Prince Castle DCFT-MCD Series User manual

Vertical Toaster
DCFT-MCD Series
527-504revF_EN Printed in USA 1/15 © 2015
Service
Manual
Product Identification
Heel and Crown Bun In-FeedBig Mac Club Bun In-Feed
LCD
Display
Temperature
Button
Left and Right
Scroll Buttons
Menu
Button
Adjustment
Knobs
Display
Indicator Light
355 East Kehoe Blvd. • Carol Stream, IL 60188 USA
Telephone: [phone] • Toll Free: 1-800-PCASTLE
Fax: [phone] • www.princecastle.com
LIMITED WARRANTY
This product is warranted to be free from defects in material and/or workmanship for a period of two (2) years from date of original
installation, not to exceed 30 months from date of shipment from our factory. Any part or component which proves to be faulty in material
and/or workmanship within the warranty period will be replaced or repaired (at the option of Prince Castle, Inc.) without cost to the
customer for parts or labor.
This warranty is subject to the following exceptions/conditions:
• Use of any non-genuine Prince Castle parts voids this warranty and all work must be performed by an authorized Prince Castle
Service Agent.
• All labor shall be performed during regular work hours. Overtime premium will not be covered.
• Travel charges are limited to 200 kilometers (100 miles) round trip, 2 hours travel time, one trip per repair.
• Damage caused by carelessness, neglect, and/or abuse (e.g., using wrong current, dropping, tampering with or altering electrical
components, or improper cleaning) is not covered.
• Equipment damaged in shipment, by fire, flood or an act of God is not covered.
• Damage to non-stick coated surfaces is not covered by this warranty.
Prince Castle will provide replacement parts to customer so customer can replace such parts if they are defective. Replacement
instructions are set out in the product’s Operation Manual.
PRINCE CASTLE SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES. THIS
IS PRINCE CASTLE’S ONLY WARRANTY. PRINCE CASTLE MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR ANY PARTICULAR PURPOSE ARE HEREBY
DISCLAIMED AND EXCLUDED.

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Table of Contents
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safe Service Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disconnect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools Required for Servicing Unit . . . . . . . . . . . . . . . . . . . . . . 4
Display Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Management Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove/Replace Curtain Sheet . . . . . . . . . . . . . . . . . . . . . . . 11
Remove/Replace Front Door Assy . . . . . . . . . . . . . . . . . . . . . 12
Remove/Replace Back Door Assy . . . . . . . . . . . . . . . . . . . . . 12
Remove/Replace Club Belts . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove/Replace Heel Compression Adjust Assy . . . . . . . . . 15
Remove/Replace Crown Compression Adjust Assy . . . . . . . . 19
Remove/Replace Membrane Switch and Display Assy . . . . . 23
Remove/Replace Motor and Drive Train Assy . . . . . . . . . . . . 24
Remove/Replace Club Assy . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove/Replace Club Gear Transfer Belt. . . . . . . . . . . . . . . 30
PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remove/Replace High Limit Switch . . . . . . . . . . . . . . . . . . . 34
Remove/Replace Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . 38
Remove/Replace Right Side Main Probe . . . . . . . . . . . . . . . 40
Remove/Replace Front Club Probe . . . . . . . . . . . . . . . . . . . . 41
Remove/Replace Rear Club Probe . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Exploded View and Parts List . . . . . . . . . . . . . . . . . . . . . . . . 45
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Service Analysis Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Allowable Labor Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Electrical Specifications
DCFT-MCDAU 240VAC, 6500W, 50 Hz, 1 Ph.
DCFT-MCDCE 200-240VAC, 4500-6500W, 50/60 Hz, 1 Ph.
DCFT-MCDNA 208VAC, 5075W, 60 Hz, 1 Ph.
DCFT-MCDNZ 230VAC, 6000W, 50 Hz, 1 Ph.
Safe Service Practices
NOTE: This service manual is intended for use by persons
having electrical and mechanical training and a level of
knowledge of these subjects considered acceptable in the
service trade. Prince Castle cannot be responsible, or assume
any liability, for injury or damage arising from the use of this
manual.
To avoid personal injury and /or property damage, it is important
that Safe Service Practices be observed, including the following
limited examples:
• Do not service the unit without first reading this manual.
• Do not attempt a repair if you have any doubt as to your
ability to complete it in a safe manner.
• Do not attempt to repair or replace any component unless all
power has been disconnected.
• Prior to returning the unit to service, ensure that:
– All electrical connections are correct and secure.
– All safety grounds are correctly and securely connected.
– All components are properly re-assembled.
Disconnect Power
Failure to disconnect power
from the unit before
servicing could result in
severe bodily injury or
death. The ON/OFF Switch
does not disconnect
incoming power to the unit.
WARNING
Serial Number Matrix
The manufacture date is encoded in the unit’s serial number. The
service bench installation date (used to determine warranty
coverage) is considered to be the end of the following month. For
example:
Serial Number: FJ0000458
Manufacture Date: June 2014
Service Bench Installation Date: July 31, 2014

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Compression Knob Puller
Tools Required for Servicing Unit
(2) Vice Grips
C-Clip Pliers
E Ring Tool (A-170)
Stubby Philips Screw Driver
Medium Philips / Flathead Screwdriver &
Precision Slotted Screwdriver.
Selection of Nut Spinners or an Appropriate Small
Socket Set
Needle Nose Pliers

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Display Menu Options

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Management Programming
Enter program
screens. Press
and hold the
MENU button for
6 seconds. The
PROGRAMMING
VERSION screen
will appear in the
LCD display for
10 seconds.
From the
PROGRAMMING
VERSION screen,
you may:
Press RIGHT scroll
button to advance to
the next menu item.
1Choose Fahrenheit or
Celsius. From the
PROGRAMMING
VERSION screen,
press the RIGHT scroll
button three times.
From the SELECT F/C
screen that appears,
press the OK button.
A. From the SET F/C
screen that
appears, use the
LEFT and RIGHT
scroll buttons to
select TEMP = F
(Fahrenheit) or
TEMP = C
(Celsius).
B. Accept the new
scale by pressing
the OK button to
return to the
SELECT F/C
screen.
NOTE: To return without accepting the new setting,
press the MENU button.
2

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Management Programming (continued)
Adjust set point
temperatures. From the
SELECT F/C screen,
press the LEFT scroll
button.
From the SET PLATEN
TEMPERATURES
screen, press the OK
button.
A. From the SET MAIN
screen that appears,
adjust the platen set
point temperature
using the RIGHT
and LEFT scroll
buttons. Accept the
new main platen
setting by pressing
the OK. The SET
CLUB FRONT
screen will appear.
B. Press OK button if
no change, or use
the RIGHT and LEFT scroll buttons to adjust, then
press OK to save. Accept the new main platen
setting by pressing the OK button. The SET CLUB
REAR screen will appear.
NOTE: To cancel without accepting the new
setting, press the MENU logo button to return to
the previous screen.
3 4 Change language.
From the SELECT
PLATEN
TEMPERATURE
screen, press the LEFT
scroll button.
From the SELECT
LANGUAGE screen,
press the OK button.
A. From the
LANGUAGE screen
that appears, use
the RIGHT and
LEFT scroll buttons
to select a different
language.
B. Accept the new
language by
pressing the OK
button to return to
the SELECT
LANGUAGE
screen.
NOTE: To return
without accepting
the new setting,
press the MENU
button.

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Management Programming (continued)
Select Toast Time.
From the
PROGRAMMING
VERSION screen,
press the LEFT scroll
button three times.
From the SELECT
TOAST TIME screen,
press the OK button.
The current toast time
selection will be
displayed.
A. Press LEFT scroll
button to decrease
the toast time. Press
OK button when you
reach desired time.
B. Press RIGHT scroll
button to increase
the toast time. Press
OK button when you
reach desired time.
5 6 NOTE: If your toaster
is not Smart enabled
and your store is not
LON integrated with
LonWorks, the LON
service is not
operational.
Initiate a LON Service
Call. From the
PROGRAMMING
VERSION screen,
press the LEFT scroll
button twice.
From the LON
SERVICE CALL
screen, press the OK
button.
On the LON SERVICE
CALL ? screen, press
left arrow under YES
button.
That will initiate LON
Service call with the
LON Gateway board.
NOTE: Initiating the
LON service will not
affect the toaster
performance.

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Management Programming (continued)
Select MFY store. From
the PROGRAMMING
VERSION screen,
press the LEFT scroll
button once.
From the MFY STORE
screen, press the OK
button.
In the MFY STORE ?
screen:
A. Select YES, (press
LEFT scroll button)
if it is MFY store.
This is the default
state for DCFT
toaster. All heaters
are active.
B. Select NO, (press
RIGHT scroll button)
if it is BOP store.
This selection will
deactivate club
platen heaters.
NOTE: Although club heaters are deactivated, front
club platen temperature will display a temperature
as high as 193°C/380°F, due to the heat transfer
from the main platen, which is normal.
7Exit programming.
Press the MENU
button from the
SELECT F/C, SELECT
PLATEN
TEMPERATURE or
SELECT LANGUAGE
screen or leave the
controls inactive for 10
seconds.
8
Toaster Settings
Description Factory
Presets
New Setting
Main Platen (Buns) 263°C/505°F
Front Club Platen 260°C/500°F
Rear Club Platen 260°C/500°F
Crown Compression B
Heel Compression 3
Toast Time 17 Sec.
Store (MFY or BOP) MFY (Club
Platens on)
Language English

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The top cover should be removed any time the unit is being
serviced.
WARNING
Unplug Unit.
1
Remove Top Cover
Failure to disconnect power
from the unit before servicing
could result in severe bodily
injury or death. The ON/OFF
Switch does not disconnect
incoming power to the unit.
WARNING
Loosen (2) thumbscrews on top cover.
2
Remove Teflon sheet.
3
Lift top cover off unit.
4

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Remove/Replace Curtain Sheet
Unplug Unit.
1
Failure to disconnect power
from the unit before servicing
could result in severe bodily
injury or death. The ON/OFF
Switch does not disconnect
incoming power to the unit.
WARNING
Loosen thumbscrews (2) that secure top cover to
frame. Set cover aside.
2
Loosen thumbscrew to remove left side door. To
remove right side door, refer to page 24 (steps 2-5).
3
Remove screws (4) that secure outer lid to frame. Set
lid and screws aside.
4
Remove 5/16” lock nuts (4) that secure curtain retainer
to frame. Set retainer and nuts aside.
5
Discard old curtain sheet.
5
Insert new curtain sheet onto frame. Note - sheet is
keyed so that it correctly aligns onto frame peg.
6
Curtain Sheet
peg
Reverse steps to reassemble components.
7

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Remove/Replace Front Door Assy Remove/Replace Back Door Assy
1Lift up handle to open front door.
2On right side of door, remove two screws that secure
pivot hinge to door. Set screws and hinge aside.
3Lift door off left side of housing and capture washer on
door peg. Set door and washer aside. Note the
position of the washer. If installed improperly, door
switch will be inoperable.
4To replace door, place washer on left door peg and
insert door into mounting hole on left side of housing.
5On right side of housing, insert pivot hinge into
mounting hole.
6Position right side of door under hinge and secure with
two screws.
7Raise door and engage handle to secure door to
housing.
8Lift up handle to open back door.
9On right side of door, remove two screws that secure
pivot hinge to door. Capture washer on pivot hinge.
Set screws, washer, and hinge aside.
10 Lift door off left side of housing. Set door aside.
11 To replace door, insert left door peg into mounting hole
on left side of housing.
12 On right side of housing, insert pivot hinge and washer
into mounting hole.
13 Position right side of door under hinge and secure with
two screws.
14 Raise door and engage handle to secure door to
housing.

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Remove/Replace Club Belts
Depending on toaster use, the club belts should be
replaced approximately every 6 months. Belts should be
replaced if worn or torn.
Turn toaster OFF and
unplug toaster.
1
Put on a pair of high temperature gloves.
2
Loosen thumbscrew on left side panel. Set panel
aside.
3
Pivot latch arm and secure in metal clip.
4
Remove belt tension by
pivoting tension arms up.
5
Remove old belts.
6
Install new belts.
7

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Remove/Replace Club Belts (continued)
Be sure that bead on belt rides in groove in belt rollers.
8
Pivot tension arms down and pivot and engage latch
arm.
9
Engage hooks on rear of
side cover into slots in
toaster frame and slide
side cover up. Tighten
thumbscrew to secure
left side panel.
10

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Remove/Replace Heel Compression Adjust Assy
Unplug the unit.
1
Failure to disconnect power
from the unit before servicing
could result in severe bodily
injury or death. The ON/OFF
Switch does not disconnect
incoming power to the unit.
WARNING
Open and remove front door. Set door aside.
2
Remove screw and
nut that secure front
lower gear cover to
immediate support.
Set cover, nut, and
screw aside.
3
Nut
Cover
Screw
4Remove retaining ring from shaft. Set ring aside.
Gear Belt
Gear
Retaining
Ring
5Remove belt from pulley and let hang in place.
6Slide gear off shaft and set aside.
7
Remove second
retaining ring
from drive shaft.
Set ring aside.
Retaining
Ring
Remove compression knobs from right side panel.
8
Remove screws (7) that secure right side panel to
frame. Set screws aside.
9
Disconnect electrical connectors (2) from panel. Set
panel aside.
10
Remove nuts (4) that secure drive train cover and drive
train to frame. Disconnect electrical connectors from
drive train/motor. Set nuts, cover, and drive train/motor
aside.
11
Remove screws (3 on left, 3 on right) that secure heel
compression assembly to frame. Set screws aside.
12
Screws
(3 on each
side)
Drive
Shaft

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Remove/Replace Heel Compression Adjust Assy (cont.)
On both left and right side of conveyor belt, secure
vice grip to bracket and top nut to hold assembly in
position.
13
Bracket
Nut
Slide assembly drive shaft out of bearing.
14
Pry assembly on left and right sides to release
assembly out of frame.
15
Release both vice grips, press downward on top edge
of assembly and pull assembly out of frame. Set
assembly aside.
16

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Feed camshaft through square opening in frame.
17
Remove/Replace Heel Compression Adjust Assy (cont.)
Use leverage in order to secure left and right sides of
conveyor into frame.
18
On both left and right side of conveyor belt, secure
vice grip to bracket and top nut to hold assembly in
position.
19
Bracket
Nut
Install Sprocket shaft and feed through intermediate
support bearing.
20
Attach (2) E-clip to sprocket shaft (Both front and back
side of bearing)
21
Install club transfer gear with 5/64" set screw.
22
Use C-Clip tool to install C-Clip over gear.
23

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Install club transfer belt over sprocket shaft gear.
24
Install 6 screws with stubby Philips screw driver.
25
Screws
(3 on each
side)
Reference Drivetrain Install. Page 24.
26
Install front door.
27
Install right side panel.
28
Plug in Unit.
29
Remove/Replace Heel Compression Adjust Assy (cont.)

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Unplug the Unit.
1
Remove/Replace Crown Compression Adjust Assy
Failure to disconnect power
from the unit before servicing
could result in severe bodily
injury or death. The ON/OFF
Switch does not disconnect
incoming power to the unit.
WARNING
Open and remove back door.
2
Remove screw and
nut that secure rear
gear cover to
intermediate support.
Set cover, nut, and
screw aside.
3
Nut
Cover
Screw
Loosen thumbscrew on left side panel. Set panel
aside.
4
Partially remove club assembly. Refer to Page 27,
step 15-17.
5
6Remove retaining ring from shaft. Set ring aside.
Retaining
Ring
Remove compression knobs from right side panel.
7
Remove screws (7) that secure right side panel to
frame. Set screws aside.
8
Disconnect electrical connectors (2) from panel. Set
panel aside.
9
10 Remove nuts (4) that secure drive train cover and drive
train to frame. Disconnect electrical connectors from
drive train. Set nuts, cover, and drive train aside.
Drive Train
Cover Nuts
11 Cut cable ties along bottom half of bundled wires
coming from crown heater.
Cable Ties

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Remove/Replace Crown Compression Adjust Assy (cont.)
Remove limit switch
covers (2). Set
covers aside.
12
Limit Switch
Covers
Remove limit switch
nuts (2) that secure
switches to frame.
Push switches
through frame.
13
Limit Switch
Nuts
Remove screws (5) that secure Electronics Tray to
frame. Set screws aside. Slide tray out so that it is fully
extended.
14
Disconnect heater wires connected to Back Heater
Switch.
15
Back Heater
Switch
Heater
Wires
Follow heater wires back through tray and cut any
cable ties that hold the wires to the tray.
16
Remove screws (3 on left, 3 on right) that secure
crown compression assembly to frame. Set screws
aside.
17
Screws
(3 on each
side)
Drive
Shaft
On both left and right side of conveyor belt, secure
vice grip to bracket and top nut to hold assembly in
position.
18
19 Slide assembly drive shaft out of bearing.
Pry assembly on left and right sides to release
assembly out of frame.
20
Release both vice grips, press downward on top edge
of assembly and pull assembly out of frame. Set
assembly aside.
21