dirt, or other foreign matter before connecting the line to the unit. Use pipe joint compound that is suitable for use with LP gas on all threaded connections. CAUTION ALL PIPE JOINTS AND CONNECTIONS MUST BE TESTED THOROUGHLY FOR GAS LEAKS. USE ONLY SOAPY WATER FOR TESTING ON ALL GASES. NEVER USE AN OPEN FLAME TO CHECK FOR GAS LEAKS. ALL CONNECTIONS MUST BE CHECKED FOR LEAKS AFTER THE UNIT HAS BEEN PUT INTO OPERATION. TEST PRESSURE SHOULD NOT EXCEED 14" W.C. INSTALLATION Step 4: Position Unit for Operation 1. Check that the unit is level. The length of each leg is adjustable by screwing the bottom portion of the leg in or out. The unit must be level for proper operation! 2. Check for adequate clearances around the unit (see page 5). 3. Check for adequate ventilation (see page 5). Toastmaster ® PAGE 10 MEDIUM DUTY COUNTERLINE Step 5: Adjust Air Shutters and Pilot Heights Installation All units are adjusted at the factory. However, burner air shutters and pilot heights should be checked at installation and adjusted if necessary. On new installations, start with the burner of the unit(s) furthest from the gas input to the manifold. This will purge the system of air. 1. Turn main gas supply "ON". 2. Follow the instructions on pages 12 to 13 light the pilots and burners. 3. If the burner flame is strong but lifting from the burner, loosen the screw on the air shutter and close the shutter a little at a time until the flame settles back onto the burner. Step 6: Condition Griddle Surface For griddle and thermostatic-griddle models, the new griddle surface should be carefully tempered and cared for in order to avoid possible damage. To break in a new griddle, first wipe it clean. Next, light all the griddle burners and turn them to low for one hour. Then gradually bring each griddle up to frying temperature. Next, spread three or four ounces of beef suet, or as a substitute, baking soda, to season it. Never allow water on a hot griddle and never wash it with soap and water. INSTALLATION PAGE 11 Toastmaster ® OPERATION OPERATION DANGER EXPLOSION HAZARD MEDIUM DUTY COUNTERLINE Purchaser of equipment must post in a prominent location, detailed instructions to be followed in the event the operator smells gas. Obtain the instructions from the local gas supplier. CAUTION To eliminate gas build up which could result in an explosion, in the event of main burner ignition failure a five minute purge period must be observed prior to re-establishing ignition source. CAUTION Top section pilots, when out, do not interrupt the flow of gas to the burners. Consequently, it is the responsibility of the operator to check the ignition of the burners, immediately after burner value has been turned "ON". Should ignition fail after 10 seconds, turn off burners, wait 5 minutes, and then try again. LIGHTING AFTER GAS HAS BEEN SHUT OFF When turning the main gas supply on after the gas supply has been shut off, do the following: 1. Make sure all of the control valves are in the "OFF" position. 2. Turn on the gas supply. 3. Light the pilots as described below. GRIDDLE Each 12"-wide griddle section has a knob on the front panel that directly controls the flow of gas, and so the heat. Turn the knob clockwise to increase the heat; turn it counterclockwise to reduce the heat. At the end of each day's use, turn all knobs to the "OFF" position. After each period of use, allow the griddle surface to cool normally. After the griddle has cooled, coat the griddle surface with a light film of cooking oil to protect the surface from moisture. To light the pilot of a griddle section, do the following: 1. Turn all control knobs to the "OFF" position. 2. Light the pilot tube located next to each burner. The pilot flame can be adjusted by turning the screw on the end of the pilot fitting. OPERATION 3. Turn burner knobs to "HI" position. The burners should have a 1/2" to 5/8" steady blue flame. Adjust if necessary. 4. To turn burners off, turn knob to "OFF" position. Toastmaster ® PAGE 12 MEDIUM DUTY COUNTERLINE CHARBROILERS MODELS OPERATION Each 12"-wide charbroiler section has a knob on the front panel that directly controls the flow of gas, and so the heat. Turn the knob clockwise to increase the heat; turn it counterclockwise to reduce the heat. At the end of each day's use, turn all knobs to the "OFF" position. To light the pilot of a charbroiler section, do the following: 1. 2. 3. 4. Turn all control knobs to the "OFF" position. Light the pilot tube located next to each burner. The pilot flame can be adjusted by turning the screw on the end of the pilot fitting. Turn burner knobs to "HI" position. The burners should have a 1/2" to 5/8" steady blue flame. Adjust if necessary. To turn burner's off, turn knob to "OFF" position. OPEN-TOP BURNER MODELS Each 12"-wide open-top burner section has two knobs on the front panel that directly control the flow of gas to the section's two burners, and so control the heat. Turn a knob clockwise to increase the heat; turn it counterclockwise to reduce the heat. At the end of each day's use, turn all knobs to the "OFF" position. To light the pilots of an open-top burner section, do the following: 1. 2. 3. 4. 5. 6. Turn all gas valves to the "OFF" position. Check to make sure pilots are in the correct position. Light the pilots. Adjust the pilot flame as necessary. Turn burner knobs to "HI" position. Each burner flame should be steady blue and impinge on the underside of a pot placed on the support grate. Adjust if necessary. To turn burners off, turn knob to "OFF" position. OVERNIGHT SHUTDOWN Turn knobs to the OFF" position to turn the burners off. Figure 5 OPERATION Main Gas Supply Valve Toastmaster PAGE 13 ® CLEANING CLEANING MEDIUM DUTY COUNTERLINE Toastmaster equipment is constructed with the best quality materials and is designed to provide durable service when properly maintained. To expect the best performance, your equipment must be maintained in good condition and cleaned daily. Naturally, the frequency and extent of cleaning depends on the amount and degree of usage. EXTERIOR AND TOP SECTIONS: 1. Keep exposed, cleanable areas of unit clean at all times. Daily: A. Remove, empty, and clean grease drawers and dirt trays. B. Clean griddle drain chutes. Monthly: A. Clean around burner air mixers and orifices if lint has accumulated. B. Visually assure proper pilot operation. STAINLESS STEEL SURFACES 1. To remove normal dirt, grease and product residue from stainless steel that operates at LOW temperature, use ordinary soap and water (with or without detergent) applied with a sponge or cloth. Dry thoroughly with a clean cloth. 2. To remove grease and food splatter, or condensed vapors, that have BAKED on the equipment, apply cleanser to a damp cloth or sponge and rub cleanser on the metal in the direction of the polishing lines on the metal. Rubbing cleanser, as gently as possible, in the direction of the polished lines will not mark the finish of the stainless steel. NEVER RUB WITH A CIRCULAR MOTION. Soil and burnt deposits which do not respond to the above procedure can usually be removed by rubbing the surface with SCOTCH-BRITE scouring pads or STAINLESS scouring pads. DO NOT USE ORDINARY STEEL WOOL, as any particles left on the surface will rust and further spoil the appearance of the finish. NEVER USE A WIRE BRUSH, STEEL SCOURING PADS (EXCEPT STAINLESS), SCRAPPER, FILE OR OTHER STEEL TOOLS. Surfaces which are marred collect dirt more rapidly and become more difficult to clean. Marring also increases the possibility of corrosive attack. Refinishing may then be required. 3. To remove heat tint - Darkened areas sometimes appear on stainless steel surfaces where the area has been subjected to excessive heat. These darkened areas are caused by thickening of the protective surface of the stainless steel and are not harmful. Heat tint can normally be removed by the foregoing, but tint which does not respond to this procedure calls for a vigorous scouring in the direction of the polish lines, using SCOTCH-BRITE scouring pad in combination with a powered cleanser. Heat tint action may be lessened by not applying, or by reducing heat to equipment during slack periods. BURNERS - GENERAL Little attention is needed, but if spillage should occur, it may be necessary to clean around pilot areas, air mixer and under burners. Use a wire brush if necessary. Periodically, burners (particularly open top type) should be removed and cleaned. Allow interior to drain. Dry thoroughly before replacing. CLEANING Toastmaster ® PAGE 14 MEDIUM DUTY COUNTERLINE CLEANING CARE OF GRIDDLES New griddles should be carefully tempered and cared for in order to avoid possible damage. To break in a new griddle, first wipe it clean. Next, light all the griddle burners and turn them to low for one hour. Then gradually bring each griddle up to frying temperature. Next, spread three or four ounces of beef suet, or as a substitute, baking soda, to season it. Never allow water on a hot griddle and never wash it with soap and water. Use a Norton Alundum Griddle Brick to clean the griddle. Always remember to heat griddle slowly because quick heat may cause costly damage. Griddle plates cannot be guaranteed against damage due to carelesness. Never place utensils on griddle. Do not overheat griddle above 550°F, as this will cause warpage or breakage. Do not use any type of steel wool. Small particles may be left on the surface and get into food products. Do not clean spatula by hitting the edge on the griddle plate. Such action will only cut and pit the griddle plate, leaving it rough and hard to clean. Do not waste gas or abuse equipment by leaving valves at "Full On" position or thermostat at a high temperature if not required. During idle periods, set valves at "Low" position or thermostats to low temperature settings to keep griddle warm. Reset valves or thermostats, as required, for periods of heavy load. Turn valves or thermostats to "OFF" at end of daily operation. CLEANING PAGE 15 Toastmaster ® ADJUSTMENTS ADJUSTMENTS WARNING MEDIUM DUTY COUNTERLINE ADJUSTMENTS AND SERVICE WORK MAY BE PERFORMED ONLY BY A QUALIFIED TECHNICIAN WHO IS EXPERIENCED IN, AND KNOWLEDGEABLE WITH, THE OPERATION OF COMMERCIAL COOKING EQUIPMENT. HOWEVER, TO ASSURE YOUR CONFIDENCE, CONTACT YOUR AUTHORIZED SERVICE AGENCY FOR RELIABLE SERVICE, DEPENDABLE ADVICE OR OTHER ASSITANCE, AND FOR GENUINE FACTORY PARTS. In case of problems in operation at initial installation, check type of gas and manifold pressure and compare with information listed on the serial plate. GAS PRESSURE REGULATOR The convertible pressure regulator is factory set at 4"W.C. for natural gas. (To convert for use with propane gas (10"W.C.), follow the procedure on page 9). To check the manifold pressure: 1. Turn all burner gas valve to "OFF" position. 2. Turn main gas valve to entire unit off. 3. Remove front panel and locate 1/8" plug in manifold. 4. Remove plug and install a fitting appropriate to connect a manometer. 5. Turn on main gas to unit and light pilots. 6. Turn all burners and ovens to full "ON" position and read manometer. 7. If manometer does not read 4"W.C. for natural gas (or 10"W.C. for propane gas), check the incoming gas line for proper pressure. 8. Remove manometer fitting and replace plug in manifold. 9. Repeat step 5. 10. Replace front panel. TOP PILOTS: NON-AERATED (YELLOW-TIPPED FLAME) TYPE Outage is often caused by an unstable flame due to over-adjustment to the point where the flame is leaving its port, or "blowing off". Often, in an effort to improve ignition, the pilots are increased too much and result in this unstable condition. These pilots are adjusted by inserting the blade of a screwdriver into the slot on the small valve, located on the manifold. The maximum flame size is approximately 3/4" with a slight yellow tip. The first indication of over-adjustment is evident when the yellow tip begins to stream into black streaks and generate carbon. Continued over-adjustment leads to the unstable lifting and blowing condition. ADJUSTMENTS ALL TOP BURNERS All burners have a primary air adjustment by means of an air shutter on the mixer face. Loosen screw and rotate mixer cap until a clear, stable blue flame is obtained. The flame should not be yellow tipped nor should it blow off the burner ports. Toastmaster ® PAGE 16 MEDIUM DUTY COUNTERLINE ADJUSTMENTS All orifices sizes and burner rate are properly set at the factory and should not be altered. Over-rated burners cause poor burner and pilot performance, resulting in less heat, and wasted gas. Over-gassed burners DO NOT heat griddles as those that are properly adjusted. Such conditions also create "hot spots" on griddles. Floating and unstable burner and pilot flames will result when solid tops are lowered into position because the rear openings of the burner compartment are not adequate to vent the enormous flue products generated by over-gassed burners. The "unburned" gas will ignite at the rear and burn in this section and even up inside the backguard or shelf venting system, causing structural members in this area to deteriorate. Also, some of these hot flue products will vent forward into the manifold compartment resulting in problems with valves and thermostats due to overheating. AGAIN, over-rated burners waste energy and cause service problems. ADJUSTMENTS PAGE 17 Toastmaster ® TROUBLESHOOTING MEDIUM DUTY COUNTERLINE TROUBLESHOOTING Consult the following table and the flowchart that begins on the following page. Problem All burners and pilots in unit will not turn on All burners produce excessive carbon deposits Only some burners in a unit produce excessive carbon deposits Only some pilots produce excessive carbon deposits Top burner will not come on Look for -Main gas supply to unit is "OFF" -Incorrect gas type supplied to unit. -Incorrect supply pressure. -Incorrect orifices. -Primary air not adjusted properly. -Pilot gas not adjusted properly. -Incorrect pilot office. -Manual valve for top burner in "OFF" position -Pilot out. -Pilot gas not adjusted properly -Clogged orifice. -Draft condition. -Improper ventilation system. -Air in gas line. Top section pilot will not stay ignited TROUBLESHOOTING Toastmaster ® PAGE 18 MEDIUM DUTY COUNTERLINE OPEN TOP BURNER TROUBLESHOOTING. TROUBLESHOOTING Common checks for all top configurations. Check that the burners are set level in the support brackets. Check that the burners are clean and all ports are clear. Remove each burner and check that the venturi is clean and free of buildup and debris. With each burner removed check that the orifice size is correct and clean and free of buildup and debris. Remove the knobs and carefully lower the top valve cover panel. NOTE : Griddle Tops NOTE : Griddle must be raised and secured or removed. CAUTION! Before raising or removing Griddle Tops. Remove the knobs and carefully lower the top valve cover panel. Check that each burner valve and orifice is in alignment with the burner. Shut off the main gas supply. Install a pressure tap in the main gas line before the range pressure regulator and install a manometer. Turn on the main gas supply. Re-light all pilots. Observe the inlet pressure. Inlet pressures for gases are: Natural = 5 to 7 in. water column Propane = 11 to 14 in. water column If the inlet pressure is low, all equipment on the main gas line should be lit and the pressure adjusted. TROUBLESHOOTING Light all burners on the range. Shut off the range burners and main gas and remove the pressure tap. Continue on next page. PAGE 19 Toastmaster ® TROUBLESHOOTING MEDIUM DUTY COUNTERLINE Continued from Previous Page With the gas supply shut off, install a pressure tap on the manifold in the plugged tap provided. Install a manometer on the pressure tap. Turn on the gas supply to the range. Re-light the pilots and turn on all the burners. Observe the manifold pressure. Manifold pressure are: Natural gas = 4 in. water column Propane gas = 10 in. water column Test each burner. Each burner should have a steady blue flame on each port of the burner. Propane burners may have a small amount of yellow tipping. This is normal. If the pressure is low, check the incoming line for obstructions. Shut off the burners and main gas and remove the pressure tap. Replace the pressure tap plug in the manifold. Re-light the pilots. Install the grates or griddle tops. If the flame is rising up off of the ports adjust the burner shutter closed. If the flame is long and yellow adjust the burner shutter open. NOTE : Griddle burners may be long and float when cold. Allow the top to heat before making burner adjustments. TROUBLESHOOTING Propane burners may have a slight popping noise when turned off. This is normal. Reinstall the front panel and knobs. Toastmaster ® PAGE 20 MEDIUM DUTY COUNTERLINE PARTS PARTS NOTICE INSTALLATION OF OTHER THAN GENUINE TOASTMASTER PARTS WILL VOID THE WARRANTY ON THIS EQUIPMENT. The serial plate is located inside of the front panel (see Figue 1 and page 3). Replacement parts may be ordered either through a Toastmaster Authorized Parts Distributor or a Toastmaster Authorized Service Agency. When ordering parts, please supply the Model Number, Serial Number, Part Number, and Description. For parts not listed, consult a Toastmaster Authorized Parts Distributor or Toastmaster Authorized Service Agency. Consult the Toastmaster authorized Parts/Service Distributor list for the Authorized Parts supplier in your area. If this list is not available, call Toastmaster at (847) 741-3300 to obtain this list. Index of Parts Diagrams Page Number 22 22 24 Description Parts for Griddle Models TMDG-24, TMDG-36 and TMDG-48 Parts for Charbroiler Models TMDC-24, TMDC-36 and TMDC-48 Parts for Open-Top Models TMDO-12, TMDO-24 and TMDO-36 PARTS PAGE 21 Toastmaster ® MEDIUM DUTY COUNTERLINE Medium Duty Counterline /Medium Duty Griddle PARTS 1 3 4 2 5 6 7 8 12 10 9 11 13 14 15 PARTS Toastmaster ® PAGE 22 MEDIUM DUTY COUNTERLINE Medium Duty Counterline /Medium Duty Griddle QUANTITY 36 1 1 3 3 3 3 3 3 1 2 1 1 1 3 1 1 1 1 2 1 1 3 1 1 1 4 1 1 4 1 1 PARTS Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number S1146910 S1178815 S1038099 S1178816 S1008755 1850351 S1178821 S1177704 1800205 1800206 1800207 S1178202 1100439 1100059 1850318 1850186 1850187 S1147007 1952678 S1172857 24 1 1 2 2 2 2 2 2 1 48 1 1 4 4 4 4 4 4 Description ELBOW STREET BLK 3/4" REGULATOR, PRESSURE (N/LP) PILOT 020 PROP. EXTENSION PILOT ORIFICE #55, (1.32) BRASS LP ORIFICE #45, (2.08) BRASS NAT. VALVE, PILOT ADJUSTING KNOB, CONTROL POLYPANEL MDC/MDG 24" POLYPANEL MDC/MDG 36" POLYPANEL MDC/MDG 48" VALVE, HI-OFF NAT/LP PIPE, BI 3/4" X 20" SCH 80 NIPPLE, BI, 3/4" X 2 MANIFOLD MDC/MDG 24" MANIFOLD MDC/MDG 36" MANIFOLD MDC/MDG 48" PLUG, PIPE BLK, 1/8" BURNER (U) DOUBLE HOLES LEGS SET OF 4/CMS,2001 PARTS PAGE 23 Toastmaster ® PARTS Medium Duty Counterline Open Top MEDIUM DUTY COUNTERLINE 3 4 1 5 2 12 7 8 11 12 14 9 13 10 15 17 18 16 PARTS Toastmaster ® PAGE 24 MEDIUM DUTY COUNTERLINE Medium Duty Counterline Open Top Key 1 2 3 4 5 6 7 8 9 10 Part Number 1850303 1850304 S1008755 S1008745 S1178202 S1177704 S1177111 S1177439 1850128 S1147007 1850307 1850319 1850202 S1178944 S1166004 S1146904 S1181100 1146910 S1178815 S1172857 1800198 1800208 1800209 12 1 1 2 2 2 2 1 1 2 1 1 QUANTITY 24 2 2 4 4 4 4 2 2 4 1 1 1 1 1 2 1 1 1 1 1 2 1 4 1 1 1 1 1 1 1 3 1 6 1 1 1 36 3 3 6 6 6 6 3 3 6 1 PARTS 11 12 13 14 15 16 17 18 Description PILOT TUBE FRONT MDO PILOT TUBE REAR MDO ORIFICE #55, (1.32) BRASS LP ORIFICE # 45, (2.08) BRASS NAT. VALVE, HI-OFF NAT/LP KNOB, CONTROL BURNER ASSEMBLY 26K SHO BURNER CAST REAR 400C PILOT LIGHT 20 OD X 17 L PLUG, PIPE BLK, 1/8" MANIFOLD MDO 12" MANIFOLD MDO 24" MANIFOLD MDO 36" TAIL PIPE MDO FITTING DOUBLE PILOT 3/16 ELBOW BLK 3/4" 90 DEGREE GRATE COUNTER TOP ELBOW STREET BLK 1/8" REGULATOR PRESSURE (N/LP) LEGS SET OF 4/CMS,2001 POLYPANEL MDO 12" POLYPANEL MDO 24" POLYPANEL MDO 36" PARTS PAGE 25 Toastmaster ® MEDIUM DUTY COUNTERLINE A product with the Toastmaster name incorporates the best in durability and low maintenance. We all recognize, however, that replacement parts and occasional professional service may be necessary to extend the useful life of this unit. When service is needed, contact a Toastmaster Authorized Service Agency, or your dealer. To avoid confusion, always refer to the model number. Serial number, and type of your unit. ~ Philippine Factory : 113 Technology Ave., Laguna Technopark, Binan Laguna, Philippines, 4024 * Tel. Nos. (632) 520-8170 to 79 Fax No.: (632) 520-8191 USA Factory : 1400 Toastmaster Drive, Elgin, IL 60120 Tel. (847) 741-3300 MANUAL MDC0804-MDO-MDC Toastmaster ®