SERVICE MANUAL GPC SERIES GAS PASTA COOKERS MODELS GPC12 GPC12S GPC16 GPC16S ML-126881 ML-126883 ML-126882 ML-126884 – NOTICE – This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. If you have attended a Vulcan Service School for this product, you may be qualified to perform all the procedures described in this manual. This manual is not intended to be all encompassing.
TABLE OF CONTENTS GENERAL .............................................................................................................................................................. 4 Introduction ............................................................................................................................................... Installation ................................................................................................................................................
TABLE OF CONTENTS (Cont.) SERVICE PROCEDURES AND ADJUSTMENTS ............................................................................................. 23 Gas Regulator Adjustment ..................................................................................................................... Thermostat Calibration ........................................................................................................................... Optional Basket Lift Assembly ..................................
GENERAL Gas Data INTRODUCTION Procedures in this manual will apply to all models unless specified. Pictures and illustrations can be of any model unless the picture or illustration needs to be model-specific. Model Models GPC12S and GPC16S are equipped with an additional tank, which is plumbed to both hot and cold water. Some models are equipped with an optional basket lift. No.
REMOVAL AND REPLACEMENT OF PARTS 3. Disconnect the main wire harness (two places) and carefully remove the panel from the fryer. COVERS AND PANELS WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. Cooker Control Panel 1. The control panel is secured with four hex head screws, two on each side of the panel and two under the flange. Remove these screws. 4. Reverse the procedure to install.
3. Disconnect the water hoses and remove the panel from the rinse station. 3. Remove hex head screws from the upper panel. 4. Reverse the procedure to install. Upper and Lower Lift Mechanism Panels WARNING: SHUT OFF THE GAS BEFORE SERVICING. 4. Remove the head screws from the lower panel. WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME. 1. Remove basket lift arm. 5.
Optional Basket Lift Timer CONTROL PANEL COMPONENTS 1. Remove the cooker control panel as outlined under Covers and Panels. WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 2. Remove all the wiring associated with the timer. Indicator Light 1. Remove the cooker control panel as outlined under Covers and Panels. 2. From the rear of the control panel, unscrew the wire cap of the light to be replaced. 3.
Relay 5. Remove all the wiring associated with the thermostat. 1. Remove the cooker control panel as outlined under Covers and Panels. 2. Remove all the wiring associated with the relay. 6. Follow the thermostat capillary to the packing nut located on the bottom of the cooker tank. 7. Access to the packing nut can be gained through the rinse station door on the right side of the pasta cooker. Remove the packing nut then remove the thermostat mounting nut. 3.
3. Disconnect the water hoses and remove the control panel from the rinse station. 8. Remove the thermostat bulb from the tank mounting brackets. NOTE: When hose fittings are removed, inspect the hose washers for cracking and wear. Replace with new washers if needed. 4. Remove the two screws securing the water fittings to the control panel and remove the fittings. 9. Reverse the procedure to install new thermostat. Water Fittings WARNING: SHUT OFF WATER BEFORE SERVICING. 1.
CONTROL BOX HOUSING GAS BURNERS WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 1. Remove the cooker control panel as outlined under Covers and Panels. WARNING: SHUT OFF THE GAS BEFORE SERVICING. 2.
5. Remove the two holding hex head screws securing the mounting bracket to the high limit. HIGH LIMIT WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 1. Drain all the water from the cooker tank. 2. Remove the left burner for direct access to the high limit. See Gas Burners for removal. 3. Remove the electrical wiring from the high limit. 6.
8. Remove the high limit bulb from the tank mounting brackets. BURNER NOZZLE AND ORIFICE WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: SHUT OFF THE GAS BEFORE SERVICING. WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME. 1. Remove the burners as outlined under Gas Burners. 2.
6. With an offset screwdriver, remove the two screws from the ignitor/pilot holding bracket and pull the assembly from the cooker tank. PILOT IGNITOR ASSEMBLY WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: SHUT OFF THE GAS BEFORE SERVICING. WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME. 1.
3. Loosen the gas line compression fitting at the elbow on top of the combination valve. GAS COMBINATION VALVE WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: SHUT OFF THE GAS BEFORE SERVICING. WARNING: ALL GAS JOINTS DISTURBED DURING SERVICING MUST BE CHECKED FOR LEAKS. CHECK WITH SOAP AND WATER SOLUTION (BUBBLES). DO NOT USE AN OPEN FLAME. 1. Remove all wiring associated with the combination valve. 4.
Rinse Tank Hose OVERFLOW HOSES 1. Drain all the water from the rinse tank. WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 2. Remove the rinse tank control panel as outlined under Covers and Panels. 3. Remove the hose clamps on the top of the hose. Cooker Tank Hose 1. Drain all the water from the cooker tank. 2. Remove the cooker control panel as outlined under Covers and Panels. 3.
DOORS OPTIONAL BASKET LIFT ASSEMBLY WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 1. There are two doors on the pasta cooker. Open the door to be removed. 2. Loosen the nuts and bolts securing the mounting bracket to the frame. Lifting Rod and Bracket 1. Remove basket lift arm. 3. Remove the door. 2. Remove upper and lower panels as outlined under Lifting Mechanism Panels. 4. Reverse the procedure to install.
Cam Cam Switch 1. Remove upper and lower panels as outlined under Lifting Mechanism Panels. 1. Remove the two nuts and bolts holding the cam switch to the motor mounting bracket. 2. Remove the bottom nut from the lifting bar, and move it to the side. 2. Remove wiring from the cam switch. 3. Remove the cam switch. 3. Remove the two screws from the crank arm holding the cam. Crank Arm and Motor 1. Remove all the wiring from the motor. 4. Remove the cam.
2. Remove the two set screws on the crank arm and the four screws holding the motor to the mounting bracket. 3. Remove the nuts and bolts securing the electrical cord holding straps (two places). 3. Remove the crank arm and motor. 4. Pull the ignition cable from the spark ignitor, and remove the wire attached to the pilot ignitor assembly bracket. 4. Reverse procedures to install all components.
Transformer POWER SUPPLY BOX INTERNAL COMPONENTS 1. Disconnect all wiring associated with the transformer. WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. To access the power box internal components, remove the two screws securing the power supply box cover. Ignitor Module 2. Remove the two screws holding the transformer. 1. Disconnect all wiring associated with the ignitor module. 2.
13. Remove the two hex head screws at the top of the flue box. COOKER TANK WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: SHUT OFF THE GAS BEFORE SERVICING. 14. Remove the center strip between the cooker and rinse tank. WARNING: SHUT OFF WATER BEFORE SERVICING. 1. Remove basket and basket hanger. 2. Drain cooker tank. 3. Remove the basket lift arm. 4.
17. Remove the fill port spray nozzle. RINSE TANK WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: SHUT OFF THE GAS BEFORE SERVICING. WARNING: SHUT OFF WATER BEFORE SERVICING. 1. Remove basket hanger, basket support rack and basket. 2. Drain rinse tank. NOTE: When reinstalling, the fill port spray nozzle should be pointed down and angled slightly to the right.
7. Remove the center strip between the cooker and rinse tank. 10. With the assistance of another person, stand in front of the pasta cooker and grasp the back and the front of the tank. Carefully tilt the tank back forward and lift the tank out of the pasta cooker body (see step 18 under Cooker Tank). 11. Remove the rinse station faucet assembly. 12. Reverse procedure to install. Retain the controls and hardware for reassembly to the new tank. 8. Disconnect the center rubber drain hose. 9.
SERVICE PROCEDURES AND ADJUSTMENTS WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCERN POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. A. To adjust, remove the cap covering the manifold pressure adjustment screw. Turn the recessed manifold pressure adjustment screw counterclockwise to decrease pressure or clockwise to increase pressure.
Relay Check OPTIONAL BASKET LIFT ASSEMBLY 1. Remove the lower lift mechanism panel as outlined under Covers and Panels in Removal and Replacement of Parts. WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 2. Connect power and switch to ON. 3. Check for 0 ohms between connections 5 and 3, 6 and 4. Adjustment 1. Allow pasta cooker to cool. 4. Turn the power OFF and disconnect. 2. Remove the cooker basket. 5.
TRANSFORMER CHECK VERIFICATION OF SPARK AT IGNITOR WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. WARNING: DISCONNECT (UNPLUG) ELECTRICAL POWER SUPPLY AND PLACE A TAG AT THE DISCONNECT SWITCH INDICATING YOU ARE WORKING ON THE CIRCUIT. 1. Remove the power supply box as outlined under Power Supply Box in Removal and Replacement of Parts. WARNING: SHUT OFF THE GAS BEFORE SERVICING. 2.
ELECTRICAL OPERATION WIRING DIAGRAMS – 26 –
TROUBLESHOOTING POSSIBLE CAUSES SYMPTOMS Gas does not ignite. No spark. Shor ted electrode on igniter/flame sense. Ignitor cable (high voltage) OPEN. Temperature control relay malfunction. Transformer inoperative. High limit thermostat open. Interconnecting wiring malfunction. Ignition module malfunction. Sparks but gas does not ignite. Gas solenoid valve off or inoperative. Manual gas valve closed. Gas supply off or insufficient gas pressure. Interconnecting wiring malfunction.
NOTES FORM 31207 (April 2002) – 28 – PRINTED IN U.S.A.
