U3-02 Owner`s Manual - Kool Technologies Inc
Contents
1. aN A KEAN aaa 9 SECTION 4 MAINTENANCE INSTRUCTIONS U 11 43 OvertunAdj stiment uu uu 11 4 2 Preventative Maintenance EE 11 SECTION 5 TROUBLESHOOTING csi enn anna wann here 13 SECTION 6 REPLACEMENT PARTS INFORMATION U 15 6 1 Howto Order Replacement Parts uD nee 15 6 2 Parts List and Reference Drawings eee eee aaa U U U uu u 15 LIST OF ILLUSTRATIONS Figure Description Page 1 US Pula owo EA E A 1 2 ME Iranister LINE es EA 3 A PUMP Hose auta ee 4 B PICKUP o 4 PICKUP HOSE 4 3 Mix Pump rene an 5 D 4 way Tee Connection uurs2440nnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 4 Pump Motor L ua A nte evening legendas ee 7 5 Mix Pump Operation nent 8 6 SEN ANKAS EEA EEES EEA ES REEKS 8 7 Overrun AdJUSUTI nU curia 11 8 Reposition Mix Pump 12 9 Pump Roller Assembly 12 10 Pump and Decal Assembly a U U aaa nennen nnns 15 Exploded Parts Illustrations2. een 17 21 Wi g DIA entm 23 SECTION 1 INTRODUCTION 1 1 DESCRIPTION The Model Remote Mix Pump is specially designed for use with Stoelting remote pressurized freezers Used with large capacity mix containers located in your bulk storage cooler the U3 Pump keeps mix handling to a minimum Stoelting s Model U3 Remote Mix Pump performs three important functions with precision and reliability First it transfers a continuous supply of mix from your remote storage containerto the freezing cylinder of your freezer quickly conveniently Second the U3 Pump precisely injects a preset amount of air into the mix maintaining overrunto assure maximum profitability Third it pressur izes the freezing cylinder forcing frozen product through the spigot at the rapid dispense rates needed by high volume locations 1 2 SPECIFICATIONS WEIGHT 24 Ibs 10 89 kg DIMENSIONS Width 9 3 4 24 8 cm Height 8 1 2 21 6 cm Depth 10 1 8 25 7 cm ELECTRICAL 1 phase 120 volts Approximately 1 6 total running amps Cord and plug attached WARRANTY One year parts UL C UL Approved NSF Approved a SESS gt SEI SSSS T VNUMGGIRRR SI h h y Figure 1 U3 Pump 4 SECTION 2 INSTALLATION INSTRUCTIONS 2 1 SHIPMENT AND TRANSIT The mix pump has been completely assembled operated and inspected at the factory Upon arrival at the final destination the mix pump must be checked
3. STOELTING iX A Polar Ware Company U3 02 Mix Pump Owner s Service Manual Manual No 513557 Our Technicians are factory trained and are certified in the Stoelting Technicare program CALL A Distributor Phone No Model No Serial No Purchase Date Start Up Date INTRODUCTION U3 02 MIX PUMP OWNER S SERVICE MANUAL This manual provides basic information about the mix pump and its components Instructions and suggestions are given covering its basic operation and care The illustrations and specifications are notbinding in detail We reserve the rightto make changes atany time without notice to mix pump or components without incurring any obligation to equip same on mix pump built prior to date of change DONOTATTEMPT tooperate the mix pump until instructions and safety precautions in the manual are read completely and thoroughly understood The mix pump should be operated only by qualified personnel If problems develop or questions arise in connection with the installation operation or servicing ofthe mix pump contact your local distributor or the company at the following location STOELTING LLC Ph 920 894 2293 502 HWY 67 KIEL WISCONSIN 53042 1600 Fax 920 894 7029 A Few Words About Safety Safety Information Read and understand the entire manual before operating or maintaining Stoelting equipment This Owner s Manual provides the operator with information for the safe operation and mainte
4. Each number multiplied by 10 represents the overrun percentage ie 4 40 overrun OVERRUN ADJUSTMENT Figure 7 Overrun Adjustment F Tighten the allen screw then place the wrench back in its clip Replace the electrical box cover and Screws plug the mix pump into its grounded 115V receptacle and turn the mix pump power switch to the ON position 4 2 PREVENTATIVE MAINTENANCE To assure trouble free operation and consistent over run when using the U3 mix pump we must follow mix hose repositioning and replacement procedures The following isthe preventative maintenance schedule A MIX PUMP HOSE REPOSITION every one or two weeks NOTE 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 Run cleaning solution through pump ND Turn pump off and if connected to freezer 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 inches of tubing has reversed fed through the pump then turn the pump off 4 Loosen small clamp at the pick up hose adapter and disconnect mix pump hose al Cut 7 1 2 inches off the end of the mix pump hose The height of the pump can be used to measure See Figure 8 Pressures for Stoelting Freezers Cut out 24 3
5. PSIG For Duke Freezers Cut out 30 3 PSIG COVER CLAMP gt MIX PILLOW CUT LINE MEASUREMENT ES PICKUP SIDE DISCHARGE SIDE 4 WAY TEE Figure 8 Reposition Mix Pump Hose 6 Reconnect mix pump hose to adapter 7 Turn pump on 8 Gently pull on the discharge hose to help remaining 6 of mix pump hose to feed thru pump until hose adapter prevents further feeding 9 Turn pump OFF and pump will be ready for normal operation NOTE Each hose is long enough for 3 repositions before replacementis required Record each event on Hose Service Record decal B MIX PUMP HOSE REPLACEMENT NOTE 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 Run cleaning solution through pump 2 Turn pump off and if connected to freezer relieve any pressure by opening the spigot WARNING THE MIX PUMP SWITCH MUST BE IN THE OFF POSITION WHEN SERVICING OR CLEANING PUMP CAUTION NEVER DISCONNECT HOSES FROM FREEZER OR PUMP WITHOUT FIRST OPENING SPIGOT TO RE LIEVE PRESSURE 3 Disconnect mix pump hose at each end 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 5 Turn pump roller assembly so o
6. for any damage that may have occurred during transit The mix pump should arrive in satisfactory condition THE CARRIER IS RESPONSIBLE FOR ALL DAMAGE IN TRANSIT WHETHER VISIBLE OR CONCEALED Do not pay the freight bill until you have checked the equipment Havethe carrier note any visible damage onthe freight bill If concealed damage and or shortage is found later advise the carrier inspector within 10 days and request inspec tion The customer must place claim for damages and or shortages in shipment with the carrier Stoelting Inc cannot make any claims against the carrier 2 2 NATIONAL SANITATION FOUNDATION COMPLIANCE REQUIREMENTS In orderto comply with NSF International NSF code 6 A This unit remote pump must be installed with a NSF listed refrigerated mix transfer line The mix transfer line must be pitched to cooler with no sags or low points to allow complete drainage Fig 2 B The product at the mix pump and in transfer lines must be maintained below 41 F 5 C COOLER WALL gt 2 3 INSTALLATION A Follow the steps below to install the mix pump in an upright position on the wall using optional pump mounting kit Allow clearance for a mix container under pump See Figure 2 1 Mount by locating four 4 hole centers on cooler wall using mounting bracket as template CAUTION KNOW THE COOLER S WALL DESIGN BEFORE DRILLING TO PREVENT PERSONAL INJURY OR PROPERTY DAMAGE 2 Drill four 4 1
7. with an internal overload that will kick out when the motor is over loaded Consult the trouble shooting section for cor rective information The internal overload will auto matically reset after cooling If the condition contin ues contact a qualified service person 3 3 OPERATION OF U3 MIX PUMP Figure 4 Pump Motor Switch This section describes the operation of the U3 mix pump NOTE Mix pump hose must be repositioned every 1 2 weeks Failure to comply will result in reduced mix pump liquid capacity dispense stoppage pop ping and possible mix pump hose leakage Ref to Note from Section 4 2 A Refer to freezer owners manual for the operation of the freezer Mix Operation The peristaltic mix pump contains one continuous mix pump hose When looking at the face of the peristaltic mix pump the left side of this 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 Fig 5 Air Operation The air compressor operates concur rently with the peristaltic mix pump Air enters thru an internal check valve on the piston downstroke The air is discharged thru a second internal check valve and an external check valve on the piston upstroke The air and mix join at the tee and then travel to the freezer ROLLER MIX PILLOW RS gt R KK x COVER CLAMP X XC XX RR 220202
8. 2 inch diameter holes into cooler wall 3 4 inch deep See Figure 3 3 Insert well nut to flange and apply silicone sealant around outside diameter of flange and cooler wall 4 Repeat steps 2 amp 3 for other located hole centers 5 Mount bracket to cooler wall with supplied wing screws Hand tighten until secure 6 Thread plastic standoffs small parts bag onto all three pump mounting studs located under the pump until bottomed 7 Mount pump to bracket with wing nuts Pump will be held above the bracket by the standoffs lt 20 FT MAXIMUM 10 FT LIFT re MAXIMUM PUMP CHECK VALVE REFRIGERATION UNIT FOR MIX LINE MIX c CONTAINER N Z FREEZER K D H Figure 2 Mix Transfer Line 3 B Mix Pump Hose Installation Follow the steps below to install the mix pump hose 1 Turn pump on 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 See Figure A PICKUP xf Figure B 7 Turn pump on 8 Gently pull on the discharge hose to help remaining 6 of mix pump hose to feed thru pump until hose adapter prevents furtherfeeding 9 Turn pump off See Figure C MIX PUMP HOSE Figure A 4 Allow the hose to feed it
9. 20210 AS REQ LUBRICANT NEVER SEEZE 61 M870229 AS REQ GREASE MULTIPURPOSE 62 M840073 AS REQ MOTOR OIL 10W 63 M820172 AS REQ ADHESIVE LOCTITE 242 31 64 M820097 ADHESIVE LOCTITE 609 US SERVICE KIT INSTRUCTIONS RETAINER j a N AIR FILTER x N lt if 8 NOTE TO REMOVE CHECK VALVE PUSI d OUT FROM BOTTOM OF VALVE HEAD wz j gt CLEAN WITH WARM SOAPY WATER amp REASSEMBLE EL e S U lt A H AUS ALLEN HEAD 7 RETAINER gt Q SCREWS 5 32 9 NC A ECCENTRIC gt bo A MOTOR POSITION SHOWN FOR U3 REMOTE ONLY ROCKER ARM A WASHER PLASTIC CRANK ARM 7 64 ALLEN WRENCH NEEDED 21 U3 02 MAIN PUMP REMOVAL U431 MAIN PUMP REMOVAL 1 TURN TOGGLE SWITCH TO OFF 1 TURN CLEAN ON OFF amp PUMP SWITCH TO OFF POSITIONS 2 UNPLUG POWER CORD FROM POWER SOURCE 2 DISCONNECT FREEZER FROM POWER SOURCE BOTH 3 VENT OR RELIEVE PRESSURE IN HOSES OR FREEZER BEFORE SIDES REMOVING HOSES 3 VENT OR RELIEVE PRESSURE IN HOSES OR FREEZER 4 REMOVE 2 SCREWS SECURING SHEET METAL ENCLOSURE BEFORE REMOVING HOSES 5 REMOVE AIR COMPRESSOR HOSE LOCATED ABOVE ON OFF 4 FROM INSIDE LOWER CAB REMOVE TAN HOSE FROM PUMP SWITCH HOUSING THEN REMOVE 4 THUMB SCREWS TO ALLOW FOR 6 REMOVE TAN HOSE FROM PUMP HOUSING THEN REMOVE 4 REMOVAL OF PUMP HOUSING THUMB SCREWS TO ALLOW FOR REMOVAL OF PU
10. 5 OD 1 4 20 Air Filter Main Pump Assembly Decal NSF 69 E a 4323334 01 COOLER WALL aS INSULATION SILICONE SEALANT MOUNTING BRACKET N WING SCREW FLANGE WELL NUT OPTIONAL MOUNTING KIT SEE SERVICE REFERENCE PAGE 19 ITEM SIDELTING PN QTY IESCRIPTION 6246 65 1 ING 1 1 BX1 3 1843 32 70DUR E lis 1 PRESSURE CONTROL MANIFOLD 3 1111815 1 CKING PLATE WASHE 4 3539405 2 UI wI 77 32 AL392 30 41595 CD VER CLAMP 6 3 586 1 FITTING UNION 1 4 x1 2 BARBED 633042 4 SCRE HUMB 10 24 X 17174 SS 1177816776017 AIR MIX 4 WAY S6204 40 UBING 25 ID MIX PUMP 10 1151965 VALVE BODY INN
11. 6 RER RARA SE S KX X RX RK INLET SIDE 4WAY TEE RR 2220 EEE 90990909050 SOS 29 02096 6 2 XX e eS te A ER 208 0660600 LOE fo Figure 5 Mix Pump Operation D Overpressure Relief Excess pressure isrelieved 3 5 DISASSEMBLY AND INSPECTION OF backwards through the peristaltic mix pump and out REMOVABLE PARTS the pickup side of the mix pump hose This will occur only if the pressure switch fails to shut off the pump Inspection of removable parts should be made whenever motor maintenance is performed or pump requires disassembly 3 4 CLEANING WARNING The mix pump must be cleaned when changing mix or THE MIX PUMP SWITCH MUST BE IN THE OFF whenever the freezer is shut off for an extended period POSITION WHEN SERVICING OR DISASSEM such as overnight or on nonbusiness days For sanitary BLING PUMP reasons mix must not be allowed to remain in the freezer lines or mix pump when the freezer is not in operation CAUTION NEVER DISCONNECT HOSES FROM FREEZER OR PUMP WITHOUT FIRST OPENING SPIGOT NOTE TO RELIEVE PRESSURE To clean the freezer refer to the freezer owner s manual for complete cleaning procedures 1 Place the CLEAN OFF ON switch in the clean positi
12. ARM amp PAD 4 77680 VALVE HEAD ASSY 5 71859 O RING 6 71860 VALVE SPRING 7 71861 NEEDLE VALVE 8 71862 SCREW 8 32 X 1 2 9 171863 VALVE GUIDE 0 71864 O RING 1 71866 5 SCREW 10 32 X 1 1 4 2 71867 O RING 3 71868 REED VALVE 4 71958 AIR FILTER 5 71870 CYLINDER SLEEVE 6 7187 PISTON SPRING 7 71872 SPRING SEAT 8 71873 PISTON 9 71874 BALL BEARING 20 652412 SCREW SHOULDER 3 8 X 3 4 S STL 21 71994 SLEEVE BEARING 22 71977 ROLLER 23 71978 SCREW 1 4 28 X 3 4 24 71979 CRANK ARM 25 71980 PULLEY LARGE ALUMINUM 26 71981 ECCENTRIC 27 71982 OB 28 71983 DIAL 29 71984 POINTER 30 71985 DOWEL PIN 3 8 X 2 5LG 31 71986 2 FLANGE BEARING 32 71987 WICK 33 2177812 3177813 REMOVABLE ROLLER ASSEMBLY 34 71988 COLLAR 35 71989 PULLEY SMALL ALUMINUM 36 71990 BELT 37 71991 2 BALL BEARING 38 674151 SHAFT ROLLER CARRIER 39 522229 5 OTOR 115 230 60 1 40 71999 4 LOCK WASHER 10 41 3171952 COVER CLAMP 42 667896 BUMPER SEAL 3 246063 PUMP BODY CASTING 44 653042 4 SCREW THUMB 10 24NC 45 71955 SET SCREW 10 32 46 77036 WASHER 1 4 47 77037 SCREW 4 40 X 1 00 48 77034 AIR FILTER RETAINER TOP 49 77035 AIR FILTER RETAINER BOTTOM 50 77033 BUMPER RING 51 71959 O RING 52 71956 WASHER NYLON 53 766430 WASHER ROUND 54 732307 TERMINAL QUICK CONNECT FEMALE 55 732112 TERMINAL QUICK CONNECT MALE 56 650146 2 SCREW SSS 8 32 X 3 16 CUP PT 57 732133 WHITE CRIMP TERMINAL 58 1177767 DECAL ROLLER HOUSING 59 1177915 SPACER 60 M8
13. ENING OVERRUN ECCENTRIC TO REDUCE SPRING TENSION YOU MUST SQUEEZE PISTON SPRING TO ALLOW RETAINER TO LIFT OFF OF PISTON SHAFT 6 REMOVE PISTON amp CYLINDER BY LIFTING UP amp OUT OF HOUSING DO NOT LOSE BALL BEARING 7 REVERSE TO ASSEMBLE NEW PARTS amp ADJUST OVERUN SCALE TO PRIOR SETTING FAS amp PISTON SPRING SPRING SEAT E DCI 22 ULTIMA PUMP WIRING DIAGRAM PRESSURE CONTROL ON OFF SWITCH OPTIONAL REMOTE SWITCH CAPACITOR a CUSTOMER PROVIDED SWITCH 115 VOLT 60HZ CAUTION QSTOATNE NEW STRAIN RELIEF KIEL WISCONSIN U S A 53042 CALL FACTORY DISCONNECT POWER SUPPLY BEFORE ELECTRICAL WIRING DIAGRAM MODEL NO U3 02 SERVICING DIAGRAM NO 1995611 23 STOELTING SK A Polar Ware Company 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 Warrantie
14. ER 11 264054 6 CLA 16 ACETAL ra 36088 04 UBI 80 ID 13 73606710 C UBI cn 14 756088 120 1 UBI 530 ID 264055 4 CLAMP P 11716 ACETAL 16 762296 1 VALVE DUTLET CHECK 17 324639 HOSE SERVICE DECAI LS 11 2864 1 VALVE BODY DUTER 19 694247 SPRING CUMP 13 16x3 8x3 4 EU SEAN UMP UN DECAI 266041 CLIP HUS Le 762236 1 CHECK VALV 2a 4607 Bg RING 11 16x778 24 56088 04 TUBING 50 ID CO 696130 CK CLIP FUR VALVE 26 264064 E CLAMP LUUP 1 2 ACETAL CAMIS INSTRUCTION TAG CAUTION 28 739040 CABLE TIE s RAY THESE 4 10 32 SCREWS TO BE TORQUED TO 31 IN LBS SEE VIEW A BELOW l VIEW A LINE UP 6 ON DIAL OPPOSITE SETSCREW ON ECCENTRIC NOTE FOR PROPER ROTATION PURPLE MUST BE CONNECTED TO YELLOW amp PURPLE MUST BE CONNECTED TO YELLOW CONNECT BLUE WITH BLACK CONNECT ORANGE WITH RED 19 ITEM STOELTING PN QTY DESCRIPTION 1 644065 SCREW 1 4 20 X 3 4 S STL 2 538306 4 NUT 10 32UNF 3 77681 ROCKER
15. MP HOUSING 5 REMOVE SIDE amp REAR PANELS amp DISCONNECT ELECTRICAL 7 CLIP WIRE TIES TO ALLOW WIRES TO BE DISCONNECTED WIRING 8 REMOVE 3 HEX BOLTS FROM BOTTOM OF PUMP ENCLOSURE 6 REMOVE AIR COMPRESSOR HOSE 9 REMOVE MAIN PUMP ASSEMBLY NOTE POSITION OF 7 REMOVE 3 HEX NUTS SECURING MAIN PUMP ASSEMBLY TO STAINLESS GUARD FOR REINSTALLATION LATER LOWER CAB WALL 10 PROCEED TO REPAIR 8 PROCEED TO REPAIR ROLLER CARRIER REPLACEMENT 1 REMOVE 4 THUMB SCREWS SECURING PUMP HOUSING 2 TURN ROLLER ASSEMBLY CLOCKWISE LEFT HAND THREAD TO REMOVE AND REPLACE WITH NEW ASSEMBLY TURNING COUNTER CLOCKWISE TO TIGHTEN 3 REPLACE PUMP HOUSING AND TIGHTEN THUMB SCREWS NOTE IF ROLLER CARRIER HAS A DECAL STATING LEFT HAND THREAD WITH 3 NUTS ON THE BACK SIDE REPLACE WITH KIT NUMBER 2177812 ROLLER ASSEMBLY ONLY IF NUTS AND DECAL ARE NOT PRESENT REPLACE WITH KIT NUMBER 3177813 ROLLERS AND SHAFT FIGURE 1 CHECK VALVE VALVE HEAD amp SPRING Qe REED VALVE AIR COMPRESSOR KIT 1 DIRT amp DEBRIS WILL RUIN A NEW AIR COMPRESSOR USE EXTREME CARE TO KEEP EVERY TOOL PART amp HANDS CLEAN REMOVE AIR FILTER amp RETAINER NOTE POSITION OF WASHER UNDER RETAINER REMOVE VALVE HEAD 4 ALLEN HEAD SCREWS REMOVE REED VALVE amp O RING NOTE POSITION OF REED VALVE SEE FIGURE 1 REMOVE PISTON SPRING BY LOOS
16. d 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 4 2 for hose replacement Lubricate squeeze roller bearings see Item 10 below 9 PUMP HAS POOR CAPACITY Lift and run limits are exceeded Pump is limited to 10 lift 20 run NOTE Also see 2 4 6 amp 7 10 PUMP IS NOISY SQUEAKING NOTE THE ACTION OF THE AIR COMPRESSOR ROCKING ARM CREATES A REPETITIVE CLICKING SOUND DURING OPERATION THIS IS NORMAL NOTE THE PERISTALTIC MIX PUMP HAS THREE SQUEEZE ROLLERS WHICH USE SELF LUBRICATING BEARINGS IF SQUEAKING EXISTS WITH THE MIX PUMP HOSE IN PLACE AND STOPS WITH THE HOSE REMOVED THE SQUEEZE ROLLER BEARINGS CAN BE LUBRICATED USING A SILICONE BASED SPRAY REMOVE THE MIX PUMP HOSE DISCONNECT PUMP FROM ELECTRICAL POWER REMOVE FOUR COVER CLAMP THUMBSCREWS REMOVE ENTIRE COVER CLAMP AS ONE UNIT SPRAY SILICONE BASED LUBRICANT ON EACH END OF EACH SQUEEZE ROLLER SPIN ROLLERS TO WORK LUBRICANT INTO BEARINGS REPEAT AS NEEDED ARE NOT BEARING FRIENDLY AND WILL ACCELERATE BEARING WEAR SECTION 6 REPLACEMENT PARTS INFORMATION 6 1 HOW TO ORDER REPLACEMENT PARTS C Part number part name and quantity needed Many To assure the receipt of the proper replacement parts part names and numbers are listed in this manual s
17. ementlabels are needed indicate the partnumber type of label location of label and quantity required Mail your name and address to STOELTING LLC ATTENTION Customer Service 502 Hwy 67 Kiel Wisconsin 53042 Labels will be furnished and mailed at no charge SAFE OPERATION IS NO ACCIDENT Observe these rules A Know the U3 pump read and understand the Owner s Manual B Wear proper clothing avoid loose fitting garments and remove watches rings or jewelry which could cause a serious accident C Maintain a clean work area avoid tripping or slipping by cleaning up the area and keeping it clean D 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 E Turn all switches to OFF prior to making any adjust ments F Do not attempt to repair or perform maintenance on the mix pump until the main electrical power has been disconnected G Do not operate the mix pump if unusual or excessive noise or vibration occurs 3 2 PUMP MOTOR SWITCH The PUMP MOTOR switch Fig 4 is located on the mix pump assembly When the pump motor switch is placed inthe 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 pump motor switch is placed in the OFF position the mix pump will be inoperative NOTE The mix pump motor is equipped
18. freezeris off foran extended period of time such as overnight or nonbusiness days The mix lines are sufficiently cleaned and sanitized when cleaning and sanitizing the pump and freezer as an assembly Once every 2 weeks if required perform the following steps A Mix 2 gallons 7 5 liters of milkstone remove solution according to the directions on the container and pump through the mix line B Cut a piece of sponge slightly larger than the inside diameter of the mix line Place the sponge inside the mix line and force through with tap water pressure A garden hose repair end clamped to the mix line works well for this purpose SECTION 4 MAINTENANCE INSTRUCTIONS 4 1 OVER RUN ADJUSTMENT The product when served is a combination of air and mix Over runisameasure ofthe amount of air blended into the mix Over run 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 and a pint of frozen product with air added weighs 12 ounces the over runis saidto be 50 percent 18 oz 12 oz 6 oz 6 12 x 100 50 The over run can be checked by placing a one pint container on an ice cream scale and zeroing out the scale 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 of product should we
19. igh 12 to 13 ounces The mix pump has been preset atthe factory to produce a product with approximately 4096 overrun Because of differences in mixformulation temperatures and baromet ric pressure this figure may vary It will be necessary for approximately 2 gallons of mix to be pumped thru the freezer before changes in the product are noticeable due to adjustments in overrun 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 and unplug the mix pump from its grounded 115V recep tacle B Remove the 2 electrical box cover screws and remove the electrical box cover 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 Fig 7 D The overrun setting is indicated by a pointed pin E To adjust overrun loosen the allenhead screw located within the center of the adjustment knob with the 5 32 allen wrench provided Rotate the adjustment knob counterclockwise to a higher number for higher overrun or clockwise to a lower number for lower overrun
20. ings and drive belts All such parts are sold ASIS 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 SHALLBE THE SOLE LIABILITY STOELTING AND THE EXCLUSIVE REMEDY OF BUYER WITH RESPECT TO EQUIPMENT SUPPLIED BY STOELTING AND IN NO EVENT SHALLSTOELTING BE LIABLE FORANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER FOR BREACH OF WARRANTY OR OTHER CON TRACTBREACH NEGLIGENCE OR OTHER TORT OR ONANY STRICT LIABILITY THEORY
21. nance 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 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 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 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 Signal Word Signal words are distinctive words used throughout this manual that alert the reader to the existence and relative degree of a hazard A 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 The signal word CAUTION indicates a potentially hazardous situation which if not av
22. ne roller is at 6 00 Cover Clamp Discharge Side Figure 9 Pump Roller Assembly 6 Use a brush that fits in the opening and brush up and down first with detergent water and then clear water 7 Connect mix pump hose to pick up hose adapter using small clamp 8 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 mix pump hose comes out the discharge side Then gently pull on the discharge hose to help remaining mix pump hose feed thru pump until hose adapter prevents further feeding then turn pump off NOTE Remove cover clamp from pump on a monthly basis to clean and check for wear Cover clamp amp roller bearings Clean parts with soap and water and re assemble 9 Reconnect mix pump hose to T using small clamp Pump is now reagy to sanitize SECTION 5 TROUBLESHOOTING 1 PUMP MOTOR DOES NOT RUN Power to pump is off Supply power to pump Low voltage Check for low 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 4 2 for hose replacement Do not use jammed portion of hose All
23. oided 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 TABLE OF CONTENTS SECTION 1 INTRODUCTION 2 556 iii 1 Ded DO CNPUO LM 1 1 2 Specifieations au rer ae dat 1 SECTION 2 INSTALLATION INSTRUCTIONS U 3 P Snipmentand O an 3 2 2 National Sanitation Foundation Compliance Requirements a 3 PEE ct u use Sasa abis ae ai 3 2 44 Mix Pump Check QUE zas aaa aia 5 SECTION 3 OPERATION INSTRUCTIONS 24uuu442002020000000000nnnnnnnnnnnnnnnnnnnnnannnnnannnnnnnnnnnnnnannnnnnannnnnnnnnnnnnnnnnn 7 371 Satety Precautions MEER 7 3 21 PUMP Motor a aaa CY Rp OE Tana OE a usasqa p ea 7 3 0 Operation MIX PUMP Rc ED 7 3 4 8 3 5 Disassembly and Inspection of Removable Parts uuu u u nennen nnne nnns nennen 8 3 6 Sanitizing and AUD ii ai AE aku aa Ru basa 9 37 Cleaning MIX LINES
24. on and agitate 5 10 minutes maximum 2 Remove suction tube from mix container Draw off the mix remaining in freezer barrel 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 warm detergent solution water thru freezer The use of soft water is recom mended along with dishwashing detergents such as Joy Dawn or equivalent 5 Place mix pump switch in OFF position Open spigot to relieve remaining pressure Figure 6 Removing Parts 6 Place the CLEAN OFF ON switch in the OFF posi tion NOTE If the mix lines or air lines are difficult to remove soften with a rag soaked in hot water Hose con nections may be sprayed with Haynes Sanitary Lu bricant for ease of removal Do not loosen or re move the mix pump cover wingnuts Maintain the mix pump hose in its operational condition 1 Loosen clamp and remove air hose 2 Remove the two wing nuts from the pressure control manifold and pull outto remove 3 Loosen clamp and disconnect mix pump hose Remove the pickup hose check valve and pickup hose adapter and bag adapter if applicable as an assembly from mix container 4 Completely disassemble both hose assemblies and check valve Place hoses pressure control manifold and o ring tee check valve and pickup hose adapter in mild detergent water and wash thoroughly Use soft bristle brushes to clean inside of fitting
25. ow internal thermal overload to reset determine overload cause and repair Pressure switch on pump is defective Check mechanical operation and continuity of pressure switch Defective motor capacitor Check motor amperage draw and or capacitor Replace motor or capacitor Defective toggle switch Check continuity repair or replace 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 PNTS TO REDUCE SYSTEM PRESSURE TO ZERO TURN PUMP ON PURGE REMANING AIR IN MIX BAG AND PICK UP HOSE Pump motor overloaded IMPORTANT Before connecting the pick up hose to the mix bag purge the mix bag of air to the extent possible Out of Mix Mix pump hose kinked inside black cover clamp Replenish mix supply Follow mix pump hose jammed repair See 1 above Hoses assembled incorrectly Refer to diagram for correct hose connections Mix pump hose service life is exceeded Reposition replace mix pump hose See Sec 4 2 Mix pump hose not connected to freezer Connect mix pump hose to freezer Ice crystals in mix Completely thaw mix prior to use Assure bag is clear of pick up tube Clear blockage Use fresh mix ol m gt x 2155 pa eigo 2 gt e
26. properly sanitizing and cleaning a pump and soft serve freezer We therefore include a sample with each new freezer For further infor mation read the directions on the packet Other products may be as effective CAUTION PROLONGED CONTACT OF SANITIZER WITH FREEZER MAY CAUSE CORROSION OF STAINLESS STEEL PARTS In general sanitizing may be conducted as follows 1 Prepare two gallons 7 5 liters of sanitizing solution following manufacturer s instruction and place pump suction inlet line into solution 2 Place mix pump switch in ON position 3 Checkfor leaks when freezer barrel is first pressur ized with sanitizing solution 4 Place freezer CLEAN OFF ON switch in CLEAN mode no refrigeration 5 After five minutes in CLEAN mode open spigot and pump the remaining sanitizing solution thru the freezer close spigot and switch the freezer and pump to OFF 6 Place pickup tube into mix bag or container of mix and start the pump 7 Open spigot allowing incoming mix to push remain ing sanitizer out of hoses and freezing cylinder Close spigot as soon as pure mix begins to come out after about one pint 8 Pushin the air bleed valve located on the front door Challenger Series and allow the mix to come within 1 2 of the air bleed valve then close the valve 9 Place freezer in the on or freezing position 3 7 CLEANING MIX LINES The mix lines must be cleaned and sanitized whenever changing mix or wheneverthe
27. remove any foreign materials that may be present A The over run adjustment is preset at the factory If an adjustment becomes necessary refer to Section 4 1 B Check for air leaks by placing the suction line into two gallons of cold water Place the freezer switch in the OFF position Close the spigot and freezer air vent Place mix pump switch in the ON position and allow the system pressure to build up and pump to shut OFF automatically Leave the pump on for ten minutes During this time do not open spigot or freezer air vent If pump does not automatically start again during this period the system is free of leaks If the pump does start there is a leak in the system Locate leak by applying a liquid detergent or bubble solution with a small brush to all tubing connections and o ring seals Correct as required SECTION 3 OPERATION INSTRUCTIONS 3 1 SAFETY PRECAUTIONS Do not attempt to operate the U3 pump until the safety precautions and operating instructions in the manual are read completely andthoroughly understood Take notice of all warning labels on the U3 pump The labels have been put there to help in maintaining a safe working environment The labels are designedto withstand washing and cleaning All labels must remain legible for the life of the mix pump Warning labels should be checked periodically to be sure they have not been removed painted over rubbed off andcanbe recognized as warning labels Ifreplac
28. s THIS WARRANTY IS EXCLUSIVE AND STOELTING HEREBY DISCLAIMS ANY IMPLIED WAR RANTY 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 obliga tions 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 bush
29. s Rinse all parts in clean hot water 5 Carefully inspect each part for wear or damage Replace worn or damaged parts 6 Prepare two gallons 7 5 liters of sanitizing solution using a USDA certified grade sanitizing solution Sanitize all removed parts then air dry 7 Check Hose Service Record decal to determine if hose reposition or replacement is required at this time Sec 4 2 8 Reassemble both hose assemblies per the diagram Fig 6 Lubricate the pressure control manifold oring with sanitary lubricant before assembly Reconnect assemblies to the pump and discharge hose per the diagram using the clamps locking plate washer and wingnuts CAUTION DO NOT FORCE PARTS THEY FIT TOGETHER EASILY WHEN PROPERLY INSTALLED 3 6 SANITIZING AND STARTUP For sanitizing to be effective it must be performed after the mix pump and freezer parts have been cleaned and just prior to filling the freezer with mix Sanitizing the night before is noteffective Tosanitize refer to local sanitary regulations for applicable codes and recommended disinfecting products and proce dures The frequency of cleaning must comply with local health regulations Use a solution containing 100 PPM of free available chlorine Use Stera Sheen Green Label Sanitizer and Cleaner or others in accordance with Health Inspection Requirements 9 NOTE Stoelting Inc has found that STERA SHEEN GREEN LABEL SANITIZER AND CLEANER does an effective job of
30. self thru the pump until 6 remains on the entering side 5 Turn pump off HOSE 6 Connect mix pump hose to pickup hose adapter using small hose clamp See Figure B CAUTION DO NOT TWIST MIX PUMP HOSE Figure C COOLER WALL b INSULATION SILICONE SEALANT MOUNTING BRACKET N WING SCREW FLANGE WELL NUT OPTIONAL MOUNTING KIT Figure 3 Mix Pump Installation 10 Connect free end of mix pump hose to 4 way Tee as shown in Figure D When all connections are complete the 4 way Tee must be lower than the black pump housing Figure D C Connect 1 2 inch 1 27 cm I D plastic food grade tubing to the check valve and then to the mix con tainer Observe check valve flow arrow Secure with hose clamps D Connect 1 2 inch 1 27 cm ID plastic food grade tubing between the large port of air mix tee and refrigerated mix transfer line Secure with large hose clamp or equivalent CAUTION AIR MIX TEE MUST REMAIN BELOW THE BLACK COVER CLAMP IF THETEEIS ABOVE THE PUMP MIX WILL DRAIN TO THE AIR COMPRESSOR RESULTING IN PUMP DAMAGE E Plug mix pump into a 115 volt grounded receptacle WARNING TO MINIMIZE SHOCK HAZARD THE REMOTE MIX PUMP MUST BE PLUGGED INTO A PROPERLY GROUNDED ELECTRICAL RECEPTACLE WITHOUT THE USE OF AGROUND ADAPTER PLUG 2 4 MIX PUMP CHECK OUT Before using the U3 Mix Pump should be thoroughly cleaned This is necessary to
31. slo lt S 5 o 109 5 5 0 5 Oo 3 3 5 w o 5 Observe flow arrow for proper orientation OVERRUN TOO LOW OR NO OVERRUN Increase overrun setting Air leak Tighten all hose clamps gt lt 3 5 at n o gt 5 o 3 z 2 2 m Contact local Stoelting Distributor gt 2 m X X c z 4 Q I Mix pump hose service life is exceeded Reposition replace mix pump hose Out of mix Replenish mix supply Decrease overrun setting Pick up leg of mix pump hose is collapsing See Section 4 2 NOTE ALSO SEE 2 ABOVE lt c 2 n 2 a o o y Q 2 5 REPLACEMENT MIX PUMP HOSE WON T FEED THROUGH PUMP Feeding hose into discharge hole of mix pump cover Feed hose into pick up side of cover Hose ends not cut squarely 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 ltem 1 above AIR EXITING MIX PICK UP HOSE DISPENSED PRODUCT AIR POPS Recent mix out condition Open spigot fully and allow excess air to belch out NOTE ALSO SEE 2 amp 4 ABOVE 8 MIX LEAKAGE FROM PUMP CAUTION To prevent mix pump damage from dried mix deposits immediately disassemble an
32. upply your dealer distributor or the company with the NOTE following information Minimum Billing is 50 00 Net 6 2 PARTSLIST AND REFERENCE DRAWINGS The following lists and drawings will aid the user when ordering parts or servicing the mix pump A Model number of equipment B Serial number of Model Stamped on nameplate Figure 10 Pump and Decal Assembly Pump and Decal Assembly Parts List ITEM STOELTING P N 1 130000 2 266018 3 324105 4 430022 3 538296 6 644116 7 647512 8 539419 9 718532 10 778027 11 1995611 12 717917 SV 12 717919 SV 13 3170824 14 3171850 15 4177692 16 4177691 17 647667 18 766950 19 223162 20 766066 21 208467 22 324509 23 2171853 24 25 1171960 26 692225 27 1171958 28 4171953 29 324023 A dd 0 W 0 m U DESCRIPTION Bag Envelope Front Loading Clip Adhesive Backed J Decal Caution Elect Shock Harness Cord 6 50 Ft Nut Hex 10 24 x 3 8 SS Screw Cap 1 4 20 x 3 4 Hx Hd Screw Mach 8 32 x 3 8 Pan Hd Nut Wing 1 4 20 Switch Toggle 10 Amp 250V Wrench Allen 5 32 Wiring Diagram U3 Pump Switch Pressure Stoelting Switch Pressure Duke Mounting Bracket Splash Guard Pump Box Cover Pump Box Screw Mach 10 24 x 1 2 Rd Hd Washer Shakeproof 10 Bushing Strain Relief Washer Lock 1 4 20 Brush Not Shown Cleaning Decal Model ID Plate Capacitor Motor Start Spacer Nylon
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