U3-02a Owner`s Manual - Kool Technologies Inc
Contents
1. 1 TURN TOGGLE SWITCH TO OFF 2 UNPLUG POWER CORD FROM POWER SOURCE 3 VENT OR RELIEVE PRESSURE OSES OR FREEZER BEFORE REMOVING HOSES 4 REMOVE 2 SCREWS SECURING SHEET METAL ENCLOSURE 5 REMOVE AIR COMPRESSOR HOSE LOCATED ABOVE ON OFF SWITCH 6 REMOVE TAN HOSE FROM PUMP HOUSING THEN REM VE 4 THUMBSCREWS TO ALLOW FOR REMOVAL OF COVER CLAMP 7 CLIP WIRE TIES TO ALLOW WIRES TO BE DISCONNECTED 8 REMOVE 3 HEX BOLTS FROM BOTTOM OF PUMP ENCLOSURE 9 REMOVE MAIN PUMP ASSEMBLY NOTE POSITION OF STAINLESS STEEI GUARD FOR REINSTALLATION LATER 10 PROCEED TO REPAIR AIR COMPRESSOR KIT 8 CHECK VALVE 8 amp SPRING 4 5 FIGURE 1 REED VALVE HOLE Z gt 1 DIRT amp DEBRIS WILL RUIN EW AIR COMPRESSOR USE EXTREME CARE TO KEEP EVERY TOOL PART amp 2 RE FILTER amp RETAINER NOTE POSITION OF piston SER UNDER RE AINER I 3 REMOVE VALVE HEAD 4 ALLEN HEAD SCREWS A REMOVE REED amp O RING NOTE PO2. 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 120 F 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 6 Place the CLEAN OFF ON switch in the OFF posi tion 3 5 DISASSEMBLY AND INSPECTION OF REMOVABLE PARTS Inspection of removable parts should be made whenever maintenance is performed or pump requires disassembly Hazardous Moving Parts Revolving pump head can grab mangle and cause serious crushing injury The Power switch must be placed in the OFF position for cleaning and power must be disconnected when disassembling or servicing Figure 6 Removing Parts System Under Pressure Never disconnect hoses from freezer or pump without first opening spigot to relieve pressure NOTE Ifthe 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 d
3. STOELTING Polar Ware Company U3 02A Mix Pump Owner s Service Manual Manual No 513606 Rev 0 April 2004 INTRODUCTION U3 02A 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 not binding in detail We reserve the right to make changes at any time without notice to mix pump or components without incurring any obligation to equip same on mix pump built prior to date of change DO NOT ATTEMPT to operate 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 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 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 hig
4. 11 42 Preventative Maintenance EE 11 SECTION 5 TROUBLESHOOTING csi 13 SECTION 6 REPLACEMENT PARTS INFORMATION U 15 61 Howto Order Replacement Parts oit nee 15 6 2 Parts List and Reference 15 WARRANTY d 23 LIST OF ILLUSTRATIONS Figure Description Page 1 Terre 1 2 Mix MO 3 A MK PUMP OSC p O 4 B PICKUP OSG T 4 PICKUP HOSE 4 3 Mix Pump Installation 5 D 3 way Tee 5 4 Pump Motor dada 7 5 Mix Pump Operation nent 8 6 Removing 8 7 11 8 Reposition Mix Pump 12 9 Pump Roller 4 42222 12 10 Pump and Decal Assembly 15 Exploded Parts Illustrations 2 24 0 17 21 Winng DIA et 22 1 INTRODUCTION 1 1 DESCRIPTION The Model U3 02A Remote Mix Pump is specially de signed for use with Stoelting remote press
5. PUMPS COCKTAIL SLUSH Scope Stoelting LLC warrants to the first user the that the evaporator assembly and compressor if applicable of Stoelting mix transfer pump cocktail and slush equipment will be free from defects in mate rials and workmanship under normal use and proper maintenance appearing within five 5 years two 2 years for Mirage equipment 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 Disclaimer of Other Warranties THIS WARRANTY IS EXCLUSIVE AND STOELTING HEREBY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE 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 ninety 90 days 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 Warranty Registration Card for the affected equipm
6. 0 X 3 4 HX HD 8 5170824 MOUNTING BRACKET 9 559419 2 WING 1 4 20 SSTL 20 692225 5 SPACER NYLON 50DX3 8LG 1 4 20 21 647667 SCREW MACH 10 24 X 1 2 RD HD 22 430022 HARNESS CORD 6 50FT 22 225162 BUSHING STRAIN 7 8 HOLE Figure 10 Pump and Decal Assembly 15 SIUELTING PN QTY 264239 4 CLAMP HOSE 3 8 9 16 D 2 324130 F ECAI 3 756067 TUBING 25 ID 4 376041 FITTING 1 4 1 2 1 4 S STL BARBED 2 324659 HOSE SERVICE DECAI 6 266041 CLIP HOSE Fi 723393 INSTRUCTI TAG CAUTION 8 739040 9 756004 40 TUBING 25 ID MIX PUMP 0 S171252 C 11 653042 4 SCREW THUMB 10 24 X 1 1 4 SS 2 370867 FITTI UNI 1 4 BARBED 264241 Se 7 15 12 15 S TE E
7. 958 AIR FILTER 7 1171870 CYLINDER SLEEVE 8 1171871 PISTON SPRING 9 71872 SPRING SEAT 20 71873 PISTON 21 71874 BALL BEARING 22 652412 SCREW SHOULDER 3 8 X 3 4 S STL 25 71994 SLEEVE BEARING 24 71977 ROLLER 25 71978 SCREW 1 4 28 X 5 4 26 71979 CRANK ARM 27 71980 PULLEY LARGE ALUMINUM 28 71981 29 692226 SPACER ROLLER HOUSING 30 1171982 1 NOB 31 1171983 DIAL 32 1171984 POINTER 33 1171985 1 DOWEL PIN 3 8 X 2 5LG 34 1171986 2 FLANGE BEARING 35 1171987 1 WICK 56 1171988 1 COLLAR 57 1171989 1 PULLEY SMALL ALUMINUM 38 1171990 1 BEL 39 455010 5 HOUSING ROLLER 40 1171991 2 BALL BEARING 41 580048 1 PLATE ROLLER HOUSING CENTER 42 580047 1 PLATE ROLLER HOUSING END 43 538296 3 NUT HEX 10 24 X 3 8 SS 44 146023 6 BALLBEARING 250 BORE DBL SEALED 45 625392 6 RETAINING RING 250 EXT 46 674152 5 SHAFT ROLLER 47 674151 SHAFT ROLLER CARRIER 48 522229 MOTOR 115 230 60 1 49 766058 4 WASHER 10 50 3171952 COVER CLAMP 51 667896 BUMPER SEAL 52 246065 PUMP BODY CASTING 53 655042 4 SCREW THUMB 10 24 54 1171955 SET SCREW 10 32 55 1177036 WASHER 1 4 56 1177037 SCREW 4 40 1 00 57 1177034 AIR FILTER 58 1177035 1 AIR FILTER RETAINER BOTTOM 59 1177033 1 BUMPER RING 60 1171959 1 O RING 61 1171956 1 WASHER NYLON 62 M830011 AS REQ GREASE MULTIPURPOSE 65 840073 AS REQ MO
8. IPMENT SUPPLIED BY STOELTING AND IN NO EVENT SHALL STOELTING BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER FOR BREACH OF WARRANTY OR OTHER CONTRACT BREACH NEGLIGENCE OR OTHER TORT OR ON ANY STRICT LIABILITY THEORY 23 24
9. 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 Loosen small clamp at the pick up hose adapter and disconnect mix pump hose 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 PSIG For Duke Freezers Cut out 30 3 PSIG COVER CLAMP MIX PILLOW CUT LINE MEASUREMENT APPROX 7 1 2 ROLLER PICKUP o SIDE DISCHARGE SIDE _ amp H 3 WAY Figure 8 Reposition Mix Pump Hose 6 Reconnect mix pump hose to adapter 3 Disconnect mix pump hose at each end 7 Tum pump on 4 Grasp the discharge hose end with one hand and turn 8 Gently pull on the discharge hose to help remaining the pump on Pull down on the hose until all of the 6 of mix pump hose to feed thru pump until hose remaining hose is removed from the pump adapter prevents further feeding T I ller i 00 9 Turn pump OFF and pump will be ready for normal SOGNO Nene operation Roller NOTE Each hose is long enough for 3 repositions be fore replacement is required Record each event gt on Hose Service Record decal Inet M WEM Discharge B MIX PUMP HOSE REPLACEMENT NOTE Mix pump hose must be replaced when tubing cannot be further repositioned ev
10. SITION OF REED VALVE SEE FIGURE 1 5 REMOVE PISTON SPRING BY LOOSENING OVERRUN ECCENTRIC REDUCE SPRING TENSION T 6 REMOVE PISTON amp CYLINDER BY LIFTING UP amp OUT OF HOUSING DO NOT LOSE BALL BEARING REVERSE TO ASSEMBI EW PARTS amp DJUST OVERUN SCALE TO PRIOR SETTING SF PISTON SPRING SPRING SEAT 20 LAS SERVICE RETAINER 7 FILTER NOTE REMOVE VALVE PUSH OUT FROM BOTTOM OF VALVE HEAD CLEAN WITH WARM SOAPY WATER amp REASSEMBLE ALLEN HEAD RETAINER SCREWS 5 32 i e ON Sg OTOR POSITION SHOWN FOR U3 REMOTE ONLY ECCENTRIC Ki SR ww SS Ka ER p PUMP HOUSING E nm d lt 5 gt P s D E d ROCKER ARM 9 d WASHER PLASTIC CRANK ARM i 7 64 ALLEN WRENCH NEEDED 5 16 ALLEN 5 WRENCH NEEDED T 21 ULTIMA PUMP WIRING DIAGRAM PRESSURE CONTROL CAPACITOR CAUTION STCETING KIEL WISCONSIN U S A 53042 DISCONNECT POWER SUPPLY BEFORE ELECTRICAL WIRING DIAGRAM MODEL NO 03 02 SERVICING DIAGRAM NO 1995611 ON OFF SWITCH 22 OPTIONAL REMOTE SWITCH CUSTOMER PROVIDED SWITCH en 1 1PH N 115 VOLT G 60HZ NEW STRAIN RELIEF CALL FACTORY STOELTING U SK _A Polar Ware Company WARRANTY MIX TRANSFER
11. TOR OIL 10W 64 M820172 AS REQ ADHESIVE LOCTITE 242 31 65 766430 WASHER ROUND 66 752507 ERMINAL QUICK CONNECT FEMALE 67 732112 ERMINAL QUICK CONNECT MALE 68 650146 2 SCREW SSS 8 32 X 3 16 CUP PT 69 732155 WHITE CRIMP TERMINAL 70 1177767 DECAL ROLLER HOUSING 71 820097 ADHESIVE LOCTITE 609 72 1177915 73 M820210 AS REQ LUBRICANT NEVER SEEZE 74 376035 FITTING TEE BRASS 1 8 27 NPT 75 717928 SWITCH PRESSURE AIR 76 376034 FITTING 1 4 BARB 1 8 27 77 718922 SWITCH PRESSURE 78 576014 FITTING INLET 79 M200162 AS REQ ADHESIVE LOCTITE 380 BLACK 18 BARBED FITTING MUST IN HORIZONTAL POSITION WHEN TIGHTENED p NOTE FOR PROPER ROTATION PURPLE MUST SS ECTED TO YELL PURPLE MUST THESE 4 10 32 SCREWS 5 CONNECTED YELLOW TO T RQUED TO 31 IN LBS CONNECT BLUE WITH BLACK CONNECT ORANGE WITH RED SEE VIEW A LINE UP 6 ON DIAL OPPOSITE SETSCREW ON ECCENTRIC 19 U 5 02 MAIN PUMP MOVAL
12. be checked periodically to be sure they have not been removed painted over rubbed off and can be recog nized as warning labels If replacement labels are needed indicate the part num ber 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 02A 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 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
13. e 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 LLC cannot make any claims against the carrier 2 2 NATIONAL SANITATION FOUNDATION COMPLIANCE REQUIREMENTS In order to comply with NSF International NSF code 6 This unit remote pump must be installed with 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 Risk of Personal Injury property Damage Verify electrical and refrigeration line location inside and behind the cooler s walls defore drilling 2 Drill four 4 1 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 fo
14. efer to diagram for correct hose connections Reposition replace mix pump hose See Sec 4 2 Connect mix pump hose to freezer Completely thaw mix prior to use Mix bag drawn against adapter Assure bag is clear of pick up tube Foreign objects in mix Clear blockage Use fresh mix Observe flow arrow for proper orientation OVERRUN TOO LOW OR NO OVERRUN Increase overrun setting Air compressor not pumping air Contact local Stoelting Distributor Reposition replace mix pump hose Replenish mix supply Decrease overrun setting NOTE ALSO SEE 2 ABOVE 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 Gently and slowly assist feeding of hose up into pick up hose side of cover Turn on motor switch Also see Item 1 above Contact local Stoelting Distributor Reposition replace mix pump hose Reposition replace mix pump hose 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 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 fil
15. ent 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 Extensions The warranty period for deinstallation reinstallation of the affected component from into the equipment is extended to twelve 12 months on the following models 50218 50318 50328 The warranty period for the drive motor to be free of defects in materials and workmanship extended to five 5 years on the following models SO218 SO318 SO328 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 hoses seals and drive belts 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 STOELTING AND THE EXCLUSIVE REMEDY OF BUYER WITH RESPECT TO EQU
16. entially 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 INTRODUCTION uuu ect cet na Ce terae raa otra to nee Sean ann na Inneren asnaq 1 Ded e a E LM 1 1 2 SPOCIICAMONS uy u uuu usa u are nie en at 1 SECTION 2 INSTALLATION INSTRUCTIONS U uu u u u uu 3 244 an 3 2 2 National Sanitation Foundation Compliance 8 3 2 3 c uses 3 2 4 Mix Pump Check QUE ana ais 5 SECTION 3 OPERATION INSTRUCTIONS 7 31 Satety Precautions MEER 7 3 21 PUMP Motor Switch a A 7 3 3 Operation Mix PUMP pe Rm 7 8 3 5 Disassembly and Inspection of Removable 8 3 6 Sanitizing and AUD u 9 3 Cleaning MIX LINES da 10 SECTION 4 MAINTENANCE INSTRUCTIONS u u u u u 11 43
17. ery four to eight weeks Failure to comply will result in hose fail ure and possible pump damage Roller at 6 00 Orientation Cover Clamp Figure 9 Pump Roller Assembly 6 Use a brush that fits in the opening and brush up and 2 Turn pump off and if connected to freezer relieve down first with detergent water and then clear water any pressure by opening the spigot 1 Run cleaning solution through pump 7 Connect mix pump hose to pick up hose adapter using small clamp Hazardous Moving Parts Revolving pump head can grab mangle and cause 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 A CAUTION NOTE Remove cover clamp from pump on a monthly basis System Under Pressure to clean and check for wear Cover clamp amp roller Never disconnect hoses from freezer or pump with bearings Clean parts with soap and water and re out first opening spigot to relieve pressure assemble serious crushing injury The Power switch must be placed in the OFF position for cleaning and power must be disconnected when disassembling or servicing 9 Reconnect mix pump ho
18. hlight 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 ahazard 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 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 pot
19. ing the U3 02A Mix Pump should be thoroughly cleaned This is necessary to remove any foreign materials that may be present A The overrun 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 bleed valve 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 3 WAY TEE CONNECTION Figure D During this time do not open spigot or freezer air bleed valve 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 attemptto operate the U3 02A pump until the safety precautions and operating instructions in the manual are read completely and thoroughly understood Take notice of all warning labels on the U3 02A pump The labels have been put there to help in maintaining a safe working environment The labels are designed to with stand washing and cleaning All labels must remain legible for the life ofthe mix pump Warning labels should
20. isconnect 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 mild detergent water and wash thoroughly Use soft bristle brushes to clean inside of fittings Rinse all parts in clean 120 F water 4 Carefully inspect each part for wear or damage Replace worn or damaged parts 5 Prepare two gallons 7 5 liters of sanitizing solution using a USDA certified grade sanitizing solution Sanitize all removed parts then air dry 6 Check Hose Service Record decal to determine if hose reposition or replacement is required at this time Sec 4 2 7 Reassemble both hose assemblies per the diagram Fig 6 Reconnect assemblies to the pump and discharge hose per the diagram using the clamps CAUTION Risk of Product Damage Do not use excessive force when assembling parts Parts 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 To sanitize refer to local sanitary regulations for applicable codes andrecommended disinfecting products and proce dures The frequency of cleaning must comply
21. l 4 796088 54 UBI ID 2 1172864 1 VALVE BODY OUTE 6 694247 SPRI COMP 137 16x37 8x374 7 696130 LUCK CLIP FUR VALVE 8 665656 1 VALV UTLET CHECK MOLDED 9 1151969 VALVE BODY INNER 20 624607 RING 11 16x7 8 21 756088 04 TUBING ID TEE MUST INSTALLED IN THIS POSITION z LARGE END OF SPRING INTO VALVE O COOLER WALL B SILICONE SEALANT MOUNTING BRACKET WING SCREW d INSULATION FLANGE OPTIONAL MOUNTING KIT SEE SERVICE REFERENCE PAGE 19 WELL NUT STOELTING QTY DESCRIPTION 1 644065 1 SCREW 1 4 20 X 5 4 5511 2 538306 4 NUT 10 32UNF S STL 1177681 1 ROCKER ARM amp 4 002841 AS REQ TEFLON THD SEAL 5 432003 1 VALVE HEAD 6 1171859 1 O RING 7 1171860 1 VALVE SPRING 8 1171861 1 NEEDLE VALVE 9 1171862 SCREW 8 32 X 1 2 10 1171865 VALVE GUIDE 1 1171864 O RING 2 762246 VALVE CHECK 1 3 551 5 1171866 5 SCREW 10 32 X 1 1 4 14 1171867 O RING 5 1171868 REED VALVE 6 1171
22. led with hot water Thoroughly clean all mix from pump See Sec 4 2 for hose replacement Lubricate squeeze roller bearings see Item 10 below SECTION 6 REPLACEMENT PARTS INFORMATION 6 1 HOWTO 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 supply your dealer distributor or tne 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 ITEM STOELTING PN QTY DESCRIPTION 1 4177692 PUMP BOX COVER 2 150000 BAG ENVELOPE FRONT LOADING 5 1995611 WIRING DIAGRAM U3 PUMP 4 2171855 01 MODEL ID PLATE 5 647512 2 SCREW MACH 8 32 X 3 8 PAN HD 6 778027 WRENCH ALLEN 5 32 X 3 0 16 7 266018 CLIP ADHESIVE BACKED 7 8 524105 DECAL CAUTION ELECT SHOCK 9 324509 DECAL CLEANING SS amp SHAKE 0 766950 WASHER SHAKEPROOF 10 1 538296 NUT HEX 10 24 X 3 8 SS 2 524595 DECAL STOELTING SWIRL LOGO 5 3171850 SPLASH GUARDD 4 4183116 PUMP BOX 5 718532 SWITCH TOGGLE 10AMP 250V 6 766066 5 WASHER LOCK 1 4IN MED SS 7 644116 5 SCREW 1 4 2
23. linder Close spigot as soon as pure mix begins to come out after about one pint 8 Push in 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 whenever the freezer is off for an 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 OVERRUN ADJUSTMENT The product when served is combination of air and mix Overrun is a measure of the amountofair blended into the mix Overruncan be expressedinterms ofthe amount of weight loss for agiven 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 run is said to be 50
24. n output check valve and second check valve on the piston upstroke The air and mix join at the tee and then travel to the freezer ROLLER MIX PILLOW So SE 9 e S NS RS lt lt 255 SY RI amp 2 COVER CLAMP XXEXA 5569 lt RI ER 25 S x A lt gt lt lt RR RR lt lt A XX INLET SIDE 3 WAY TEE 2222 Hn SS SA 5555521 25555501 H 6 50 XX lt gt 2990050 552555 52525250 2555550 5 gt lt gt e Figure 5 Mix Pump Operation D Overpressure Relief Excess pressure is relieved backwards through the peristaltic mix pump and out the pickup side of the mix pump hose This will occur only if the pressure switch fails to shut off the pump motor 3 4 CLEANING The mix pump must be cleaned when changing mix or whenever the freezer is shut off for an extended period such as overnight or on nonbusiness days For sanitary reasons mix must not be allowed to remain in the freezer lines or mix pump when the freezer is not in operation NOTE 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 position and agitate 5 10 minutes maximum
25. ndicator plate numbered 3 thru 8 and an adjustment knob Fig 7 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 Each number multiplied by 10 represents the overrun percentage ie 84 40 overrun OVERRUN ADJUSTMENT Figure 7 Overrun Adjustment 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 overrun when using the U3 mix pump we must follow mix hose repositioning and replacement procedures The follow ing is the 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 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
26. off automati cally When the pump motor switch is placed in the OFF position the mix pump will be inoperative 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 Figure 4 Pump Motor Switch 3 3 OPERATION OF U3 MIX PUMP This section describes the operation of the U3 mix pump CAUTION Risk of Product Damage 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 Hose leak age may damage the pump roller assembly and void the factory warranty A Refer to freezer owners manual for the operation of the freezer B 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 C Air Operation The air compressor operates concur rently with the peristaltic mix pump Air enters thru an intake check valve on the piston downstroke The air is discharged thru a
27. percent 18 oz 12 oz 6 oz 6 12 x 100 50 The overrun can be checked by placing a one pint container onanice cream scale and zeroing out the scale Then fill a one pint container with frozen product The container shouldbefilled overthetop and leveled with a straightedge The product should not contain any air pockets When weighed on anice cream scale one pint of product should weigh 1210 13 ounces The mix pump has been preset at the factory to produce a product with approximately 4096 overrun Because of differences in mix formulation temperatures and baro metric 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 receptacle Remove the 2 electrical box cover screws and remove the electrical box cover 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 i
28. pump until hose adapter prevents further feeding Figure B 7 Turn pump on 9 Turn pump off See Figure C PICKUP HOSE Figure C Connect 1 2 inch 1 27 cm I D plastic food grade tubing to the mix check valve and then to the mix container Observe E INSULATION check valve flow arrow Secure with hose clamps SILICONE SEALANT D Connect 1 2 inch 1 27 cm ID plastic food grade tubing between the large port of air mix tee and MOUNTING BRACKET refrigerated mix transfer line Secure with large hose clamp or equivalent WING SCREW In CAUTION Risk of Product Damage Air mix Tee mustremain belowthe black Cover clamp OPTIONAL If the Tee is above the pump mix will drain to the air MOUNTING compressor resulting in pump damage KIT WELL NUT Figure 3 E Plug mix pump into a 115 volt grounded receptacle Mix Pump Installation 10 Connect free end of mix pump hose to 3 way Tee as shown in Figure D When all connections are WARNING Hazardous Voltage Remote mix pump must be plugged into a propely complete the 3 way Tee must be lower than the black pump housing grounded electrical receptacle Do not alter the plug or add a ground adapter plug Altering the plug to fit into an outlet of different configuration may cause fire risk of electrical shock product damage and will void the warranty 2 4 MIX PUMP CHECK OUT Before us
29. r 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 MAXIMUM PUMP CHECK VALVE REFRIGERATION UNIT FOR MIX LINE K MIX CONTAINER FREEZER D Figure 2 Mix Transfer Line 3 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 MIX PUMP HOSE Figure A 4 Allow the hose to feed itself thru the pump until 6 remains on the entering side 5 Turn pump off 6 Connect mix pump hose to pickup hose adapter using small hose clamp See Figure B CAUTION Risk of Product Damage Avoid twisting mix pump hose while feeding into cover Twisting the hose may cause the hose to rupture PICKUP HOSE 8 Gently on the discharge hose to help remaining 6 of mix pump hose to feedthru
30. se to Tee using small clamp 42 Pump is now ready to sanitize SECTION 5 TROUBLESHOOTING 1 PUMP MOTOR DOES NOT RUN Power to pump is off Supply power to pump 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 Pump motor overloaded Allow 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 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 Follow mix pump hose jammed repair See 1 above R
31. urized freezers Used with large capacity mix containers located in your bulk storage cooler the U3 02A Pumpkeeps mix handling to a minimum Stoelting s Model U3 02A Remote Mix Pump performs three important functions with precision and reliability First it transfers a continuous supply of mix from your remote storage container to the freezing cylinder of your freezer quickly and conveniently Second the U3 02A Pump precisely injects a preset amount of air into the mix maintaining overrunto assure maximum profitability Third itpressurizesthe freezing cylinder forcing frozen product through the spigot at the rapid dispense rates needed by high volume locations 1 2SPECIFICATIONS WEIGHT 24 Ibs 10 89 kg DIMENSIONS Width 9 3 4 24 8 Height 8 1 2 21 6 cm Depth 10 1 8 25 7 cm ELECTRICAL 1 phase 115 volts Approximately 1 6 total running amps Cord and plug attached WARRANTY One year parts UL C UL Approved NSF Approved Figure 1 U3 02A Pump 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 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 th
32. 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 NOTE Stoelting LLC has found that STERA SHEEN GREEN LABEL SANITIZER AND CLEANER does an effective job of 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 Risk of Product Damage Avoid prolonged contact of sanitizer with freezer Pro longed contact may cause corrosion of stainless steel parts and void factory warranty 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 Check for 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 cy
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