Stoelting Freezer U421 U444 User Manual

Model U421/U444

(Serial #17978 and up)

OWNER'S MANUAL

Manual No. 513595-4 July, 2004 Rev. 1

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Phone No.: _________________________

(fill in or affix label)

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STOELTING® OWNER'S MANUAL

FOR

MODEL U421/U444

CAB MODEL SOFT-SERVE PRESSURIZED FREEZER

This manual provides basic information about the freezer. Instructions and suggestions are given

covering its basic operation and care.

The illustrations and specifications are not binding in detail. We reserve the right to make changes

at any time without notice, to the freezer and its components, without incurring any obligation to

modify or provide new parts for freezers built prior to date of change.

DO NOT ATTEMPT to operate the freezer until instructions and safety precautions in this manual

are read completely and are thoroughly understood. If problems develop or questions arise in

connection with installation, operation or servicing of the freezer, contact the company at the

location listed below.

STOELTING, LLC

502 Hwy 67

Kiel, WI 53042-1600

Tele: 920-894-2293

Fax: 920-894-7029

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TABLE OF CONTENTS

Section 1 .............................................................................................................. 1

1.1

1.2

Description.............................................................................................. 1

Specifications.......................................................................................... 2

Section 2 .............................................................................................................. 3

2.1

2.2

2.3

2.4

2.5

Safety Precautions .................................................................................. 3

Shipment & Transit .................................................................................. 4

Freezer Installation................................................................................... 4

Installing Permanent Wiring...................................................................... 4

Mix Pump ................................................................................................ 5

Section 3 .............................................................................................................. 9

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

Safety Precautions .................................................................................. 9

Operating Controls and Indicators ............................................................ 9

Important Information Regarding Cleaning and Sanitizing......................... 11

Disassembly of Freezer Parts.................................................................. 12

Cleaning Disassembled Parts ................................................................. 13

Sanitize Freezer Parts ............................................................................. 13

Cleaning the Freezer ............................................................................... 14

Assembling the Freezer........................................................................... 14

Sanitizing ................................................................................................ 16

Initial Freeze down and Operation ............................................................ 16

Mix Information ........................................................................................ 17

Operation of Mix Pump ............................................................................ 18

Mix Pump Cleaning ................................................................................. 18

Disassembly and Inspection of Removable Parts..................................... 18

3.9

3.10

3.11

3.12

3.13

3.14

Section 4 .............................................................................................................. 21

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

Freezer Adjustment ................................................................................. 21

Product TemperatureAdjustment ............................................................. 21

Overrun Adjustment ................................................................................. 21

Mix Pump Hose Reposition ..................................................................... 22

Mix Pump Hose Replacement.................................................................. 22

Cab Temp.Adjustment............................................................................. 22

Drive Belt TensionAdjustment.................................................................. 22

Condenser Cleaning (Air Cooled Freezers) ............................................. 23

Preventative Maintenance........................................................................ 23

Extended Storage ................................................................................... 23

Troubleshooting ....................................................................................... 24

Section 5 .............................................................................................................. 29

5.1

5.2

How to Order Replacement Parts ............................................................ 29

Parts Lists and Reference Drawings........................................................ 29

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ILLUSTRATIONS

Figure 1 Model U421/U444 Series Freezer .........................................1

Figure 2a Air-Cooled Specifications ......................................................2

Figure 2b Water-Cooled Specifications .................................................2

Figure 3 Decal Locations.....................................................................3

Figure 4 Water/ElectricalConnections .................................................4

Figure 5 AugerRotation.......................................................................5

Figure 6 MixHoseInstallation...............................................................5

Figure 7 MixPump...............................................................................6

Figure 8 3-wayTee ..............................................................................7

Figure 9 Mix Inlet Tube & Probe Assy. Clip...........................................7

Figure 10 Hose Holder...........................................................................7

Figure 11 OperatingControls.................................................................9

Figure 12 Auger Flight Wear & Front Auger Support Bushing Wear .......12

Figure 13 Front Door Disassembly ........................................................13

Figure 14 AugerFlightRemoval.............................................................13

Figure 15 Rear Seal Removal ................................................................13

Figure 16 Rear Seal Lubrication ............................................................14

Figure 17 SpringInstallation ...................................................................14

Figure 18 Front Door Assembly .............................................................15

Figure 19 Air Bleed Valves ....................................................................16

Figure 20 DrainingSanitizer ..................................................................16

Figure 21 Refrigerated Cabinet .............................................................17

Figure 22 MixPumps.............................................................................18

Figure 23 RemovableParts ...................................................................19

Figure 24 Cleaning Air Tube ..................................................................19

Figure 25 Cleaning Feed Tube ..............................................................19

Figure 26 MixPumpTubeRouting .........................................................19

Figure 27 Potentiometer ........................................................................21

Figure 28 OverrunAdjustment ................................................................21

Figure 29 TemperatureControlCab ......................................................22

Figure 30 BeltAdjustment ......................................................................23

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A Few Words About Safety

Safety Information

Read and understand the entire manual before

operating or maintaining Stoelting equipment.

Safety Alert Symbol:

This symbol Indicates danger, warning or caution.

Attention is required in order to avoid serious personal

injury. The message that follows the symbol contains

important information about safety.

This Owner's Manual provides the operator with

information for the safe operation and maintenance of

Stoelting equipment. As with any machine, there are

hazards associated with their operation. For this

reason safety is emphasized throughout the manual.

To highlight specific safety information, the following

safety definitions are provided to assist the reader.

Signal Word:

Signal words are distinctive words used throughout

this manual that alert the reader to the existence and

relative degree of a hazard.

The purpose of safety symbols is to attract your

attention to possible dangers. The safety symbols,

and their explanations, deserve your careful attention

and understanding. The safety warnings do not by

themselves eliminate any danger. The instructions or

warnings they give are not substitutes for proper

accident prevention measures.

WARNING

The signal word “WARNING” indicates a potentially

hazardous situation, which, if not avoided, may result

in death or serious injury and equipment/property

damage.

CAUTION

If you need to replace a part, use genuine Stoelting

parts with the correct part number or an equivalent

part. We strongly recommend that you do not use

replacement parts of inferior quality.

The signal word “CAUTION” indicates a potentially

hazardous situation, which, if not avoided, may result

in minor or moderate injury and equipment/property

damage.

CAUTION

The signal word “CAUTION” not preceded by the safety

alert symbol indicates a potentially hazardous situa-

tion, which, if not avoided, may result in equipment/

property damage.

NOTICE

The signal word “NOTICE” indicates information or

procedures that relate directly or indirectly to the

safety or personnel or equipment/property.

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SECTION 1

INTRODUCTION

1.1 DESCRIPTION

The Stoelting U421 and U444 floor model freezers are pres-

sure fed. The freezers are equipped with fully automatic

controls to provide a uniform product. The U421 freezer is

designed to operate with almost any type of commercial

soft serve or non-dairy mixes available, including ice milk,

ice cream, yogurt, and frozen dietary desserts. The U444

freezer is designed to dispense soft serve product from

the right side and shake product from the left side.

This manual is designed to assist qualified personnel and

operators in the installation, operation and maintenance

of the Stoelting Model U421 and U444 pressure freezer.

Figure 1. Model U421/U444 Series Freezer

1.2 SPECIFICATIONS

MODEL U421/U444

Width: 26-3/4" (68cm)

Depth: 39-3/4" (101cm)

Height: 65-3/4" (167cm)

DIMENSIONS

WEIGHT

925lbs. (419,5 kg)

975lbs. w/Crate (442 kg)

208/230 volt, 1 Ph or 3 Ph, Two 2 H.P. drive motors

and Two 11860 BTUH Compressors

ELECTRICAL

Water or air cooled. req's 3" (7,6cm) all around clearance and 10" (25cm) top

clearance. Water cooled req's 1/2" (1,3cm) NPT water and drain fittings.

COOLING

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Figure 2a. Air-Cooled Specification

Figure 2b. Water Cooled Specification

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SECTION 2

INSTALLATION INSTRUCTIONS

2.1 SAFETY PRECAUTIONS

Do not attempt to operate the freezer until the safety If danger, warning or caution labels are needed, indicate

precautions and operating instructions in this manual are the part number, type of label, location of label, and

readcompletely andarethoroughly understood.

quantity required along with your address and mail to:

Takenoticeofallwarninglabelsonthefreezer.Thelabels

have been put there to help maintain a safe working

environment.Thelabelshavebeendesignedtowithstand

washing and cleaning. All labels must remain legible for

the life of the freezer. Labels should be checked periodi-

callytobesuretheycanberecognizedaswarninglabels.

STOELTING,LLC

ATTENTION: Customer Service

502 Hwy. 67

Kiel, Wisconsin 53042

Figure 3. Decal Locations

23 324015

324722

324798

324141

723526

324393

324800

324799

324208

324103

324686

324107

324125

324151

324198

130000

324584

324158

324106

324566

Decal Mix Low

Decal 2 x 1-1/4 Blk on White

Tag, Caution - Supply Voltage

Decal GM Header (Stoelting Logo)

Decal GM Header (Stoelting Swirl)

Decal DQ Header (DQ Logo)

Decal Caution Hazard.Moving

Decal Standby/Serve

Decal Temperature Control

Decal Manual Reset

Decal Arrow

Decal Clean-Off-Serve Switch

Decal Caution - Rotating Blades

Tag Read Manual & All Decals

Decal Stoelting Swirl Logo

Decal Cab ON/OFF

723552

324803

324804

324805

324346

324797

324242

324200

324014

324496

Pump On/Off

Decal Refrig. Leak Check

Decal Caution - Rotating Shaft

Decal Danger Automatic Start

Decal Caution Moving Parts

Decal Elect.Shock Hazard

Decal Field Connections

Decal Attention Installer

Bag, Envelope Front Loading

Decal Adequate Ventilation

Decal Copper Conductors Only

Decal Caution Wiring Mat'l

Decal Wired According To

Decal Freezing

Water Cooled Only

324065

723525

723517

324107

Decal Water Inlet

Tag Winterizing Disconnect Line

Tag, W/C Tower Instructions

Decal Caution Moving Parts

Air Cooled Only

324346

324107

Decal Hazardous Moving Parts

Decal Caution Moving Parts

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2.2 SHIPMENT AND TRANSIT

D. The freezer must have a minimum of 3" (7,5cm)

-6" (15cm) high ambient conditions- of space on all

sides and 10" (25cm) at the top for proper circula-

tion.

The freezer has been assembled, operated, and in-

spected at the factory. Upon arrival at the final destina-

tion, the freezer must be checked for any damage which

may have occurred during final transit.

CAUTION

With the method of packaging used, the equipment should

arrive in excellent condition. THE CARRIER IS RESPON-

SIBLE FORALLDAMAGE IN TRANSIT, WHETHER VIS-

IBLE OR CONCEALED. Do not pay the freight bill until

the freezer has been checked for damage. Have the car-

rier note any visible damage on the freight bill. If concealed

damage and/or shortage is found later advise the carrier

Risk of product damage

Air cooled condenser requires proper ventilation. Fail-

ure to provide adequate ventilation will void factory

warranties.

within ten days and request inspection. The customer E. Water-cooled freezers need an adequate water

must place claim for damage and/or shortages in ship-

ment with the carrier. Stoelting, LLC. cannot make

any claims against the carrier.

supply. Install 1/2" (12,7mm) pipe or 1/2" (12,7mm)

inside diameter copper water line to the freezer.

Connect water outlet to a drain using a 1/2"

(12,7mm) inside diameter line. Automatic washer

hoses work well for final connections. All water

connections must comply with local codes. Fig. 4.

2.3 FREEZER INSTALLATION

WARNING

Installation must be performed by a qualified electri-

cian/refrigeration specialist. Incorrect installation may

cause personal injury, severe damage to the machine

and will void factory warranties.

WARNING

Lifting hazard

Do not attempt to lift freezer manually. Use proper lift-

ing equipment such as a forklift, lift table, or pallet

jack, with lifting device positioned beneath the freezer’s

base. Ensure that personnel remain clear of suspended

load. Failure to do so may result in personal injury

and/or damage to the freezer that will void any factory

warranties.

Figure 4. Water/Electrical Connections

CAUTION

Flush all water lines before installation. In stores with

sediment in water, add suitable filter or strainer to water

inlet.

Installation of the freezer involves moving the freezer close

to its permanent location, removing all crating, setting in

place, assembling parts, and cleaning.

F. Place the CLEAN-OFF-SERVE switches in the OFF

position before continuing. Figure 11.

A. Uncrate the freezer.

2.4 INSTALLING PERMANENT WIRING

Permanentwiringisrequiredbylocalcodes,thefollowing

proceduremustbeperformed:

B. Install the four casters. Turn the threaded end into

the freezer until zero threads are showing. To level,

turn out casters no more than 1/4" maximum, then

tighten all jam nuts.

WARNING

C. The freezer must be placed in a solid level position.

Hazardous voltage

High voltage will shock, burn or cause death. Turn off

and lock out main power disconnect before installing

wiring. Do not operate machine with cabinet panels

removed.

NOTE

Accurate leveling is necessary for correct drainage of

freezer barrel and to insure correct overrun.

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A. Refertothenameplateattherearofthefreezerfor

specific electrical requirements. Make sure the

power source in the building matches the freezer

nameplate requirements. Bring the wires into the

junction boxes through the access holes in the

bottom rear of the freezer. Figure 4.

Auger shaft rotation is clockwise as viewed through the

clear plastic front door. If the rotation is not clockwise,

turn main electrical power OFF. Then reverse L1 and L3

electrical power lines to the junction box (three phase

only). Re-check auger shaft rotation. Figure 5.

NOTICE

Three phase freezers in areas of unbalanced

electrical loads require special attention when

connecting input electrical power. The unbal-

anced leg of power (called wild or high) must be

connected to L2 in the junction box.

NOTICE

Verify actual voltage. Machine is equipped with

a transformer to supply a control circuit. You

will need to check voltage on terminal C1 and

C2 on EACH control board. (Located behind

decorative header panel on front of machine.)

Transformers are located behind electrical panel

enclosing control boards. Access these by re-

moving top panel of machine. Actual transformer

voltage should read 20-28 V.A.C.

Figure 5. Auger Rotation

2.5 MIX PUMP

A. Mix Pump Hose Installation

Follow the steps below to install the mix pump hose.

1. Turnpumpon.

B. Remove the lower back panel and the two junc-

tion box covers located at the bottom of the

freezer.

2. Feed one end of mix pump hose into the entering or

pick-up hose side (left) of black cover.

3. Gently push the hose into the black cover until it

begins to feed.

C. lnstall permanent wiring according to local

code.

4. Allow the hose to feed itself thru the pump until 6"

(15cm) remains on the entering side.

D. Check the auger shaft rotation by placing the

MAIN DRIVE switch in the CLEAN position.

6" (15cm)

Figure 6. Mix Hose Installation

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B. Connect1/2inch(12,7mm)I.D. plasticfoodgrade

tubing to check valve and then to the mix con-

tainer. Observe check valve flow arrow. Secure

with hose clamps. Then place assembly thru hole

in cover and install retainer clip. Figure 9.

5.Turnpumpoff.

6.Connect mix pump hose to pickup hose

adapter using small hose clamp.

CAUTION

DO NOT TWIST MIX PUMP HOSE.

7.Turnpumpoff.

C. Connect1/2inch(12,7mm)I.D. plasticfoodgrade

tubing between the large port of air/mix tee and

refrigerated mix transfer line. Secure with large

hose clamp or equivalent. Figure 9.

CAUTION

8.Allow remaining 6" (15cm) of tubing to feed hru

pumpuntilhoseadapterpreventsfurtherfeeding.

Air/Mix tee must remain below the black cover/

clamp. If the tee is above the pump mix will

drain to the air compressor resulting in pump

damage.

9.Turnpumpoff.

10.Connect free end of mix pump hose to 3-way Tee

D. Connect mix low cords.

Figure 7. Mix Pump

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Refrigerated

Mix Transfer

Line

Å 3-way Tee

Large PortÆ

(Air/Mix)

Figure 8. 3-way Tee

Low Mix Cord

Cover

Retainer

Clip

Mix

Container

Figure 9. Mix Inlet Tube & Probe Assy. Clip

Hose Holder

Figure 10. Hose Holder

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SECTION 3

INITIAL SET-UP AND OPERATION

3.1 SAFETY PRECAUTIONS

3.2 OPERATING CONTROLS AND INDICATORS

SAFE OPERATION IS NO ACCIDENT; observe these Before operating the freezer, it is required that the op-

rules:

erator know the function of each operating control. Refer

to Fig.11 for the location of the operating controls on the

freezer.

A. Know the freezer. Read and understand the operat-

ing instructions.

WARNING

Hazardous voltage

B. Notice all warning labels on the freezer.

TheCLEAN-OFF-ONswitchmustbeplacedintheOFF

positionwhendisassemblingforcleaningorservicing.

The freezer must be disconnected from electrical

supply before removing any access panel. Failure to

disconnect power before servicing could result in

death or serious injury.

C. Wear proper clothing.Avoid loose fitting garments,

and remove watches, rings or jewelry which could

cause a serious accident.

D. Maintain a clean work area. Avoid accidents by

cleaning the area and keeping it clean.

A. Spigot Switch

E. Stay alert at all times. Know which switch, push

button or control you are about to use and what

effect it is going to have.

When the spigot handle is opened the SPIGOT

switch will start the auger drive and refrigeration

systems.Whenthespigothandleisclosed,thedrive

motorandcompressorwillremainonuntiltheproduct

in the barrel reaches the proper temperature.

B. Clean-Off-ServeSwitch

F. Disconnect electrical power for maintenance.

Never attempt to repair or perform maintenance on

the freezer until the main electrical power has been

disconnected.

The CLEAN-OFF-SERVE switch is a three position

toggle switch used to control the operation of the

refrigeration system and auger. When the switch is

placed in the CLEAN position, the refrigeration sys-

tem will be off and auger will rotate for cleaning.

G. Do not operate under unsafe operating condi-

tions. Never operate this freezer if unusual or exces-

sive noise or vibration occurs.

Figure 11. Operating Controls

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When the switch is placed in the OFF position, the

refrigeration system and auger will not operate.

When the switch is placed in the SERVE position,

therefrigerationsystemandaugerwilloperateauto-

matically.TheswitchshouldbeplacedintheSERVE

position for normal operation.

C. Cabinet-Off-On Switch

The CABINET-OFF-ON switch is a two position

toggle switch. When the switch is placed in the OFF

position, the lower cabinet refrigeration system will

not run. When the switch is placed in the ON

position, the lower cabinet refrigeration system will

run until the preset temperature is reached; then

cycle ON and OFF to maintain that temperature.

D. Cab Indicator Light

A flashing light indicates the cab OFF-ON switch is

intheOFFposition, norefrigeration. PlacetheOFF-

ON switch in the ON position for cab refrigeration.

E. Pump Switch

The pump motor switch is a two position toggle

switch. When the switch is placed in the OFF

position, the pump will not run. When the switch is

placedintheONposition, thepumpwillrununtilthe

preset pressure is reached, then cycle ON and OFF

as product is drawn to maintain that pressure.

F. Standby/Serve Switch

The standby/serve switch is a two position toggle

switch. When the switch is placed in the standby

position the freezer will cycle to maintain a tempera-

ture below 41°F (-15°C). When the switch is in the

Serve position the freezer will cycle to maintain a

servableproduct.

G. Freezing Switch

The freezing switch is a two position toggle

switch. When the switch is placed in the MAXIMUM

position the freezer will be forced to run 30 seconds

after the temperature control is satisfied.

H. High Head Pressure Cut Out

If the head pressure exceeds 445 psig (28 bar) air

cooled andwater cooled, the high head pressure

cutout will trip. The reset button can be accessed

from the side of the

freezer.

Low Mix Light

The low mix light will illuminate when the liquid level

in the mix container drops below two gallons.

J. Front Door Safety Switch

Thefrontdoorsafetyswitchpreventstheaugerfrom

turning when the front door is removed. The switch

is open when the door is removed and closed when

the door is properly installed.

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CLEANING

3.3IMPORTANTINFORMATIONREGARDING

CLEANINGANDSANITIZING

Is the removal of soil materials from a surface.

Isaprerequisiteforeffectivesanitizing.

Soft serve and shake freezers require special

consideration when it comes to food safety and

propercleaningandsanitizing.

NOTE

An UNCLEAN surface will harbor bacteria that can

defy sanitizing efforts.

The following information specifically covers issues

for cleaning and sanitizing frozen dessert freezers.

This information is meant to supplement a

comprehensivefoodsafetyprogram.

Bacteria can develop and resist sanitizing efforts

within a layer of soil material (milkstone). Thorough

cleaningproceduresthatinvolvemilkstone

removal are critical for operators of frozen

dessertmachines.

Soil Materials Associated with Frozen Dessert

Machines

SANITIZING

MILKFAT/BUTTERFAT–Ascomponentsofice-

cream/frozen custard mix, these soils will

accumulate on the interior surfaces of the machine

and its parts. Fats are difficult to remove and help

attribute to milkstone build-up.

Kills bacteria.

Can be effective on clean surfaces only.

DOES NOT clean or remove milkstone.

NOTE

Using a SANTITIZER on an unclean surface

will not guarantee a clean and safe frozen

dessert machine.

MILKSTONE – Is a white/gray film that forms on

equipment and utensils that come in contact with

dairy products. These films will accumulate slowly

on surfaces because of ineffective cleaning, use of

hard water, or both. Milkstone is usually a porous

deposit, which will harbor microbial

contaminants and eventually defy sanitizing

efforts.

Proper Daily Maintenance:

The Only Way to Assure Food Safety and

Product Quality

Properdailymaintenancecaninvolveawidevariety

of products and procedures. Overall, the products

and procedures fall into three separate categories.

(Please note that this is a brief overview intended for

informationalpurposesonly.)

1. CLEANING–Thisinvolvesdrainingmixfromthe

freezer barrel and rinsing the machine with

water. Next, a cleaner is run through the

Once milkstone has formed, it is very difficult to

remove. Without using the correct product and

procedure, it is nearly impossible to remove a thick

layer of milkstone.

(NOTE:general-purposecleanersDONOTremove

milkstone.) This can lead to high bacteria counts

and a food safety dilemma.

machine. Then, the machine is disassembled

and removable parts are taken to the sink for

cleaning.

IT IS BEST TO CONTROL MILKSTONE ON A

DAILYBASISBEFOREITCANBECOMEA

SIGNIFICANTFOODSAFETYPROBLEM.

2. MILKSTONE REMOVAL – Since almost all

cleaners do not have the ability to remove

milkstone, the use of a delimer becomes

necessary. Although this procedure may not be

needed on a daily basis, it will usually follow the

cleaning procedure. It requires letting a delimer

solution soak in the machine for an extended

period of time. Individual parts are also soaked

in a deliming solution for an extended period of

time (more about delimers in Additional

Information).

In addition to food safety, milkstone can cause

premature wear to machine parts which can add to

costs for replacement parts or possibly more

expensive repairs if worn machine parts are not

replaced once they have become excessively worn.

Important Differences Between Cleaning and

Sanitizing

CLEANINGvs.SANITIZING

3. SANITIZING – After the machine has been

cleaned and contains no milkstone, the

machineisreassembled. ThenaFDA-approved

sanitizing solution is run through the machine to

kill bacteria. The machine is then ready for food

preparation.

It is important to distinguish between cleaning and

sanitizing. Although these terms may sound

synonymous, they are not. BOTH are required for

adequatefoodsafetyandpropermachine

maintenance.

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The ideal concentration of chlorine needs to be 100

ppm (as stated by the FDA).

As a recommended cleaner and sanitizer for your

frozendessertmachine,STERA-SHEENhasproven

to be one of the best daily maintenance products for:

NOTE

Follow the directions on the container for proper

concentration.

CLEANING–Thoroughremovalofallsolids

including butterfat and milk fat.

There are two main factors that contribute to falling

chlorine concentrations in a sanitizing solution.

MILKSTONEREMOVAL–Completeremovalof

milkstone.

1. PRODUCT USE – As the chlorine in the

solution is being used, chlorine concentrations

fall.

SANITIZING–FDA-approvednorinsesanitizer

for food contact surfaces.

Additional Information

2. TIME – As time passes, small amounts of

chlorine “evaporate” from the solution. (That is

why you can smell it.)

THEUSEOFDELIMERS

A delimer is a strong acid that has the ability to

dissolve milkstone. This type of chemical may

become necessary once high levels of milkstone

havedeveloped. Whiletheseproductsarevery

effectiveforremovingHIGHlevelsofmilkstone,they

are not ideal for two reasons:

Sanitizing solutions should not be allowed to fall

below 100 ppm chlorine. New solutions should be

mixed once old solutions become ineffective.

3.4 DISASSEMBLY OF FREEZER PARTS

1. PRODUCT SAFETY – Strong acids are

dangerouschemicalsandhandlingthem

requiressafety

WARNING

Moving machinery can grab, mangle and dis-

member. Place the CLEAN-OFF-SERVE toggle

switch in the OFF position before disassembling

for cleaning or servicing. Placing the CLEAN-OFF-

SERVE toggle switch in the SERVE position dur-

ing cleaning or servicing may result in serious

personal injury.

2. MACHINE DAMAGE – Strong acids will attack

metalandrubbercausingprematurewearof

parts. The use of a delimer needs to be closely

monitored to avoid damage to machine surfaces

and parts.

With proper daily use of STERA-SHEEN or it’s

equivalent, there is no need for the use of a

DELIMER.

Beforeusingthefreezerforthefirsttime,completefreezer

disassembly,cleaningandsanitizingprocedureswillneed

tobefollowed.Routinecleaningintervalsandprocedures

must comply with the local and state health codes.

Inspection for worn or broken parts should be made at

every disassembly of the freezer for cleaning or other

purposes. All worn or broken parts should be replaced to

ensure safety to both the operator and the customer and

tomaintaingoodfreezerperformanceandaqualityprod-

uct.Twonormalwearareasaretheaugerflightsandfront

auger support bushing (see Figure 12).

DONOTUSEBLEACH

BLEACHHASABSOLUTELYNO CLEANING

PROPERTIES.

BLEACH IS CORROSIVE. It can and will

damage components of the machine causing

prematurewearandmetalcorrosion.

GENERALPURPOSECLEANERS

To disassemble the freezer, refer to the following steps:

General purpose cleaners do not have the ability to

remove milkstone. Milkstone will become a problem

if not remedied with additional products and

procedures.

Wear Line

THE USE OF CHLORINE TEST STRIPS

“Test strips” are used to determine concentrations of

active chlorine in sanitizing solutions. To use the

strips, tear off a small portion and submerge it into

the sanitizing solution. Then, compare the color

change to the color key on the side of the test strip

dispenser to determine the approximate chlorine

concentration.

Figure 12. Auger Flight Wear & Front Auger

Support Bushing Wear

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A. Disassembly Of Front Door

1. Remove the front door by turning off the black

knobs and then pulling the front door off the studs.

2. Remove the air bleed valve by unscrewing the

knob while holding the valve stem from behind.

Remove the compression spring and push air

bleed valve through the rear of the front door.

3. Remove the spigot through the bottom of the front

door (see Figure 13). Remove all O-rings from

spigot and air bleed valve.

Figure 15. Rear Seal Removal

3.5 CLEANINGDISASSEMBLEDPARTS

Disassembled freezer parts require complete cleaning,

sanitizing and air drying before assembling. Local and

state health codes will dictate the procedure required.

Somestatehealthcodesrequireafoursinkprocess(pre-

wash, wash, rinse, sanitize, air dry), while others require

a three sink process (without the pre-wash step). The

followingproceduresareageneralguidelineonly.Consult

yourlocalandstatehealthcodesforproceduresrequired

in your location.

A. To clean the freezer parts, disassemble all parts.

(Refer to section 3.4 for the disassembly of freezer

parts.)

Figure 13. Front Door Disassembly

B. Disassembly Of Auger

B. Place all front door and auger parts in clean 90° to

110°F (32°C to 43°C) water and wash thoroughly

(four sink procedure only).

1. Remove the front auger support by pulling it

straight out of the freezer barrel.

C. Place all parts in 90° to 110°F (32°C to 43°C) , mild

detergent water and wash thoroughly.

2. Remove the plastic bearing from the front auger

support.

3. Remove the auger by pulling slowly and rotating

out of the freezer barrel. As the auger is

D. Rinse all parts with clean 90° to 110°F (32°C to

43°C)water.

withdrawn, remove each plastic flight and spring

from the auger. Be careful not to scratch inside of

freezer barrel when removing flights or auger.

Remove the spring from each auger flight.

F. Sanitize all freezer parts following procedures out

linedbelow.

3.6 SANITIZE FREEZER PARTS

A. Use a sanitizer mixed according to manufacturer's

instructionstoprovidea100partspermillionstrength

solution. Mix sanitizer in quantities of no less than 2

gallons of 90° to 110°F (32°C to 43°C) water. Allow

the sanitizer to contact the surfaces to be sanitized

for 5 minutes. Any sanitizer must be used only in

accordance with the manufacturer's instructions.

B. Placeallpartsinthesanitizingsolutionfor5minutes,

thenremoveandletairdrycompletelybeforeassem

bling in freezer.

Figure 14. Auger Flight Removal

4. Keep the rear of the auger tipped up once it is

clear of the freezer barrel.

5. Wipe spline lubricant off hex end of auger with a

paper towel. Remove the rear seal. Figure 15.

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3.7CLEANINGTHEFREEZER

CAUTION

Lubricate

with

Socket

Risk of Product Damage

Do not use acid cleaners, strong caustic compounds

or abrasive materials to clean any part of the freezer

exterior or plastic parts.

Lubricant

Lubricate with Petrogel

Figure 16. Rear Seal Lubrciation

The exterior should be kept clean at all times to

preserve the lustre of the stainless steel. A good

grade of stainless steel has been used on the

freezer to ease clean-up. To remove spilled or dried

mix, simply wash the exterior in 90° to 110°F (32°C

to 43°C) , soapy water and wipe dry.

C. Lubricate the hex drive end of auger with a small

amount of white socket lubricant. A small container

of socket lubricant is shipped with the freezer.

Do not use highly abrasive materials as they will

mar the finish. A mild alkaline cleaner is recom-

mended. Use a soft cloth or sponge to apply the

cleaner. For best results, wipe in the direction of the

grain of the steel.

D. Screw the springs onto the studs in plastic flights.

Spring must be screwed into the flights com-

pletely to provide proper tension (see Figure 17).

A. Cleantherearsealsurfacefrominsideofthefreezer

barrel.

B. Using this sanitizing solution and the large barrel

brush provided, sanitize the barrel by dipping the

brush in the sanitizing solution and brushing the

inside of the barrel.

C. Removethereardriptraybypullingfromsidepanel.

Clean and replace drip tray.

3.8ASSEMBLINGFREEZER

Toassemblethefreezerparts,refertothefollowingsteps:

NOTICE

Figure 17. Spring Installation

Petro-Gel sanitary lubricant or equivalent must be

used when lubrication of freezer parts is specified.

E. Install first flights to bottom of auger, rotate, add

successiveflightsfrombottomastheaugerispushed

slowlyintothefreezerbarrel.Carefullyengageauger

with drive socket in speed reducer by rotating auger

slowly and pushing on end of auger.

NOTICE

The United States Department of Agriculture and

the Food and Drug Administration require that lubri-

cants used on food processing equipment be certi-

fied for this use. Use Lubricants only in accordance

with the manufacturer's instructions.

F. Applyathinfilmofsanitarylubricanttotheinsideand

outsideofthefrontaugersupportbearing,thenplace

on the front of the auger. Assemble the front auger

support onto the auger bearing.

A. Assemble all O-rings onto parts dry, without lubri-

cation. Then apply a thin film of sanitary lubrication

to exposed surfaces of the O-rings.

B. Lubricate rear seal area on auger shaft with a thin

layerofsanitarylubricant.InstalltherearsealO-ring.

Lubricate outside of rear seal O-ring with sanitary

lubricant.

NOTICE

Position the front support on auger so legs do not

interfere with the pin on the back of the front door

assembly. Front door must push auger in slightly

when it is being tightened to prevent the rear seal

from leaking.

C. Installstainlesssteelrearsealadapterintorearseal

dry (without lubricant). Lubricate inside surface of

rear seal adapter and install onto auger shaft. DO

NOTlubricateoutsideofrearaugerseal (seeFigure

16).

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G. Assemble O-rings onto the spigot dry, without

lubrication.Thenapplyathinfilmofsanitarylubricant

to the outside of the O-rings and spigot bodies.

H. Install the spigot through the bottom of the front

door ( see Figure 18).

Figure 18. Front Door Assembly

Assemble the air bleed valve O-ring onto the air

bleed valves. Position the O-ring in groove close to

thewidepart. Applyathinfilmofsanitarylubricantto

the O-rings.

J. Insert the air bleed valve from the back of the front

door. Install compression springs onto air bleed

valves, then screw knobs on finger tight.

K. Apply a thin film of sanitary lubricant to the door seal

O-rings, and fit into the grooves on the rear of the

frontdoor.

L. Placethefrontdoorassemblyonthemountingstuds

and push front door against the freezer carefully.

M. Secure front door assembly by placing the knobs on

the studs and tighten until finger tight only. Do not

overtighten.ProperO-ring seal can be observed

through the transparent front door.

N. Move the spigot handles to the closed position.

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3.9 SANITIZING

C. Let sanitizing solution fill the freezer barrel to air bleed

valve, then close the valve by pulling out to lock in

place.

Sanitizing must be done after the freezer is clean and just

before the freezer is filled with mix. Sanitizing the night

before is not effective. However, you should always clean

the freezer and parts after using it.

D. Place the CLEAN-OFF-SERVE toggle switch in

the ON position while pressing the CLEAN switch.

WARNING

The United States Department of Agriculture and

the Food and Drug Administration require that

all cleaning and sanitizing solutions used with

food processing equipment be certified for this

use.

When sanitizing the freezer, refer to local sanitary regula-

tions for applicable codes and recommended sanitizing

products and procedures. The frequency of sanitizing must

comply with local health regulations. Mix sanitizer ac-

cording to manufacturer’s instructions to provide a 100

parts per million strength solution. Mix sanitizer in quan-

tities of no less than 2 gallons of 90°F to 110°F 90° to

110°F (32°C to 43°C) water. Allow sanitizer to contact the

surfaces to be sanitized for 5 minutes. Any sanitizer must

be used only in accordance with the manufacturer’s in-

structions.

Figure 20. Draining Sanitizer

E. Check for leaks when the freezer barrel is first

pressurized with sanitizing solution.

1. Check for leaks at the plastic front door, the

O-rings may not be sealed.

2. Check the drain located at the center of the

Drip Tray for leaks coming from the rear of the

Rear Auger Seal.

3. Check inside cab unit for leaks at hose connec-

tions.

F. Using a sanitized soft bristle brush or equivalent,

dipped in sanitizing solution, clean mix container.

G. After five minutes, open spigot to expel sanitizing

solution. Drain all solution from freezer using both

spigots (See Figure 20).

Air Bleed Valves

H. Close the spigot and place the mix pump switch

and the CLEAN-OFF-SERVE switch in the OFF

position.

Figure 19. Air Bleed Valves

CAUTION

The freezer is now sanitized and ready for adding mix.

Risk of Product Damage

3.10 INITIAL FREEZE DOWN AND OPERATION

Avoid prolonged contact of sanitizer with freezer parts.

Prolonged contact of sanitizer with freezer may cause

corrosion of stainless steel parts.

This section covers the recommended operating proce-

dures to be followed for the safe operation of the freezer.

A. Sanitize just prior to use according to instructions

outlined in this manual.

B. Prepare the desired amount of mix and then fill each

storage container with approximately 3 gallons or

more of mix. Place a container(s) of mix in the re-

frigerated cabinet. If drawing from a storage container,

place the draw tube through the cover to the bottom

of the container. If drawing from a bag in a box, re-

move the cap, push out all of the air, and insert the

adaptor.

A. Prepare 3 gallons of sanitizing solution following

manufacturer's instructions, and pour into storage

container.

B. Place the mix pump switch in the ON position and

open air bleed valve on the front door by pushing

valve in and holding (see Figure 19).

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The freezer is designed to dispense the product at a

reasonable draw rate. If the freezer is overdrawn, the

result will be a soft product and air pops. If this should

occur, allow the freezer to run for approximately 30

seconds before dispensing additional product. After a

while the operator will sense or feel when the freezer is

beginning to fall behind, and will slow down on the rate of

draw so as not to exceed the freezer's capacity.

Do not operate the freezer when the MIX LOW light is

on or with less than 1-3/4" (4.4 cm) of mix in the

mix container. Refill the mix container immediately.

Mix Low

Sensor

3.11MIXINFORMATION

Figure 21. Refrigerated Cabinet

Mix can vary considerably from one manufacturer to

another.Differencesintheamountofbutter-fatcontentand

quantity and quality of other ingredients have a direct

bearingonthefinishedfrozenproduct.Achangeinfreezer

performance that cannot be explained by a technical

problem may be related to the mix.

C. Place the mix pump switch in the ON position. The

mix pump switch is located in the upper left hand

corner, inside the refrigerated cabinet. Immediately

open the spigot and let approximately 8 ounces of

liquid mix with sanitizing solution drain out of the

spigot.

Proper product serving temperature varies from one

manufacturer's mix to another. Soft serve mixes should

provide a satisfactory product in the 17° to 20°F (-7° to

-6°C) range. Most shake mixes freeze to proper consis-

tency at 27°F (-2.8°C). Diet and low-carb mixes typically

freeze to proper consistency at higher temperatures.

D. Close the spigot and open the air bleed valve on the

front door by pushing the valve in and holding. Allow

the barrel to fill until the mix level is 1/2" (2.7 cm)

below air bleed valve, then release valve and pull

closed to lock in place.

When checking the temperature, stir the thermometer in

the frozen product to read the true temperature.

Mix does not improve with age. Old mix, or mix that has

been stored at too high a temperature, can result in a

finished product that is less than satisfactory from the

appearance and taste standpoint. To retard bacteria

growthindairybasedmixes,thebeststoragetemperature

range is between 36° to 40°F (2.2° to 4.4° C).

E. Start the compressor and drive by placing the

CLEAN-OFF-SERVE switch in the SERVE position

F. The product will be ready to serve after the compres-

sor and drive have cycled off, or in approximately 12

minutes.

G. The refrigeration is automatically actuated when the

spigot is opened. For normal dispensing, open the

spigot no more then 90°. (This is when the handle

knob is pointed directly away from the front door.)

This position provides excellent control over the prod-

uct and aids in making desired shaped portions.

Close spigot completely after dispensing.

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C. Theover-runadjustmentispresetatthefactory.Ifan

adjustment becomes necessary, refer to Section 4.

3.12 OPERATION OF MIX PUMP

The pump switch is located on the front of the freezer.

When the pump switch is placed in the ON position, the

mix pump motor will be actuated to pump mix into the

freezer cylinder. When the set pressure is reached, the

mix pump will shut off automatically. When the switch is

placed in the OFF position, the mix pump will be inopera-

tive.

NOTICE

Any cleaning procedure must always be followed

by sanitizing before filling freezer with mix. (Refer to

section 3.3)

3.13 MIX PUMP CLEANING

The mix pump is approved for CIP (clean in place) and is

thoroughlycleanedascleaningsolutionsarepumpedthru

the freezer. We recommend completely disassembling

thepumpandconnectingtubingevery14daysforinspection

ofpartstoconfirmtheCIPhasbeenproperlyperformed.If

any residue is detected clean or replace those parts as

outlinedbelow.

NOTE

The mix pump motor is equipped with an internal

overload that will “trip”, disabling the pump when the

motor is overloaded. Consult the trouble shooting

section for corrective information.The internal over-

load will automatically reset after cooling. If the con-

dition continues, contact a qualified service person.

1. Place CLEAN-OFF-SERVE switch in CLEAN posi-

tion. Allow the auger to agitate for 5 to 10 minutes.

CAUTION

2. Remove suction tube from mix container. Draw off the

mix remaining in freezer barrel.

Risk of Product Damage

Mix pump hose must be repositioned every 1 -2 weeks

or 60 hours of operation. Failure to comply will result

in reduced mix pump liquid capacity, dispense stop-

page, popping, and possible mix pump hose leak-

age. Hose leakage may damage the pump roller as-

sembly and void the factory warranty.

3. Pump 2 gallons (7.5 liters) of cold potable water thru

freezer until water at spigot is free of mix.

4. Pump 2 gallons (7.5 liters) of 90° to 110°F (32°C to

43°C) detergent solution water thru freezer. The use

of soft water is recommended, along with dishwashing

detergents such as “Joy,” “Dawn,” or equivalent.

A. Mix Operation: The peristaltic mix pump contains

onecontinuousmixpumphose.Whenlookingatthe

face of the peristaltic mix pump, the left side of the

hose is the suction or pickup. The right side of the

hose is the discharge. Mix is drawn up the suction

side of the hose and transferred thru the discharge

side to the freezer (see Figure 22).

5. Place mix pump switch in OFF position. Open spigot

to relieve remaining pressure.

6. Place CLEAN-OFF-SERVE switch in OFF position.

B. AirOperation:Theaircompressoroperateswhenever

the peristaltic mix pump is running. Air enters thru a

check valve on the piston downstroke. The air is

discharged thru a second check valve, on the piston

upstroke. The air and mix join at the tee and then

traveltothefreezer.

3.14 DISASSEMBLY AND INSPECTION OF

REMOVABLE PARTS

Inspection of removable parts should be made whenever

maintenance is performed or pump requires disassembly.

WARNING

Hazardous Moving Parts

Hose

Holder

Mix

Discharge

Revolvingpumpheadcangrab, mangle, andcause

serious crushing injury. The Power switch must be

placed in the OFF position for cleaning and power

must be disconnected when disassembling or

Mix

Intake

servicing.

CAUTION

3-way Tee

System Under Pressure

Never disconnect hoses from freezer or pump without

first opening spigot to relieve pressure.

Figure 22. Mix Pumps

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NOTE

9. Sanitize assembled freezer as per instructions

outlined in Section 3.9).

If the mix lines or air line is difficult to remove, soften

with a rag soaked in hot water. Hose connections

may be sprayed with Haynes Sanitary Lubricant for

ease of removal. Do not loosen or remove the mix

pump cover wingnuts. Maintain the mix pump hose

in its operational condition.

1. Loosen clamp and remove air hose from pump

compressor.

2. Loosen clamp and disconnect mix pump hose.

Remove the pickup hose, mix check valve and pickup

hose adapter (and bag adapter if applicable) as an

assembly from mix container.

3. Completely disassemble both hose assemblies and

check valve. Place hoses, tee, check valve assem-

bly, and pickup hose adapter in 90° to 110°F (32°C to

43°C), mild detergent water and wash thoroughly. Use

soft bristle brushes to clean inside of fittings. Rinse

all parts in clean 90° to 110°F (32°C to 43°C) water

(see Figure 23).

Figure 24. Cleaning Air Tube

4. Carefully inspect each part for wear or damage.

Replace worn or damaged parts.

5. Wash feed tube and air tube with 90° to 110°F deter-

gent water and brushes provided. Rinse with clean,

90° to 110°F water (See Figure 24 and 25).

6. Prepare two gallons (7.5 liters) of sanitizing solution

using a USDA certified grade sanitizing solution.

Sanitize all removed parts, then air dry.

Figure 25. Cleaning Feed Tube

7. Check Hose Service Record decal to determine if

hose reposition or replacement is required at this

time.

Pump

Compressor

8. Reassemble both hose assemblies per the diagram

located on the inside of the cab door. Reconnect

assemblies to the pump and discharge hose, using

the clamps. (See Figure 26 or refer to Section 2.5

Mix Pump).

Figure 23. Removable Parts

Figure 26. Mix Pump Tube Routing

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SECTION 4

MAINTENANCE INSTRUCTIONS

4.1 FREEZER ADJUSTMENT

ThemixpumpthatfillstheleftfreezingcylinderoftheU444

This section is intended to provide maintenance person- has been preset at the factory to produce a soft serve

nel with a general understanding of the freezer adjust- product with approximately 40% overrun. The mix pump

ments. It is recommended that any adjustments in this that fills the right freezing cylinder of the U444 has been

section be made by a qualified person.

preset at the factory to produce a shake product with

approximately 50% overrun. The left and right pumps on

theU421havebeenpresettoproduceasoftserveproduct

4.2 PRODUCT TEMPERATURE ADJUSTMENT

A potentiometer is used to control the product tempera- with approximately 40% overrun. Because of differences

ture.Tochangethetemperatureoftheproduct,followthe inmixformulation,temperaturesandbarometricpressure,

steps below:

thisfiguremayvary.Itwillbenecessaryforapproximately

2 gallons (7,5 liters) of mix to be pumped thru the freezer

before changes in the product are noticeable due to

adjustmentsinoverrun.

A. Loosen the two screws under the header display

sign, then pull sign out and down.

B. Use a screw driver to make desired adjustment. A

label near the potentiometer will give complete in-

structions (see Figure 26).

Overrun is controlled by the length of the air compressor

piston stroke within the piston cylinder. Lengthening the

stroke within the cylinder will increase overrun. Con-

versely, shortening the stroke will decrease overrun. To

perform an overrun adjustment, refer to the following

procedure:

A. Turn the mix pump switch to the OFF position .

B. Remove the lower back panel from freezer.

C. On air compressor side of pump, locate the long/

slender piston rocking arm. The rocking arm down-

ward travel is limited by a stationery cam. On the face

of the cam there is an overrun setting indicator plate

numbered 3 thru 8 and an adjustment knob (see

Figure 27).

Figure 27. Potentiometer

4.3 OVERRUN ADJUSTMENT

The product when served is a combination of air and mix.

Overrunisameasureoftheamountofairblendedintothe

mix.

Overrun can be expressed in terms of the amount of

weight loss for a given volume. For example, if a pint of

liquid mix weighs 18 ounces (510 grams) and a pint of

frozen product with air added weighs 12 ounces (340

grams), the overrun is said to be 50 percent "18 oz. (510

grams) - 12 oz. (340 grams) = 6 oz. (170 grams)", (6 /12)

x 100 = 50%.

Overrun Adjustment

Figure 28. Overrun Adjustment

D. The overrun setting is indicated by a pointed pin.

The overrun can be checked by placing a one pint

containeronanicecreamscaleandzeroingoutthescale.

Then fill a one pint container with frozen product. The

container should be filled over the top and leveled with a

straightedge. The product should not contain any air

pockets. When weighed on an ice cream scale, one pint

(473 milliliters) of product should weigh 12 to 13 ounces

(340 to 368,5 grams) for an overrun of 45 to 50%.

E. To adjust overrun, loosen the allenhead screw

(located within the center of the adjustment knob)

with the 5/32" (4mm) allen wrench provided. Rotate

the adjustment knob counterclockwise to a higher

number for higher overrun, or clockwise to a lower

number for lower overrun. Each number multiplied by

10 represents the overrun percentage (ie: #4 = 40%

overrun).

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F. Tighten the allen screw, then place the wrench back

in its clip. Replace the lower back panel and secure

with the four screws. Turn the mix pump power switch

to the ON position.

CAUTION

UTION

Never disconnect hoses from freezer or pump with-

out first opening spigot to relieve pressure.

4.4. MIX PUMP HOSE REPOSITION (every one or

two weeks.)

3. Disconnect mix pump hose at each end.

NOTICE

4. Grasp the discharge hose end with one hand

and turn the pump on. Pull down on the hose

until all of the remaining hose is removed from

the pump.

Mix pump hose must be repositioned every 1 - 2

weeks. Failure to comply will result in reduced mix

pump liquid capacity, dispense stoppage, popping,

and possible mix pump hose leakage.

5. Connect new mix pump hose to pick-up hose

adapter, using small clamp.

1. Run cleaning solution through pump.

6. Insert free end of hose into the pick-up (suction

side) hose side of the black cover. Gently push

the hose into the black cover until it begins to

self-feed. Allow the hose to feed itself through

the pump until the pick-up hose adapter pre-

vents further feeding, then turn the pump off.

2. Turn pump off and relieve any pressure by

opening the spigot.

3. Grasp the pick-up hose end of the mix pump

hose with one hand and turn the pump on. Pull

down on the pick-up hose end until 12 to 14"

(30-1/2 to 35-1/2cm) of tubing has reverse fed

through the pump, then turn the pump off.

7. Reconnect mix pump hose to T using small

clamp. Pump is now ready to sanitize.

4.6 CAB TEMPERATURE ADJUSTMENT

Atemperaturecontrolisusedtocontrolcabtemperature.

To change the temperature, follow the steps below:

4. Loosen small clamp at the pick-up hose

adapter and (Viewed from Back) disconnect

mix pump hose.

A. Remove the six screws holding the left side panel

and remove panel.

5. Cut 7-1/2" (19 cm) off the end of the mix pump

hose.

B. Use a small screwdriver to adjust the temperature

control. Turn counterclockwise for a warmer tem-

perature and clockwise for a colder temperature. It

will take about an hour for the cab temperature to

change. Figure 28.

6. Reconnect mix pump hose to adapter.

7. Continue normal operation. Mix hose will

automatically reposition itself with adapter near

black cover.

C. Install side panel and secure with the six retaining

screws.

NOTICE

Each hose is long enough for 3 repositions before

replacement is required. Record each event on

Hose Service Record decal.

4.5 MIX PUMP HOSE REPLACEMENT

NOTICE

Mix pump hose must be replaced when tubing can-

not be further repositioned (every four to eight

weeks). Failure to comply will result in hose failure

and possible pump damage.

Figure 29. Temperature Control Cab

1. Run cleaning solution through pump.

4.7 DRIVE BELT TENSION ADJUSTMENT

To check belt tension, refer to Figure 29 and follow the

steps below:

2. Turn pump off and relieve any pressure by

opening the spigot.

WARNING

The Mix pump switch must be in the "Off" position

when servicing or cleaning pumps.

Disconnect electrical supply to freezer before ser-

vicing.

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A. Remove either side and back panels.

B. Press firmly on one belt. Figure 29.

NOTICE

If the condenser is not kept clean, loss of refrig-

eration efficiency will result.

4.9PREVENTATIVEMAINTENANCE

Itisrecommendedthatapreventativemaintenancesched-

ule be followed to keep the freezer clean and operating

properly. The following steps are suggested as a preven-

tativemaintenanceguide.

WARNING

Never attempt to repair or perform any maintenance

on freezer until all main electrical power has been

disconnected.

TheUnitedStatesDepartmentofAgricultureandtheFood

and Drug Administration require that lubricants used in

food zones be certified for this use. Use lubricants only in

accordance with the manufacturer's instructions.

Figure 30. Belt Adjustment

C. When the tension is properly adjusted, the outside

of the depressed belt should be approximately in

line with the inside of the other belt.

A. Daily Checks

Check for any unusual noise or condition and repair

immediately.

D. If an adjustment is necessary, loosen the four motor

plate retaining nuts, adjust belt tension then re

tighten the four nuts.

B. Month Checks

1. Check drive belts for wear and tighten belts if

necessary. (Refer to Section 4.7.)

NOTICE

Belt life will be increased if new drive belts are tight-

ened after two or three weeks of operation.

2. Check the condenser for dirt. (Refer to Section

4.8).

4.8 CONDENSER CLEANING (AIR-COOLED

FREEZERS)

The condenser requires periodic cleaning. To clean the

condenser, refer to the following steps:

WARNING

Never attempt to repair or perform any maintenance

on freezer until all main electrical power has been

disconnected.

NOTICE

Some freezers have a condenser filter, to clean re-

move and wash in warm soapy water. Rinse in clean

water and shake dry, taking care not to damage

filter in any way.

4.10EXTENDEDSTORAGE

Refertothefollowingstepsforwinterizingthefreezerorfor

storingthefreezeroveranylongperiodofshutdowntime.

A. Visually inspect the condenser for dirt.

A. Clean thoroughly with warm detergent all parts that

come in contact with mix. Rinse in clear water and

dry all parts. Do not sanitize.

B. If the condenser is dirty, place a wet towel over the

condenser.

NOTICE

Do not let cleaning solution stand in freezer barrel

or mix pump during the shutdown period.

C. Using compressed air or CO2 tank, blow out the dirt

from the back of the condenser. Most of the dirt will

cling to the wet towel.

B. Remove, disassemble, and clean the front door,

auger shaft, and mix pump. Leave disassembled

during the shutdown period.

CAUTION

Thisprocedureemitsaloudnoice. Wearhearprotec-

tion to prevent hearing loss.

C. Place plastic auger flights in a plastic bag with a

moist paper towel. This will prevent flights from

becoming brittle if exposed to dry air over an

extended period of time (over 30 days).

D. An alternative method is to clean with a con-

denserbrushandvacuum.

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D. For water-cooled freezers that are left in unheated

buildings, or buildings subject to freezing, the water

must be shut off and disconnected. Disconnect

fittings at water valve inlet and water outlet lines at

the freezer. The fittings are located at the rear of the

freezer. Run the compressor for 2 - 3 minutes to

open water valve. Blow out all water, first through

water inlet, then through water outlet lines with air or

carbon dioxide. Also drain water supply line to the

freezer.

E. Place the mix pump ON-OFF switch, and the

CLEAN-OFF-SERVE switch in the OFF position.

F. Disconnect from the source of electrical supply in

the building.

4.11 TROUBLESHOOTING

The Troubleshooting Table lists the common problems

that can occur to the freezer.

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FREEZER

PROBLEM

FREEZER POSSIBLE CAUSE

REMEDY

Drive motor (auger)

"kicks-out", or does

not run.

1. Power to freezer is off.

2. Drive motor overloaded.

1. Check power to freezer.

2. Wait 15-20 min. for Thermo overload

to reset.

3. Low line voltage.

3. Check, must be +\-10% of

nameplate voltage.

4. Product too hard.

4. Raise overrun and/or product

temperature. (See Section 4.3 or 4.2)

5. Install front door securely.

5. Front door not installed securely.

Compressor does not

operate.

1. Power to freezer if off.

2. Drive motor overloaded.

1. Check power to freezer.

2. Wait 15-20 min. for Thermo overload to

reset.

3. Low line voltage.

3. Check, must be +/-10% of nameplate

voltage.

4. Compressor internal overload is

cut-out.

5. Front door not installed securely.

4. Check condenser (air cooled)(See Sect.

4.8), or water suppy (water cooled).

5. Install front door securely.

Product too soft.

1. Temperature setting is too high.

2. Product break down.

3. Standby/Serve Switch in Standby

position.

1. Adjust temperature. (See Section 4.2)

2. Fill with fresh product.

3. Place Standby/Serve Switch in Serve

position.

Freeze-up. (Product

will not dispense

easily.)

1. Temperature setting is too low.

2. Low overrun setting.

3. Low pump pressure.

1. Adjust temperature. (See Section 4.2)

2. Raise overrun. (See Section 4.3)

3. Check pump pressure.

4. Large air pocket in barrel.

5. Auger turning counter-clockwise.

4. Purge air from barrel.

5. Change rotation to clockwise.

Rear auger seal leaks. 1. Rear auger seal not lubricated.

2. Seal missing or installed wrong.

1. Lubricate seal. (See Section 3.8)

2. Check. (See Section 3.8)

3. Replace shaft.

3. Worn or scratched shaft.

Spigot leaks.

1. Spigot parts are not lubricated.

2. Chipped or worn o-rings.

1. Lubricate. (See Section 3.8)

2. Replace O-rings.

3. O-rings on spigot installed wrong.

4. Nicks or scratched on front door

where spigot is located.

3. Remove spigot and check O-rings.

4. Replace front door.

Drive belts slipping or

squealing.

1. Drive belt tension not correct.

2. Worn belt(s).

1. Adjust belt tension. (See Section 4.7)

2. Replace belts.

3. Temperature setting is too low.

4. Low overrun.

3. Adjust temperature. (See Section 4.2)

4. Check for air leak.

Mix temperature too

warm in cab.

1. System low on refrigerant.

2. Temperature control set too

warm.

1. Add refrigerant. (Refrig. Service)

2. Remove left side panel and locate

temperature control and follow

instructions on decal.

Mix temperature too

cold in cab.

1. Temperature control set too cold.

1. Remove left side panel and locate

temperature control and follow

instructions on decal.

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MIX PUMP

1. PUMP MOTOR DOES NOT RUN

Power to pump is off.

Supply power to pump.

Low voltage.

Check for low line voltage.

Mix pump hose jammed inside black cover/clamp.

Disconnect pump from power source. Remove four

cover/clamp thumb screws. Separate cover/clamp

halves and remove outer half. Remove jammed hose.

Re-install cover/clamp and tighten four thumb screws

securely. Allow motor thermal overload to reset. See

Sec. 2.5 for hose replacement. Do not use jammed

portion of hose.

Pump motor overloaded.

Allow internal thermal overload to reset; determine

overload cause and repair.

Pressure switch on pump is defective.

Defective motor/capacitor

Contact your local Stoelting Distributor.

Defective toggle switch.

2. PUMP OPERATES BUT CYLINDER WILL NOT FILL

NOTE 1: A PROPERLY WORKING PUMP WILL FILL AN 8 OZ. CUP WITH MIX IN ABOUT 9 SECONDS.

NOTE 2: IMMEDIATELY AFTER A "BAG CHANGE" THE PUMP MAY BE UNABLE TO RE-ESTABLISH IT'S

PRIME WITH THE SYSTEM AT OPERATING PRESSURE. IN THIS CASE, TURN THE PUMP OFF. DRAW 2-3

PINTS TO REDUCE SYSTEM PRESSURE TO ZERO. TURN PUMP ON. PURGE REMAINING AIR IN MIX BAG

AND PICK-UP HOSE.

IMPORTANT: Before connecting the pick-up hose to the mix bag, purge the mix bag of air to the extent

possible.

Out of Mix.

Replenish mix supply.

MIx pump hose kinked inside black cover/clamp.

Hoses assembled incorrectly.

Mix pump hose service life is exceeded.

Mix pump hose not connected to freezer.

Ice crystals in mix.

Follow mix pump hose jammed repair. (See #1 above.)

Refer to diagram for correct hose connections.

Reposition/replace mix pump hose. See Sec. 2.5.

Connect mix pump hose to freezer.

Completely thaw mix prior to use.

Mix bag drawn against adapter.

Foreign objects in mix.

Assure bag is clear of pick-up tube.

Clear blockage. Use fresh mix.

Mix Check Valve is installed backwards.

3. OVERRUN TOO LOW OR NO OVERRUN

Overrun setting too low.

Observe flow arrow for proper orientation.

Increase overrun setting.

Air leak.

Tighten all hose clamps.

Air compressor not pumping air.

4. OVERRUN TOO HIGH

Contact local Stoelting Distributor.

Mix pump hose service life is exceeded.

Out of mix.

Reposition/replace mix pump hose.

Replenish mix supply.

Overrun setting too high.

Decrease overrun setting.

See Section 2.5.

Pick-up leg of mix pump hose is collapsing.

NOTE: ALSO SEE "2" ABOVE.

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5. REPLACEMENT MIX PUMP HOSE WON'T FEED THROUGH PUMP

Feeding hose into discharge hole of mix pump cover.

Hose ends not cut squarely.

Feed hose into pick-up side of cover.

Carefully cut hose end off squarely (no tails).

Force feeding too quickly.

Gently and slowly assist feeding of hose up into pick-up

hose side of cover.

Pump motor not running.

Turn on motor switch. Also see Item 1 above.

6. AIR EXITING MIX PICK-UP HOSE

Pickup tube check valve missing.

7. DISPENSED PRODUCT AIR "POPS"

Overrun setting too high.

Contact local Stoelting Distributor.

Reposition/replace mix pump hose.

Reduce dispense rate.

Mix pump hose service life is exceeded.

Overdrawing the freezer's capacity.

Recent "mix-out" condition.

Open spigot fully and allow excess air to "belch" out.

NOTE: ALSO SEE 2 & 4 ABOVE.

8. MIX LEAKAGE FROM PUMP

CAUTION: To prevent mix pump damage from dried mix deposits, immediately disassemble and clean

pump.

Mix pump hose service life is exceeded.

Remove mix pump hose. Disconnect pump from power

source. Remove mix pump cover/clamp. THOROUGHLY

rinse three squeeze rollers using a spray bottle filled

with hot water. Thoroughly clean all mix from pump. See

Sec. 2.5 for hose replacement.

9. PUMP HAS POOR CAPACITY

Lift and run limits are exceeded.

NOTE: Also see 2, 4, 6 & 7.

Pump is limited to 10' lift, 20' run.

10. PUMP IS NOISY/SQUEAKING

NOTE: THE ACTION OF THE AIR COMPRESSOR ROCKING ARM CREATES A REPETITIVE CLICKING

SOUND DURING OPERATION. THIS IS NORMAL.

11. MIX IN AIR HOSES

Air/mix tee above black cover/clamp.

Air leak.

Air/mix tee must be below black cover/clamp.

Tighten all hose clamps.

Mix hose on wrong air/mix tee fitting.

Refer to diagram for correct hose connections.

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SECTION 5

HOW TO ORDER REPLACEMENT PARTS

5.1HOWTOORDERREPLACEMENTPARTS

To assure the receipt of the proper replacement parts,

supply your Authorized Stoelting Distributor with the

followinginformation:

A. Modelnumberofequipment.

B. Serial number of model (stamped on nameplate)

C. Part number, part name, and quantity needed.

NOTICE

Minimum billing is $50.00 Net.

5.2PARTSLISTANDREFERENCEDRAWINGS

The following lists and drawings will aid the user when

orderingpartsorservicing.

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FRONT DOOR PARTS

Drawing

Index No.

Part No.

Description

O-ring, Front Door

625133

624520

O-ring, Air Bleed Valve

Spring, Air Bleed Valve

Knob, Air Bleed, Black

Stem, Air Bleed Valve

Spigot Handle

694200

482004

2110116

1107123

570998

2146293

2157892

2143024

624655

624645

3152581

624677

1177905

482035

Retaining Pin

Spigot Extension, 2.1

Spigot Extension, 1.5

Spigot Extension, 3.2

Spigot O-ring

Spigot Extension O-ring

Spigot, White

Spigot O-ring

Front Door

Knob, Black

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AUGER PARTS

Drawing

Part

Index No.

Number

Qty.

Description

2104552

149003

381804

694255

4151178

624678

1151859

667868

Auger Front Support

Front Bearing

Plastic Flight

Spring

Auger

Rear Seal O-ring

Rear Seal Adaptor

Rear Seal

MISCELLANEOUS PARTS

Description

Part No.

Haynes Spray 12 oz.(340 grams) -------------------- 508017

Petro-Gel Tube 4 oz. (113 grams) --------------------508135

Spline Lubricant 2 oz. (57 grams) --------------------508048

Brush 4"x 8"x16" (10cm x 20cm x 40,5cm) -------208135

Brush 2.5"x 4"x12" (6,5cm x 10cm x 30,5cm)---- 208146

Brush .25"x 4"x14" (,6cm x 10cm x 35,5cm) ----- 208380

Brush 1"x3.5"x18" (2,5cm x 9cm x 45,5cm) ------208465

Drip Tray --------------------------------------------------- 744273

Drip Tray Grid --------------------------------------------- 417006

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Figure 7. Mix Pump

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DECALS

Qty.

Part Number

Description

324200

324798

324797

324800

324799

324141

324509

324014

324686

723525

324106

H.P. Manual Reset

Clean-Off-Serve

Standby/Serve

Cab Off-On

Pump Off On

Caution, Haz. Rot. Blade - Front Panel

Cleaning - Right Side

Auger Rotation - Evap. Enclosure Rear

Danger - Start Auto, on Evap. Support between belts & motors support brkt.

Winterizing, Attach to water hose near bottom

Caution - Elec. Wiring Mat'ls must conform between water couplings, one rear

panel bottom

324346

324107

324208

723552

723517

Caution - Haz. Mov. Parts, on inside of mtr support brkt @ rear

Caution - Haz. Mov. Parts, on cond. bkt. rear & (2) on evap. enclosure sides

Attn - Ref. Lk Chk, on evap. enclosure sides

Tag - Supply volt., inside J-Box

Card - Inside one J-Box

ID Tags, Back Panel Top

324548

Add. Vent Back Panel Ctr Top

Made in U.S.A. - Back panel

324103

324151

324125

324242

324565

324158

324566

130000

324065

324803

324804

324805

Caution - Rot. Shaft, on gearbox support bracket

Field Connections, J-Box cover, outside

Danger Elec.Shock, J-Box covers outside, back panel bottom

Warm/Cold, @ T-Stat

Night/Serve - Temp. Control Bracket

Use copper cond. only, inside both J-boxes

Wired According to, on elec. schematic envelope

Elec. Schematic Envelope

Water Inlet - Back panel above inlet coupling

Header panel decal (Stoelting Logo)

Header panel decal (Stoelting Swirl)

Header panel decal (DQ Logo)

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GENERAL ORDER ADVICE

Customer No.: ________________ Customer P.O. No.: ________________ Stoelting Order No.: ______________

SoldTo: _____________________________________

____________________________________________

Contact Name: _______________________________

Phone: ______________________________________

Date: __________________________________________

ShipTo: ________________________________________

_______________________________________________

Fax #: ______________________________________

Terms of Payment: _______________________________

Requested Routing: ______________________________

Freight: Collect __________ Prepaid __________ Prepay & Add __________ Account # ________________

Third Party Billing

_____________________________________

FAX or CALL your local distributor.

Order Comments: Always use original factory replacement parts to assure optimum machine performance. Simply

use this form to order from your distributor. Call 920-894-2293 for Commercial Products to direct you to your local

distributor.

MODEL/PART NUMBER

508135

QTY.

DESCRIPTION

UNIT $

EXT. $

Petro-Gel

508048

Spline-Lube 2 oz.

Auger Flights

381804

149003

Auger Front Bushing

Auger Rear Seal

Auger Rear Seal O-Ring

Cleaning Brushes

Cleaning Card (Laminated)

Owner's Manual

667868

624678

208135

208380

208387

208465

208467

236036

513596

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GENERAL ORDER ADVICE

Customer No.: ________________ Customer P.O. No.: ________________ Stoelting Order No.: ______________

SoldTo: _____________________________________

____________________________________________

Contact Name: _______________________________

Phone: ______________________________________

Date: __________________________________________

ShipTo: ________________________________________

_______________________________________________

Fax #: ______________________________________

Terms of Payment: _______________________________

Requested Routing: ______________________________

Freight: Collect __________ Prepaid __________ Prepay & Add __________ Account # ________________

Third Party Billing

_____________________________________

FAX or CALL your local distributor.

Order Comments: Always use original factory replacement parts to assure optimum machine performance. Simply

use this form to order from your distributor. Call 920-894-2293 for Commercial Products to direct you to your local

distributor.

MODEL/PART NUMBER

508135

QTY.

DESCRIPTION

UNIT $

EXT. $

Petro-Gel

508048

Spline-Lube 2 oz.

Auger Flights

381804

149003

Auger Front Bushing

Auger Rear Seal

Auger Rear Seal O-Ring

Cleaning Brushes

Cleaning Card (Laminated)

Owner's Manual

667868

624678

208135

208380

208387

208465

208467

236036

513596

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WARRANTY

SOFT SERVE / SHAKE FREEZERS

1. Scope:

Stoelting, LLC warrants to the first user (the “Buyer”) that the freezer cylinders, hoppers, compressors,

drive motors, speed reducers, auger and auger flights of Stoelting soft serve / shake freezers will be free

from defects in materials and workmanship under normal use and proper maintenance appearing within

five (5) years, and that all other components of such equipment manufactured by Stoelting will be free from

defects in material and workmanship under normal use and proper maintenance appearing within twelve

(12) months after the date that such equipment is originally installed.

2. Disclaimer of Other Warranties:

THIS WARRANTY IS EXCLUSIVE; AND STOELTING HEREBY DISCLAIMS ANY IMPLIED

WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

3. Remedies:

Stoelting’s sole obligations, and Buyer’s sole remedies, for any breach of this warranty shall be the repair

or (at Stoelting’s option) replacement of the affected component at Stoelting’s plant in Kiel, Wisconsin, or

(again, at Stoelting’s option) refund of the purchase price of the affected equipment, and, during the first

twelve (12) months of the warranty period, deinstallation/reinstallation of the affected component from/into

the equipment. Those obligations/remedies are subject to the conditions that Buyer (a) signs and returns

to Stoelting, upon installation, the Checklist/Warranty Registration Card for the affected equipment, (b)

gives Stoelting prompt written notice of any claimed breach of warranty within the applicable warranty

period, and (c) delivers the affected equipment to Stoelting or its designated service location, in its original

packaging/crating, also within that period. Buyer shall bear the cost and risk of shipping to and from

Stoelting’s plant or designated service location.

4. Exclusions and Limitations:

This warranty does not extend to parts, sometimes called “wear parts”, which are generally expected to

deteriorate and to require replacement as equipment is used, including as examples but not intended to

be limited to o-rings, auger seals, auger support bushings and drive belts. All such parts are sold

AS IS.

Further, Stoelting shall not be responsible to provide any remedy under this warranty with respect to any

component that fails by reason of negligence, abnormal use, misuse or abuse, use with parts or equipment

not manufactured or supplied by Stoelting, or damage in transit.

THE REMEDIES SET FORTH IN THIS WARRANTY SHALL BE THE SOLE LIABILITY

STOELTINGANDTHEEXCLUSIVEREMEDYOFBUYERWITHRESPECTTOEQUIPMENT

SUPPLIEDBYSTOELTING;ANDINNOEVENTSHALLSTOELTINGBELIABLEFORANY

INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER FOR BREACH OF

WARRANTY OR OTHER CONTRACT BREACH, NEGLIGENCE OR OTHER TORT, OR ON

ANY STRICT LIABILITY THEORY.

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