COUNTER MODEL POPCORN MACHINES MODELS 49, 49D, 49SL 59, 59D, 59SL 89, 89D, 89SL
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1 Star Manufacturing International Inc. Installation and Operating Instructions COUNTER MODEL POPCORN MACHINES MODELS 49, 49D, 49SL 59, 59D, 59SL 89, 89D, 89SL
2 GENERAL INSTALLATION DATA CAUTION THOUROUGHLY INSPECT YOUR MACHINE ON ARRIVAL INSTALLATION CAUTION Do not connect to any other type of current or the machine will be seriously damaged. 120 VOLT MACHINES 240 VOLT MACHINES GENERAL OPERATING INSTRUCTIONS CAUTION DO NOT COVER THESE AIR VENT HOLES as serious damage will result. 1.) 2.)
3 GENERAL OPERATING INSTRUCTIONS - continued 3.) 4.) 5.) 6.) WARNING Do not leave the Kettle and Motor switch "ON" when the machine is not in use. Do not immerse the Kettle in water or allow water to come in contact with the Heating element. Popping Corn in dry kettle is not recommended. Do not connect machine to Direct Current, as this unit is designed to operate on Alternating Current only! MAINTENANCE Keep The Popping Unit Clean To remove Kettle: To change Sign Display Lamps (on Sign Lighted Models): MAINTENANCE and REPAIRS
4 49, 49D STAR MANUFACTURING INT L 10 SUNNEN DRIVE ST. LOUIS,MO WIRE DIAGRAM
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8 Old Style Hinge Bracket = N/A Use C3-Y C3-Y2612 instead Long Jumper 2C Oz. Kettle 49 Series 59 Series
9 PARTS LIST January 22, 2014 Model: 49 & 59 Kettle Series Popcorn Machines Fig No Part Qty Description Application C NLA 1 120V (49 & 59 SERIES) 1-31 C NLA 1 KETTLE ASSY COMPLETE 240V (49 & 59 SERIES) C NLA 1 120V (59& 59D SERIES) 1 2F CASTING KETTLE 8 oz 2 C JUMPER LONG 3 2T THERMOSTAT, 550V B-200 1/4 TURN CLOWISE = 30 F RISE 4 C3-Y BRACKET-KETTLE HINGE CP C3-Y BRACKET-KETTLE PLATED 5 2C SCREW, MACHINE 2C-Y BOLT 1/4-20X1/2 HEX STL NP 7 C ELEMENT CLAMP ASSY 8 2C WASHER 3/16 STL NP 9 2C SCREW 10-24X3/8 RHP STL 13 C3-Y INSULATION MANNINGLAS 14 2C SCREW 1/4-20X2 ST SET C NLA 1 KETTLE HANDLE ASSY # , # & BELOW 15 2P SPRING-HANDLE TORSION 16 2A ROD, HANDLE PLATED 17 2R-8293, NLA 1 HANDLE HARDWOOD BLACK 18 2C WASHER 1/4 STL 19 2C NUT 1/4-20 BR ACORN NP 24 2C SCREW-ADJUST SG1508 # , # & BELOW 25 2A PIN-COTTER 3/32DX3/4 SS # , # & BELOW C HANDLE AND ROD ASSY COMPLETE 2A PIN-GROOVE 1/80X5/8 ST 2A-Y ROD-HANDLE-PLATED 2R-09-WB HANDLE BLACK 3/8-16 2B-Y CLIP-HANDLE 2P SPRING-HANDLE TORSION 24 2V-Y RETAINER 25 C3-Y CAM C KETTLE CONDUIT W/WIRES 20 C KETTLE LEAD WIRE ASSY 21 2P CAP-TWIST LOCK L5-15P 22 2E CONDUIT, FLEXIBLE E CONNECTOR 3/8 TB#266 2K BUSHING-7/16 ODX-028 C KETTLE SHELL ASSY OLD STYLE 49 & C-Y WASHER 2C SCREW 8-32X1/2 RHP STL NP 27 2C NUT ACHD BR NP 31 2N-Y ELEMENT 1420 WATTS/9.6 OHMS 120V 2N-Y ELEMENT 1420 WATTS/40 OHMS 240V
10 Long Jumper Old Style Hinge Bracket = N/A Use C3-Y C3-Y2612 instead Short Jumper Short Jumper Old Style Element Clamps = N/A Use C3-Y3140 instead Long Jumper 14 Oz. Kettle 89 Series
11 PARTS LIST EFFECTIVE rb MODEL 89 Series Machines Key Part Per Unit Description 14 Oz. Kettle Assembly 1-31 C KETTLE ASSEMBLY COMPLETE - 120V (# & BELOW) N/A - Use C C3-Y2612 instead C KETTLE ASSEMBLY COMPLETE - 120V (# & ABOVE) (10 Lbs shipping weight) C KETTLE ASSEMBLY COMPLETE - 240V (# & ABOVE) 1 2F KETTLE CASTING (Sand Cast Material) 2 C KETTLE JUMPER - LONG 3 2T THERMOSTAT (1/4 turn clockwise = 30 0 F rise) 4 C KETTLE HINGE BRACKET (# & BELOW) N/A - Use C3-Y C3-Y2612 instead C3-Y KETTLE HINGE BRACKET (# & ABOVE) 5 2C MACHINE SCREW (1/4-20 x 1/2 Flat Head) 2C-Y MACHINE SCREW (1/4-20 x 1/2 Hex Head) 6 C KETTLE JUMPER - SHORT 7 C THERMOSTAT CLAMP 8 2C BURR 9 2C SCREW (10-24 x 3/8) 10 C THERMOSTAT CLAMP 11 2C SCREW (10-24 x 3/4) 13 C3-Y KETTLE INSULATION 14 2C STUD (1/4-20 x 2) 15-19, C KETTLE HANDLE ASSEMBLY COMPLETE 24,25 (# & BELOW) 15 2P KETTLE HANDLE SPRING 16 C KETTLE ROD HANDLE w/pin 17 2R KETTLE HANDLE (wood) 18 2C BURR (1/4) 19 2C ACORN NUT (1/4-20) 24 2C SCREW - ADJUSTING 25 2A COTTER KEY IMPORTANT: WHEN ORDERING, SPECIFY VOLTAGE OR TYPE GAS DESIRED INCLUDE MODEL AND SERIAL NUMBER PAGE 1 OF 2 Some items are included for illustrative purposes only and in certain instances may not be available. Star Manufacturing International, Inc.
12 PARTS LIST EFFECTIVE rb MODEL 89 Series Machines Key Part Per Unit Description 14 Oz. Kettle Assembly 15-19, C KETTLE HANDLE ASSEMBLY COMPLETE 24,25 (# & ABOVE) 2A PIN - GROOVE 2A-Y KETTLE ROD HANDLE 2R-Y KETTLE HANDLE (plastic) 2C-Y CLIP - LATCH HANDLE 2P KETTLE HANDLE SPRING 2V-Y RETAINER / SPACER C3-Y CAM C KETTLE CONDUIT COMPLETE (w/wires & twist-loc plug) 20 C KETTLE LEAD WIRE ASSEMBLY (2 wire set w/terminals) 2C WIRE TERMINAL 2I INSULATOR BEAD 21 2P MALE TWIST-LOC PLUG 22 C KETTLE CONDUIT C3-Y GROUND STRAP 23 2E SQUEEZE CONNECTOR 2K BUSHING (for conduit) 26 C KETTLE SHELL W/WASHER (# & BELOW) (needs C HANDLE also) 2C-Y WASHER (1 x 1/4 ) 2C SCREW (holds shell to casting) 27 2C ACORN NUT (10-24) 28,29 C3-Y NEW STYLE ELEMENT CLAMP (use qty. 3 each of Key #8 & #9) 8 2C BURR 9 2C SCREW 30 2N-Y KETTLE ELEMENT - 120V (300W/ 40 ohms) (SMALL) (blue dot) 2N-Y KETTLE ELEMENT - 240V (300W/ 40 ohms) (SMALL) (red dot) 31 2N-Y KETTLE ELEMENT - 120V (1500W/ 9.6 ohms) (blue dot) 2N-Y KETTLE ELEMENT - 240V (1500W/ 9.6 ohms) (red dot) (Element design was changed in 6/87) IMPORTANT: WHEN ORDERING, SPECIFY VOLTAGE OR TYPE GAS DESIRED INCLUDE MODEL AND SERIAL NUMBER PAGE 2 OF 2 Some items are included for illustrative purposes only and in certain instances may not be available. Star Manufacturing International, Inc.
13 Hi-Temp Wire = 1N-E2052 Right Hinge w/pin = C Screw = 2C-1646 Left Hinge w/pin = C Screw = 2C-1646 Left Leaf Hinge Long = C Screw = 2C-1512 (10-24x3/8) Nut = 2C-2559 Right Leaf Hinge Long = C Screw = 2C-1512 (10-24x3/8) Nut = 2C-2559 Motor Support Assy. C New Style Hinge Bracket C3-Y2612
14 PARTS LIST April 7, 2010, Key Part MODEL 8 oz. & 14 oz. Machines Parts 49, 59, 89 Series Machines Per Unit 1 C3-Y KETTLE & LID SUPPORT 2 C RIGHT KETTLE LID ASSEMBLY W/HANDLE N/A - No replacement 2R KNOB - KETTLE LID 2C SCREW (not shown) 3 2P-Y BEARING ASSEMBLY (PLASTIC) 4 C LEFT KETTLE LID ASSEMBLY 5-13 C KETTLE LATCH ASSEMBLY COMPLETE 5 C3-Y KETTLE LATCH 6 C KETTLE LATCH SPRING 7 2C SCREW (10-24x3/8) 2C WASHER-SHAKE (#10) (not shown) 8 2C SCREW (10-24x1-1/2) 9 2C ACORN NUT (10-24) 10 2C ACORN NUT (8-32) 11 2C SCREW (8-32x3/8) 2C WASHER-SHAKE (#8) (not shown) 12 C KETTLE LID PIN SPRING 13 C HINGE LATCH 14 C3-Y KETTLE HINGE MOTOR HOUSING (# & UP) 15 2E /3 SWITCH-TOGGLE (QTY.1 ON 59D & 89D ONLY for motor) (QTY.3 ON # , # , # & ABOVE) 2E-Y SWITCH-ROCKER (# TO # ) (not shown) (# TO # ) (# TO # ) 2E SWITCH-ROTARY (59D & 89D ONLY for kettle & lights) (not shown) 2R KNOB-ROTARY SWITCH (not shown) 16 C MOTOR COVER ASSEMBLY 17 PS MOTOR W/GEAR BOX & LEAD WIRES (120V) C MOTOR W/GEAR BOX & LEAD WIRES (240V) 17a 2A-9556 NLA 1 MOTOR GEAR W/SHAFT (#5900 imprinted) (PLASTIC) 17b 2A MOTOR GEAR (#5318 imprinted) (METAL) 17c 2A-Y MOTOR GEAR - SMALL (PLASTIC) 2I-H MOTOR GROMMETS (not shown) 18 C KETTLE HINGE PIN 19 2A-Y HAIRPIN (# , # , # & BELOW) 20 2A AGITATOR SHAFT 21 2A-Y UNIVERSAL 22 2A COTTER PIN 23 2B AGITATOR BLADE (SPRING)(49 & 59 SERIES) (4 LONG) 2B AGITATOR BLADE (SPRING)(89 SERIES) (4-1/4 LONG) 24 C AGITATOR COLLAR 25 2C SET SCREW (8-32) IMPORTANT: WHEN ORDERING, SPECIFY VOLTAGE OR TYPE GAS DESIRED INCLUDE MODEL AND SERIAL NUMBER Description & Model Designation Some items are included for illustrative purposes only and in certain instances may not be available. PAGE OF 1 4 Star International Holdings, Inc. Company
15 PARTS LIST April 7, 2010, MODEL 8 oz. & 14 oz. Machines Parts 49, 59, 89 Series Machines Key Part Per Unit Description & Model Designation C AGITATOR ASSEMBLY COMPLETE (49 & 59 SERIES) (TO UPDATE/UPGRADE - # , # & BELOW) C AGITATOR ASSEMBLY COMPLETE (89 SERIES) (TO UPDATE/UPGRADE - # & BELOW) 20 2A-Y AGITATOR SHAFT (4-7/16 LONG) 20 2A-Y AGITATOR SHAFT (5-7/16 LONG) 2C-Y GROOVE - PIN (not shown) 21 2A-Y UNIVERSAL 22 2A-Y CLIP - SHAFT 23 2B-Y AGITATOR BLADE (49 & 59 SERIES) (8-1/4 LONG) 2B-Y AGITATOR BLADE (89 SERIES) (8-3/4 LONG) 24 2A-Y AGITATOR COLLAR 25 2C SET SCREW (8-32) C AGITATOR ASSEMBLY COMPLETE (49 & 59 SERIES) (# , # & ABOVE) N/A-USE C Instead C AGITATOR ASSEMBLY COMPLETE (89 SERIES) (# & ABOVE) N/A-USE C Instead 26 2S-Y WARMER LAMP (120V, 250W) 2S-Y WARMER LAMP - RED (120V, 250W) (used on 49D only) C3-Y CORN DRAWER ASSEMBLY (not as shown) 29 2R HANDLE 2R-Z KNOB (not shown) CUSTOMER S VIEW, NOT SERVER S C RIGHT DOOR COMPLETE (49) C RIGHT DOOR COMPLETE (49D) (# & BELOW) N/A-No replacement C RIGHT DOOR COMPLETE (49D) (# & ABOVE) C RIGHT DOOR COMPLETE (59 & 89 SERIES, 89W) N/A-No replacement 30 C DOOR HINGE ASSEMBLY-RIGHT (49D) (# & ABOVE) C DOOR HINGE ASSEMBLY-RIGHT 31 C3-Y STRIKE - MAGNETIC LATCH 32 2R KNOB - DOOR (2C-1506 = SCREW) 33 C3-Y DOOR - PLEXIGLASS (49) (15 x 9-1/2 W/2 holes) C3-Y DOOR - PLEXIGLASS (49D) (# & ABOVE) (15 x 9-1/2 W/3 holes) C3-Y DOOR - PLEXIGLASS (59 & 89 SERIES, 89W) (15 x 13 W/2 holes) N/A-No replacement 2M-Y INSTRUCTIONS - CLEAR (not shown) IMPORTANT: WHEN ORDERING, SPECIFY VOLTAGE OR TYPE GAS DESIRED INCLUDE MODEL AND SERIAL NUMBER Some items are included for illustrative purposes only and in certain instances may not be available. PAGE OF 2 4 Star International Holdings, Inc. Company
16 PARTS LIST April 7, 2010, MODEL 8 oz. & 14 oz. Machines Parts 49, 59, 89 Series Machines Key Part Per Unit Description & Model Designation CUSTOMER S VIEW, NOT SERVER S C LEFT DOOR COMPLETE (49) C LEFT DOOR COMPLETE (49D) (# & BELOW) N/A-No replacement C LEFT DOOR COMPLETE (49D) (# & ABOVE) C LEFT DOOR COMPLETE (59 & 89 SERIES, 89W) N/A-No replacement 31 C3-Y STRIKE - MAGNETIC LATCH 32 2R KNOB - DOOR (2C-1506 = SCREW) 34 C DOOR HINGE ASSEMBLY-LEFT (49D) (# & ABOVE) C DOOR HINGE ASSEMBLY-LEFT 2M-Y INSTRUCTIONS - CLEAR (not shown) 35,36 2Q-Y GLASS (49 SERIES) (PURCHASE LOCALLY, if possible) (ALL SIDES) (24-5/8 x 19-5/8 x 1/8 double strength) 35 2Q FRONT GLASS (59 & 89 SERIES, 89W) (PURCHASE LOCALLY, if possible) (26-5/8 x 24-5/8 x 1/8 double strength) 2Q-Y FRONT GLASS (89T, TIFFANY) 2M-Y SIGN - FRONT GLASS (89P, PATRIOT) 36 2Q SIDE GLASS (59 & 89 SERIES, 89W) (PURCHASE LOCALLY, if possible) (22-5/8 x 24-5/8 x 1/8 double strength) 2Q-Y SIDE GLASS (89T, TIFFANY) 2M-Y SIGN - SIDE GLASS (89P, PATRIOT) 37 2I-Z GLASS CHANNEL (UPRIGHT) (Will need to be cut to 24-11/16 ) 38 2I-Z GLASS CHANNEL (SIDE, BOTTOM) (59 & 89 SERIES, 89W) (Will need to be cut to 21-13/16 ) 39 2I-Z GLASS CHANNEL (FRONT, BOTTOM) (59 & 89 SERIES, 89W) (25-3/8 ) 2I-Y GLASS CHANNEL (BOTTOM) (49 SERIES) 40 C1-S LEAD IN CORD - 120V (49 SERIES) C LEAD IN CORD - 240V (49 SERIES) C LEAD IN CORD - 120V (59 SERIES) C LEAD IN CORD - 120V (89 SERIES) C LEAD IN CORD - 240V (59 & 89) C LEAD IN CORD - 120V (59D, 59SL, 89D, 89SL) C LEAD IN CORD - 240V (59D, 59SL, 89D, 89SL) 2K-Y BUSHING - STRAIN RELIEF (120V) 2K-Y BUSHING - STRAIN RELIEF (240V) 2E FEMALE WALL RECEPTACLE (120V only) 41 C TOP ASSEMBLY (49) N/A-No replacement C TOP ASSEMBLY (49D, # & BELOW) C TOP ASSEMBLY (49D, # & ABOVE) C TOP ASSEMBLY (59 & 89) N/A-No replacement C TOP ASSEMBLY (59D & 89D) (less sign) N/A-No replacement C TOP ASSEMBLY (89SL) IMPORTANT: WHEN ORDERING, SPECIFY VOLTAGE OR TYPE GAS DESIRED INCLUDE MODEL AND SERIAL NUMBER Some items are included for illustrative purposes only and in certain instances may not be available. PAGE OF 3 4 Star International Holdings, Inc. Company
17 PARTS LIST April 7, 2010, MODEL 8 oz. & 14 oz. Machines Parts 49, 59, 89 Series Machines Key Part Per Unit Description & Model Designation 42,43 2C MAGNET & BRACE 44 2E-T FEMALE TWIST LOCK RECEPTACLE 45 C PILOT LIGHT ASSEMBLY - 120V (49, 59, 89, 89W ) C PILOT LIGHT ASSEMBLY - 240V (49, 59, 89 ) C PILOT LIGHT ASSEMBLY - 120V (49D, 59D, 89D) C PILOT LIGHT ASSEMBLY - 240V (49D, 59D, 89 D) N/A-No replacement 46 2E-Y SOCKET - LAMP C3-Y CLIP C3-Y LAMPSHIELD (49 & 59 SERIES) C3-Y LAMPSHIELD (89 SERIES) 47 C COVER - CONTROL (59, 89) (not shown) C COVER - CONTROL (59D, 89D) (not shown) C3-Y COVER - CONTROL (49 SERIES) (not shown) (alias SWITCHPLATE) 48 C FRONT LOWER DOOR ASSEMBLY (49 SERIES) C FRONT LOWER DOOR ASSEMBLY (59 & 89 SERIES) C FRONT LOWER DOOR ASSEMBLY (89W) 2A-Y FOOT 2M-Y DECAL FRESH POPPED POPCORN (59, 89) N/A-No replacement 2M-Y DECAL - SWITCHES, KETTLE & WARMER 2M-Y DISPLAY SIGN (49SL) (back) N/A-No replacement 2M-Y DISPLAY SIGN (49SL) (front) N/A-No replacement 2M DISPLAY SIGN (59D, 89D) N/A-No replacement 2M-Y DISPLAY SIGN (49) C3-Y DISPLAY SIGN (49D) (woodgrain design) N/A-No replacement 2M-Y DISPLAY SIGN (89W) 2M-Y DISPLAY SIGN (89SL) N/A-No replacement 2S DISPLAY LAMP (59D, 89D) N/A-No replacement C3-Y RETAINER BOTTOM (for sign) 2N WARMER ELEMENT - 120V (not shown) 2N WARMER ELEMENT - 240V (not shown) C CORN SCOOP - METAL (not shown) 2L-Y CORN CUP (3/4 cup) (not shown) 2L-Y OIL CUP (1/4 cup) (not shown) IMPORTANT: WHEN ORDERING, SPECIFY VOLTAGE OR TYPE GAS DESIRED INCLUDE MODEL AND SERIAL NUMBER Some items are included for illustrative purposes only and in certain instances may not be available. PAGE OF 4 4 Star International Holdings, Inc. Company
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