Alto Shaam 1360-DCH Installation Manual
#8907 • 4/2001
OPERATION and CARE MANUAL
®
COOK/HOLD/SERVE SYSTEMS
W164 N9221 Water Street ●P.O. Box 450 ●Menomonee Falls, Wisconsin 53052-0450 U.S.A.
PHONE: 262.251.3800 FAX: 262.251.7067 • 800.329.8744 U.S.A. ONLY WEBSITE:
800.558.8744 U.S.A./CANADA 262.251.1907 INTERNATIONAL www.alto-shaam.com
HOT FOOD DELIVERY CART
MODEL: 1360-DCH
Cart pictured with optional
motorized drive assembly
The Alto-Shaam Delivery Cart has
been thoroughly tested, checked for
calibration, and inspected to insure
only the highest quality cart is provided. When you receive your cart,
check for any possible shipping
damage and report it at once to the
delivering carrier.
See Transportation
Damage and Claims
section located in this manual.
If the Delivery Cart was not received from the carrier in an
upright position but appears to be undamaged, carefully restore
the unit to the correct position as soon as possible.
Remove uncrated unit from the skid with a lift-truck or roll it
off the skid by means of a temporary ramp provided in the crate.
CAUTION: If a lift-truck is used to remove the
Delivery Cart from the skid, caution should be
used to avoid damage to the drive motor assembly
located beneath the unit.
The cart is complete with accessories. Check to insure that all
the accessories ordered have been received with the unit.
Save all the information and instructions packed inside the
cart. Complete and return the warranty card to the factory as
soon as possible to insure prompt service in the event of a
warranty parts and labor claim.
NOTE: Any claims for warranty must include the full model
number and serial number of the cart.
1. Insure that the voltage stamped on the nameplate matches
the available power source. An identification tag is perma-
nently mounted on the cart.
2. This unit is provided with an electrical cord.
3. The electrical outlets used for the Delivery Cart must be
properly grounded in accordance with the National Electrical
Code and applicable local codes. For further details, please
refer to the appropriate electrical wiring diagram.
4. Before plugging the unit in or disconnecting from the power
source, make certain all thermostats are in "
OFF" position.
The unit power switches are located on the control panel.
Food quality and service are more important than ever in
today's institutional food service market. Alto-Shaam recognizes
this fact and developed the Delivery Cart using the highest quality stainless steel, insulating material, and the finest workmanship. This cart is a self-contained, complete hot meal delivery
system. It is simple in concept and is designed to adapt to a
completely new or to any existing institutional food service
method of preparation.
The heat source for the hot compartments consist of a resistance wire element. This thermal cable element is wrapped in
exact configurations against the walls of the heated compartments providing an evenly applied, highly controlled heat input.
The design and operational characteristics of the cart provide
even heat application and maintain the quality of hot foods for
longer periods of time.
Through the best arrangement of the controls, operation of
this appliance is simplified. The power switches will automatically energize all functions.
✓The Delivery Cart should be used for food preparation only.
✓For the best service, the unit should be level.
✓The Delivery Cart should not be operated in an enclosed area,
exposed to excessive heat, steam, water, or any other adverse
conditions.
✓Use caution to protect against the risk of electric shock when
operating in the presence of water or other liquids.
✓Always move the unit to the workplace BEFORE connecting
the power cord to the appropriate outlet.
✓Always disconnect from power source before servicing or
cleaning the unit.
✓If a motor drive is on the unit, always refer to the motor drive
instructions BEFORE moving the card.
Carts with the optional motor drive assembly contain rechargeable batteries that were fully charged prior to shipment. Failure
to properly store the unit and charge the batteries will cause battery failure, and the battery warranty will become null and void.
Be sure to store this cart in a cool and dry location. If the cart
will not be activated for service within 30 days of receipt, the
batteries must be charged by connecting the cord to electrical
power for storage duration.
When removed from active service, the unit can remain continuously connected to power to maintain full battery charge.
Be sure to turn the Drive System Power Switch OFF when not
in use.
ENSURE POWER SOURCE
MATCHES VOLTAGE STAMPED
ON UNIT NAMEPLATE
RECEIVING and UNPACKING
ELECTRICAL INSTALLATION
SYSTEM DESCRIPTION
Operation and Care Manual 1360-DCH • 1
IMPORTANT SAFEGUARDS
EXTENDED STORAGE &
BATTERY CHARGING
SERIAL NUMBER AND WARRANTY CODE
IDENTIFICATION MODEL NUMBER
MODEL
SERIAL NO. WATTS
VOLTS
MAXIMUM RATED VOLTAGE MAXIMUM RATED FREQUENCY
EXAMPLE
xxx-xx
xxxx-xx xxxx
AC
ALTO-SHAAM INC. MILW. WI. PAT. NO. 3521030
1 PH
MAXIMUM RATED
WATTAGE
xx
HZxxx
1. Clean cart thoroughly before using. Wipe exterior with a
clean, damp cloth. Clean interior, side racks, and trays with
a mild soap solution and sanitize. Clean the door gaskets
prior to use.
2. To install the side racks in the compartments, position the
keyhole openings in the tray side racks over the shoulder
bolts located on the sides of the interior oven compartments.
Push down to lock the tray side racks into position. Insert
drip spill pan directly on the bottom surface of each oven
compartment.
START-UP....
1.
Connect the electric cord to an appropriate electrical outlet.
If the optional retractable electric cord is on the unit,
pull and
release the retractable cord horizontally, not vertically or
slanted from its receptacle, gently guiding it back into its
receptacle.
2. Close the compartment vents located on the inside of each
compartment door. If the unit has the four door option,
ensure that the four (4) removable metal door strips are positioned properly on front and rear sides of the unit. Close the
doors.
3. Press the power switches ON for the appropriate right or left
compartments.
4. Preheat the empty compartments (without trays) at 200° F
(93°C) for approximately one hour.
5. Load the cart with hot food only. The purpose of the delivery
cart is to maintain hot food at proper serving temperature.
Only hot
food should be placed into the delivery cart.
Before
loading the cart with food, use a food thermometer to make
certain all products have reached an internal temperature
range of 140° to 160°F (60° to 71°C). Any food product not
within the proper temperature range should be heated before
loading it into the cart.
6. Load covered plates, bowls and service trays into appropriate
compartments. Plates, bowls and covers should be heat resistant. Load assembled trays into preheated cart as quickly as
possible to maintain maximum heat.
In the unit with four doors, the removable metal door strips
will have to be repositioned to accommodate the trays in the
center of the unit. Hang them vertically on their appropriate
screw attachment to keep them from being misplaced. These
metal door strips must be put back properly for the unit to
operate efficiently.
7. Securely close the doors of the cart after loading trays. When
loading or unloading individual heated compartments, the
doors to the other compartments should remain closed.
8. After the cart has been completely filled with product, check
to make certain the doors are securely closed, and reset the
thermostat to the desired setting. The thermostats are located
at the front center under a lift-up cover.
NOTE: The
digital temperature display buttons cannot be used to adjust
temperature. They are for factory use only.
9. The proper temperature range for the products being held
will depend on the type and quantity of product. When holding food for prolonged periods, it is advisable to periodically
check the internal temperature of each item with a food thermometer to assure maintenance of the proper temperature
range of 140° to 160°F (60° to 71°C).
DELIVERY....
1.
Transport the cart to the designated service area. Before
moving the cart, turn the right and left power switches
OFF.
Disconnect the electric cord from the outlet making sure that
the cord is returned properly back into its receptacle.
For
minimal wear to the optional retractacle cord, pull and release
the cord horizontally, not vertically or slanted
. Upon reaching
the service area, plug this cord into an appropriate outlet and
turn the power switches
ON. Foods will be automatically
maintained at proper serving temperatures throughout the
service period.
2. Unload covered plates or trays as needed for meal service.
When unloading one compartment of the cart, the doors to
the remaining compartments should remain closed in order
to retain maximum heat.
For the four-door option unit, the metal door strips will have
to be repositioned when removing the trays at the center of
the cart. Always remember to put these metal strips back
properly so that the unit will operate efficiently.
For best service all meals should be served in a timely
manner. Following meal service, press the right and left
power switches
OFF and return the electric cord
properly to its receptacle.
3. Transport cart to designated cleaning areas. Clean cart and
trays after each meal service. Follow care and cleaning guidelines located in this manual.
Operation and Care Manual 1360-DCH • 2
Use hand protection
when handling hot
compartment items
OPERATIONAL PROCEDURES
For proper sanitation, do not
put soiled trays back into the
cart until all meals are served.
Food flavor and aroma are usually so closely related that it
is difficult, if not impossible, to separate them. There is also an
important, inseparable relationship between cleanliness and food
flavor. Cleanliness, top operating efficiency, and appearance of
equipment contribute considerably to savory, appetizing foods.
Good equipment that is kept clean, works better and lasts longer.
Most food imparts its own particular aroma and many foods
also absorb existing odors. Unfortunately, during this absorption, there is no distinction between GOOD and BAD odors.
The majority of objectionable flavors and odors troubling food
service operations are caused by bacteria growth. Sourness, rancidity, mustiness, stale or other OFF flavors are usually the
result of germ activity.
The easiest way to insure full, natural food flavor is through
comprehensive cleanliness. This means good control of both visible soil (dirt) and invisible soil (germs). A thorough approach to
sanitation will provide essential cleanliness. It will assure an
attractive appearance of equipment, along with maximum efficiency and utility. More importantly, a good sanitation program
provides one of the key elements in the prevention of food-borne
illnesses.
A controlled holding environment for prepared foods is just
one of the important factors involved in the prevention of foodborne illnesses. Temperature monitoring and control during
receiving, storage, preparation, and the service of foods are of
equal importance.
The most accurate method of
measuring safe
temperatures of
both hot and
cold foods is by
internal product
temperature. A
quality thermometer is an
effective tool for
this purpose, and should be routinely used on all products that
require holding at a specific temperature.
A comprehensive sanitation program should focus on the
training of staff in basic sanitation procedures. This includes
personal hygiene, proper handling of raw foods, cooking to a
safe internal product temperature, and the routine monitoring of
internal temperatures from receiving through service.
Most food-borne illnesses can be prevented through proper
temperature control and a comprehensive program of sanitation.
Both these factors are important to build quality service as the
foundation of customer satisfaction. Safe food-handling practices to prevent food-borne illness is of critical importance to the
health and safety of your customers. HACCP, an acronym for
Hazard Analysis (at) Critical Control Points, is a quality control
program of operating procedures to assure food integrity, quality, and safety. Taking steps necessary to augment food safety
practices are both cost effective and relatively simple. While
HACCP guidelines go far beyond the scope of this manual,
additional information is available by contacting the
USDA/FDA Food-borne Illness Education Information Center at
(301) 504-6803.
Chefs, cooks and other specialized food service personnel
employ varied methods of cooking. Proper holding temperatures for a specific food product must be based on the moisture
content of the product, product density, volume, and proper
serving temperatures. Safe holding temperatures must also be
correlated with palatability in determining the length of holding
time for a specific product.
Halo Heat maintains the maximum amount of product
moisture content without the addition of water, water vapor, or
steam. Maintaining maximum natural product moisture preserves the natural flavor of the product and provides a more genuine taste. In addition to product moisture retention, the gentle
properties of Halo Heat maintain a consistent temperature
throughout the cabinet without the necessity of a heat distribution fan, thereby preventing further moisture loss due to evaporation or dehydration.
In an enclosed holding environment, too much moisture
content is a condition which can be relieved. A product achieving extremely high temperatures in preparation must be allowed
to decrease in temperature before being placed in a controlled
holding atmosphere. If the product is not allowed to decrease
in temperature, excessive condensation will form increasing
the moisture content on the outside of the product. Most Halo
Heat Holding Equipment is provided with a thermostat control
between 60° and 200°F (16° to 93°C). If the unit is equipped with
vents, close the vents for moist holding and open the vents for
crisp holding.
If the unit is equipped with a thermostat, use a metalstemmed indicating thermometer to measure the internal
temperature of the product(s) being held. Adjust the thermostat
setting to achieve the best overall setting based on internal
product temperature.
HOLDING TEMPERATURE RANGE
MEAT FAHRENHEIT CELSIUS
BEEF ROAST — Rare 140°F60°C
BEEF ROAST — Med/Well Done 1 60 °F71°C
BEEF BRISKET 160°— 175°F71°— 79°C
CORN BEEF 160°— 175°F71°— 79°C
PASTRAMI 160°— 175°F71°— 79°C
PRIME RIB — Rare 140°F60°C
STEAKS — Broiled/Fried 140°— 160°F60°— 71°C
RIBS — Beef or Pork 160°F71°C
VEAL 160°— 175°F71°— 79°C
HAM 160°— 175°F71°— 79°C
PORK 160°— 175°F71°— 79°C
LAMB 160°— 175° F71°— 79°C
POULTRY
CHICKEN — Fried/Baked 160°— 175°F71°— 79°C
DUCK 160°— 175°F71°— 79°C
TURKEY 160°— 175°F71°— 79°C
GENERAL 160°— 175°F71°— 79°C
FISH/SEAFOOD
FISH — Baked/Fried 160°— 175°F71°— 79°C
LOBSTER 160°— 175° F71°— 79°C
l SHRIMP — Fried 160°— 175°F 71°— 79° C
BAKED GOODS
BREADS/ROLLS 120°— 140°F49°— 60°C
MISCELLANEOUS
CASSEROLES 160°— 175°F71°— 79°C
DOUGH — Proofing 80°— 100°F27°— 38°C
EGGS —Fried 150°— 160°F66°— 71°C
FROZEN ENTREES 160°— 175°F71°— 79°C
HORS D'OEUVRES 160°— 180°F71°— 82°C
PASTA 160°— 180°F71°— 82°C
PIZZA 160°— 180°F71°— 82°C
POTATOES 180°F82°C
PLATED MEALS 180°F82°C
SAUCES 140°— 200°F60°— 93°C
SOUP 140°— 200° F60°— 93° C
VEGETABLES 160°— 175°F71°— 79° C
THE HOLDING TEMPERATURES LISTED ARE SUGGESTED GUIDELINES ONLY.
Operation and Care Manual 1360-DCH • 3
GENERAL HOLDING GUIDELINESSANITATION GUIDELINES
INTERNAL FOOD PRODUCT TEMPERATURES
HOT FOODS
DANGER ZONE 40° TO 140°F(4° TO 60°C)
CRITICAL ZONE70° TO 120°F(21° TO 49° C)
SAFE ZONE 140° TO 165°F (60° TO 74°C)
COLD FOODS
DANGER ZONE ABOVE 40°F (ABOVE 4°C)
SAFE ZONE 36°F TO 40° F(2°C TO 4° C)
FROZEN FOODS
DANGER ZONE ABOVE 32°F (ABOVE 0°C)
CRITICAL ZONE0° TO 32°F(-18° TO 0° C)
SAFE ZONE 0 °F OR BELOW (-18°C OR BELOW)
The cleanliness and appearance of
this equipment will contribute considerably to operating efficiency and savory,
appetizing food. Good equipment that is
kept clean works better and lasts longer.
A comprehensive program of sanitation
will provide essential cleanliness. It will
assure an attractive appearance of the equipment, along with
maximum efficiency and utility. All these factors are important
to build quality service as the foundation of patient satisfaction.
1. Wipe and clean the power cord if necessary. Return properly
to its receptacle. Let unit cool.
2. Remove detachable items such as trays, side racks, metal door
strips, and lower drip trays. Wash these items in the dishwasher. Let dry.
3. Clean all interior compartments after each meal service. Any
spilled food should be removed with a clean, damp
cloth and any good alkaline or alkaline chlorinated
based commercial detergent or grease solvent at the
recommended strength. Use a plastic scouring pad or
oven cleaner for difficult areas. Avoid the use of
abrasive cleaning compounds, chloride based cleaners, or cleaners containing quaternary salts. Rinse
well to remove all residue and wipe dry.
4. All delivery cart door gaskets are removable.
To maintain a good door seal and to extend
the life of the gaskets, periodically wash the
gaskets with warm sudsy water. Always
rinse well to remove all soap or detergent
residue.
5. To help maintain the protective film coating on polished
stainless steel, clean the exterior of the cabinet with a
cleaner recommended for stainless steel surfaces. Spray
the cleaning agent on the cloth and wipe with the grain of the
stainless steel.
NOTE: Never use hydrochloric acid (muriatic acid) on
stainless steel.
6. In the event the delivery cart is out of operation for an extend-
ed period of time, thoroughly clean and sanitize the cart and
clean the door gaskets prior to use.
Always follow appropriate state and local health (hygiene) regulations regarding all applicable cleaning and sanitation requirements for equipment.
The doors on all compartments of the delivery cart have been
adjusted at the factory to provide a proper seal. Routine maintenance of the delivery cart should include a periodic examination
of the door gasket to make certain a good seal is maintained.
Proper adjustment can be tested by pulling a dollar bill through
the gasket seal and feeling a slight resistance.
Minor adjustment to the doors is made at the hinges in one
direction -- IN and OUT. There is no need to adjust the doors upand-down, or side-to-side.
For in-and-out adjustment, loosen the three (3) screws holding the plate to the door hinge. Move the door OUTWARD to
LOOSEN the gasket seal or INWARD to TIGHTEN the gasket
seal. The adjustment faces are grooved so that movement is fixed
when the screws are retightened. Adjust the hinges so that the
door face and the unit face are parallel, and the portion of the gasket at the hinge-side does not bind when the door closes.
Following adjustment, retest for proper seal as indicated above.
Tire pressure requires periodic checking. Add air as required to
maintain a pressure level not to exceed 60 pounds per square inch
( 4 bars).
CARE and CLEANING
Disconnect the food delivery cart from
the power source before cleaning.
DOOR ADJUSTMENT
Operation and Care Manual 1360-DCH • 4
At no time should the interior or
exterior of the cabinet be steam
cleaned, washed down or flooded
with water or liquid solution.
Use caution to prevent flooding
the electrical control panel and
motor areas. Severe damage or
electrical hazard could result,
voiding the warranty.
TIRE MAINTENANCE
1360-DCH • Rear View
Standard Model
Operation and Care Manual 1360-DCH • 5
MOTOR DRIVE CONTROL OPERATION
FAST/SLOW SPEED SWITCH (YELLOW)
ON/OFF POWER SWITCH
(
BLUE)
REVERSE DRIVE CONTROL BUTTONS
EMERGENCY STOP BUTTON
(
RED)
BATTERY CHARGE INDICATOR LIGHTS
FORWARD DRIVE CONTROL BUTTONS
MOTOR DRIVE CONTROL
A two-speed Motor Drive Control
is located at both ends of the cart to
propel the unit in both forward and
reverse. Slow speed is 0.9 mph (1.4
km/hr) and fast speed is 1.9 mph
(3.1 km/hr).
ON/OFF POWER SWITCH
The ON/OFF power switch (BLUE)
controls the Motor Drive Control
and is located at the top of the drive
control housing at one end of the
cart only. To engage the drive
control press the ON/OFF power
switch to the "ON" position. Allow
2 to 3 seconds for control to initialize before using Forward/Reverse
Control buttons.
FAST/SLOW SPEED SWITCH
The yellow FAST/SLOW speed
switch is located left of the
ON/OFF Power Switch. To engage
Fast Speed, depress the yellow
switch – the switch will illuminate.
For best results,
start in Slow Speed.
The cart will accelerate to speed
within 3 to 4 seconds. Once cart is
moving – engage Fast Speed. This
will minimize cart “surge”.
FORWARD DRIVE
CONTROL BUTTONS
The forward drive control buttons
are located toward the bottom of
the drive control housing. Pressing
either of these buttons will move
the cart forward or toward the
operator.
MOTION BEEPER
There is an audible signal whenever
the drive control is engaged in either
a forward or reverse motion.
IMPORTANT
FOR THE SAFEST METHOD
OF OPERATION, A CART
OPERATOR SHOULD
ALWAYS BE POSITIONED AT
THE FRONT OF THE CART IN
WHICHEVER DIRECTION THE
CART IS MOVING.
AS A SAFETY PRECAUTION DO NOT GUIDE CART FROM THE BACK.
GUIDE THE UNIT TO DESTINATION BY PULLING FROM EITHER END OF THE CART.
To keep drive batteries fully charged, the cart must remain connected to the power source
when not in service. Turn drive system power switch OFF when not in use.
REVERSE DRIVE
CONTROL BUTTONS
The reverse drive control buttons are
located toward the top of the drive control
housing. Pressing either of these buttons
will move the cart in reverse or away from
the operator.
EMERGENCY STOP BUTTON
When pushed, the red emergency stop
button completely disengages the motor
drive control and will immediately halt all
cart movement. To restore motor drive
function, turn and release the emergency
stop button in a clockwise direction.
BATTERY INDICATOR LIGHTS
When the motor drive control switch is in
the "ON" position, a battery light will illuminate indicating the condition of the battery
charge: RED, low; YELLOW, medium; or
GREEN, full. To recharge the battery when
indicating a medium or low charge, connect the cart to the power source until the
charge is restored (one hour minimum). If
battery charge is insufficient to maintain
the cart through the service period or while
en route, the motor drive assembly brake
must be released and the cart manually
moved to a power source. ( SEE SECTION TITLED
MOTOR DRIVE FOR DETAILED INSTRUCTIONS.)
EMERGENCY STOP
BATTERY
LOW FULL
®
Operation and Care Manual 1360-DCH • 6
CART FREEWHEELING and
DRIVE SAFETY FEATURES
To freewheel the cart manually, the Drive Power
Switch must be OFF – then the Drive Brake must be
placed in the OFF position. See Drive Brake Caution
below. Restore the Drive Brake to the ON position
upon freewheeling completion.
ALARM CONDITION No. 1
With the Drive Power Switch ON – and then the Drive
Brake turned OFF – the drive unit provides dynamic
braking (movement is possible, but difficult). If either
Forward/Reverse Drive Control Buttons are
depressed, the motion beeper will sound an alarm and
the Drive Motor will not operate. To clear the alarm
and restore operation, turn the Drive Brake ON.
ALARM CONDITION No. 2
If the Drive Power Switch and Drive Brake are both
OFF – then the Drive Power Switch is turned ON, the
motion beeper will sound an alarm and the drive
motor will not operate. To clear the alarm and restore
operation, turn the Drive Brake ON, then turn the
Drive Power Switch OFF and then ON again.
ALARM CONDITION No. 3
If either Forward or Reverse Drive Control Button is
depressed and the Drive Power Switch is turned ON,
the motion beeper will sound an alarm and the drive
motor will not operate - OR - if either Forward or
Reverse Drive Control Button is depressed immediately after the Drive Power Switch is turned on, the
motion beeper will sound an alarm and the drive
motor will not operate.
ALARM CONDITION No. 4
If the cart power cord is connected to power and then
the Drive Power Switch is turned ON, the motion
beeper will sound an alarm, the green “full” battery
indicator light will flash, and the drive motor will not
operate. To clear the alarm and restore operation, disconnect the cart power cord from the power supply;
turn the Drive Power Switch OFF for 5 seconds and
then turn it ON again.
ALARM CONDITION No. 5
If the Drive Power Switch is ON, and the cart power
cord is connected to power, the green “full” battery
indicator light will flash. If either Forward/Reverse
Drive Control Button(s) are depressed, the motion
beeper will sound an alarm and the drive motor will
not operate. To clear the alarm and restore operation,
disconnect the cart power from the power source; turn
the Drive Power Switch OFF for 5 seconds and then
turn it ON again.
MOTOR DRIVE BRAKE
IF DRIVE BATTERY LOSES
CHARGE IN TRANSIT,
DISENGAGE BRAKE
1. Move handle of brake clockwise to the OFF posi-
tion. Turn Drive System Power Switch
OFF.
2. Manually push the cart to an appropriate outlet
and connect power cord for a minimum of 30
minutes.
FOR A FULL CHARGE, CART MUST BE
CONNECTED TO THE POWER SOURCE FOR A MINIMUM
OF
1 HOUR.
3. Following recharge period, move brake handle
counter-clockwise to the
ON position.
To keep batteries fully charged, the cart must remain connected to the power source when not in service. Turn
Drive System Power Switch OFF when not in use.
BATTERY CHARGER
The battery charger is located on the Motor Drive
Assembly. The charger includes one bi-color indicator
light to show the charging state of the battery.
A. The yellow light indicates the charger is in opera-
tion but the motor drive battery has not yet
reached full charge.
B. A green light indicates the battery has reached full
charge. Charger can operate indefinitely without
harming the battery.
The motor drive brake must be engaged at all times unless it becomes necessary
to move the cart manually. After moving the cart manually, the wheels of the cart and the motor drive assembly
will respond to even a slight incline unless the brake is reset. Maintaining a "set" brake to keep the cart in a
stationary position is an important safety factor.
Drive Brake • Caution
OFF
ON
BRAKE HANDLE
DRIVE BRAKE
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