Carpigiani K3-E Installation Manual

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Combination shake/sundae dispenser K 3 – K3/E

Equipment Operating Manual

This manual is for the exclusive use of

licensees and employees of

McDonald’s Systems Inc

Manufactured by:

Carpigiani Group

Via Emilia, 45

Anzola dell'Emilia Bologna 40011

ITALY

Telephone: Fax:

Edition: 5 Edited: AM

Date: 10/2012 Checked:

SB/AO

Modification: 1.2.9 Approved;

First Printing March 2006 Printed in Italy Version 5: October 2012 Updates:

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Carpigiani K 3 User’s guide

Table of Contents

CONVENTIONAL SYMBOLS ..................................................................................................... 5

REMOVING MACHINE FROM PACKAGING ................. ....................................................... 6

WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) .................................. 7

TROUBLESHOOTING BACTERIA CONTAMINATION ...................................................... 7

1. INTRODUCTION ................................................................................................................... 9

1.1 GENERAL INFORMATION .................. .................................................. ....................... 9

1.1.1 MANUFACTURER'S IDENTIFICATION DATA .............................. ............................ 9

1.2 INFORMATION ABOUT THE MACHINE ........... ......................................................... 9

1.2.1 GENERAL DATA .......................................................................................................... 9

1.2.2 INTENDED USE ............ ............................................................................................... 9

1.2.3 NOISE ............................ ................................ ................................ ............................... 9

1.2.4 TECHNICAL FEATURES ... .. ..................................................................................... 10

1.2.5 MACHINE ASSEMBLY IDENTIFICATION ......... ................................ ... .................. 10

1.2.6 AUTOMATIC PASTEURISATION CYCLE ................................................................ 11

1.2.7  TEMPERATURE CONTROL ...................................................................................... 11

1.2.8 TANK LIDS HOLDER ................................................................... ... .......................... 11

1.2.9 MIXER (OPTIONAL) .................................................................................................. 12

2. INSTRUCTIONS FOR USE ................................................................................................ 13

2.1 CONTROLS ................................ .................. ...................... ..................... ..................... ..... 13

2.1.1 MILK SHAKE FUNCTIONS ..................... .................................................................. 14

2.1.2  SUNDAE FUNCTIONS .............................................................................................. 19

2.2  OPERATIONS ................................................................................................................ 24

2.2.1 DISPENSING MILK SHAKE ...................................................................................... 24

2.2.2 DISPENSING SUNDAE ............................................... .. ................................ ............. 24

2.3 PROGRAMMED CLEANING CYCLE ......................................................................... 24

2.4 POWER BLACK- OUT .................................................................................................. 25

3. DAILY CLOSING PROCEDURES .................................................................................... 26

3.1 SHAKE SIDE .................................................................................................................. 26

3.1.1 DISASSEMBLING AND CLEANING THE COMPONENTS: ....................................... 26

3.1.2 SANITIZING THE DOOR AREA: .................................................................................. 26

3.1.3 SYRUP LINE CLEANING / SANITIZING ........................................................ ... .......... 26

3.1.4 PREPARING THE MACHINE FOR THE OVERNIGHT HEAT TREATMENT CYCLE. 27



3.1.5 FRONT PANEL CLEANING ......................................................................................... 27 

3.2 SUNDAE SIDE ............................................................................................................... 28

3.2.1. SANITIZING THE DOOR AREA SURFACE: .................................................................. 28

3.2.2 TOPPING PUMPS CLEANING: .................................................................................. 28

3.2.3 PREPARING THE MACHINE FOR THE OVERNIGHT PASTEURISATION CYCLE. 28

3.2.4 FRONT PANEL CLEANING ......................................................................................... 28 

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Carpigiani K 3 User’s guide

 DAILY OPENING PROCEDURES............... ... ................................................................ .. 29

4.1  MILK SHAKE SIDE ....................................................................................................... 29

4.1.2 STARTING UP THE MACHINE: .. ... ................................ ... ................................ .. ..... 29

4.2  SUNDAE SIDE ............................................................................................................... 30

4.2.1 SANITIZING THE DOOR AREA: .................................................................................. 30

4.2.2 PREPARING HOT TOPPINGS: ................................................................................... 30

4.2.3 STARTING UP THE MACHINE: ................................................................................. 30

5. WEEKLY CLEANING ................................................. ....................................................... 31

5.1 WASHING AND SANITIZING OF THE TOPPING CONTAINERS ........................... 31

5.1.1 CLEANING OF THE TOPPING BINS: .................................................... ..................... 31

5.1.2 CLEANING OFTHE TOPPING HOPPER ..................................................... ............... 31

5.2 DISASSEMBLING, WASHING AND SANITIZING OF THE HOT TOPPING PUMPS 31



5.3 CHECK TOPPING PUMP TEMPERATURE AND VOLUME ...................................................... 33

6. EVERY 14 DAYS CLEANING ...... ................................ ... ................................ ... ............... 34

6.1 DISASSEMBLING AND CLEANING THE MILK SHAKE SIDE .................................... ............... 34

6.1.1 CLEANING THE SHAKE SYRUP SYSTEM .................................................................. 34

6.1.2 DRAINING AND CLEANING THE MILK SHAKE SIDE ........................... .. ............. 35

6.1.3 DISASSEMBLING OF THE SHAKE MIX PUMP ...................................................... 37

6.1.4 DISASSEMBLING OF THE SHAKE DISPENSING DOOR..... .................................. 38

6.1.5 DISASSEMBLING OF THE SHAKE CYLINDER’S BEATER ................................... 39

6.2 DISASSEMBLING AND CLEANING OF THE SUNDAE SIDE 40

6.2.1 DRAINING AND CLEANING OF THE SUNDAE SIDE ............................................ 40

6.2.2 DISASSEMBLING OF THE MIX PUMP................................................................. 42

6.2.3 DISASSEMBLING OF THE SUNDAE DISPENSING DOOR ................................... 43

6.2.4 DISASSEMBLING OF THE SUNDAE BEATER ........................................................ 43

6.3 WASHING AND SANITIZING OF COMPONENT PARTS ..................................... ...... ..... ..... ... .. 44

6.4 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS ................ 46

6.4.1 REASSEMBLY OF THE SHAKE CYLINDER BEATER ............................................. 46

6.4.2 REASSEMBLY OF THE SHAKE DISPENSING DOOR............................................. 47

6.4.3 REASSEMBLY OF THE SHAKE MIX PUMP ............................................................ 48

6.4.4 REASSEMBLY OF THE MIX HOPPER AGITATOR ............................................. 50

6.5 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS ..................... 50

6.5.1 REASSEMBLY OF THE SUNDAE BEATER .................................... ... ....................... 50

6.5.2 REASSEMBLY OF THE SUNDAE DISPENSING DOOR .......................................... 50

6.5.3 REASSEMBLING OF THE SUNDAE MIX PUMP ..................................................... 51

6.5.4 REASSEMBLING OF THE MIX TANK AGITATOR .................................................. 52

6.6 SANITIZING OF THE ENTIRE MACHINE ................................................................. 52

6.6.1 SANITIZE THE HOPPER ........................................................................................... 52

6.6.2 SANITIZE THE PUMP AND FREEZING CYLINDER .............................................. 52

6.6.3 DRAIN THE SANITIZER ............................................................................................ 52

6.7 SYRUP SANITIZING, PRIMING AND CALIBRATION (SHAKE SIDE) ...................... ..... 53

6.8 MIX PRIMING ............................. ................................................... ............................... 54

7. MONTHLY CLEANING ..................................................................................................... 55

7.1 CLEAN MESH FILTERS (ONLY FOR AIR COOLED VERSION) ............................................... 55

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 PREVENTATIVE MAINTENANCE ................................................................................. 56

8.1 CHECK OUT LIST ......................................................................................................... 56

8.2 PERIODICAL CHECK-UP AND MAINTENANCE ......................................................... 57

8.2.1 PERISTALTIC PUMP TUBE REPLACEMENT INSTRUCTION .................. .................................. 57

9. TROUBLESHOOTING ..................... ................................... ................................ ............... 59

9.1 ALARMS ........................................................................................................................ 59

FOLLOWING FIND THE ALARM LIST: ................ ............................................................... 59

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Carpigiani K 3 User’s guide

Conventional Symbols

ATTENTION ELECTRIC SHOCK DANGER

The staff involved is warned that the in observance of safety rules in carrying out the operation described may cause an electric shock.

ATTENTION GENERAL DANGER

The staff involved is warned that the operation described may do harm if not carried ou t in the observance of safety rules.

NOTE

It points out significant information for the staff involved.

WARNING

The staff involved is warned that the in observance of information may cause a loss of data and damages to the machine.

PROTECTIONS

This symbol placed by description side means that the operator must use personal protections against an implicit risk of accident.

SAFETY

When using industrial equipment and plants, one must be aware of the fact that drive mechanisms (rotary motion), high voltage of the components, as well as parts subject to high temperatures may cause serious damages to persons and things.

The person in charge for plant’s safety must be on the look-out that

- an uncorrect use or handling is av oid ed

- Safety devices must neither be removed nor tampered

- Only original spare parts are to be used especially as far as those components with safety fu nctions are concerned (ex.: protection microswitches, thermostats).

To achieve the above, the following is necessary:

- At working place an instruction manual relevant to the machine should be available.

- Such documentation must be carefully read and regulations must consequently be followed.

- Only adequately skilled personnel will have to be assigned to electrical equipment.

WARNING

The machine must be installed only by a specialized and authorized technician; when installing the machine, insert a differential magnetothermal protection switch on all poles of the line, adequately sized to the absorption power shown on machine data plate and with contact opening of 3 mm at least. This switch is used to cut off the power supply. Any replacement of the power cable must be carried out only by a specialized and authorized technician.

 Never put your hand into the machine, during production and cleaning opera tions. Before carrying

out any maintenance operation, make sure that the machine is in “STOP” position and main switch has been cut out.

 It is forbidden to wash the machine by means of a stream of water under pressure.  Disconnect electrical power before removing any side or rear panel.

 CARPIGIANI is not responsible for any accident that might happen during operation, cleaning

and/or servicing of its units, if this warning has not been fully complied with.

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Carpigiani K 3 User’s guide

Removing machine from packaging

1. Check the Shock-watch label which indicates whether the goods have been mishandled; inspect the cardboard shipping carton for signs of damage. (See fig.1)

2. Cut the metal straps (beware of snapping metal), lift the cardboard carton up and off of the pallet (see picture

2).

3. Remove bag and Styrofoam prote ction. Inspect the m achine ag ain for sig ns of shipping da mage or rough handling. If damage is visible, notify the r estaurant manager and/or the shipping company (see fig. 3).

Fig. 1 Fig. 2

Fig. 3

CAUTION

removal from the pallet must be carried out by two qualified persons in material handling and in the

observation of safety rules.

4. The machine is attached to the pallet by 4 bolts. The bolt heads are on the bottom side of the pallet and they tighten into threaded holes on the bottom of the machine. The two wooden shims, pl aced sideways under the machine, make it possible to keep the wheels ¼" of the surface of the pallet (see fig. 4).

5. Now loosen the packing bolts from the bottom side of the pallet, on one side only, and let them drop to the floor. It is not necessary to remove the side panels of the machine to do this (see fig. 4).

6. Slightly, incline the machine on one side and remove the wooden block. Please be careful. The wood blocks keep the machine castors off the pallet by ¼" their removal will cause the machine to drop that distance (see fig. 5).

7. Repeat the same procedure on the other side.

8. After the removal of the wooden blocks, the machine will directly rest with its wheels on the pallet.

9. In order to unload the machin e from the pallet, use the w ooden ramps, su pplied with the machine. Plac e the wooden ramps in position against the rear side of the machine and push the machine from FRONT SIDE moving it to the rear. Two persons, one in front and one in the rear, must handle and control the unit (see fig. 6).

Fig. 4 Fig. 5 Fig. 6

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Carpigiani K 3 User’s guide

WEEE (Waste Electrical and Electronic Equipment)

In accordance with European Directives 2006/66CE on batteries and accumulators and waste batteries and accumulators and with 2002/96/EC on WEEE (Waste Electrical and Electronic Equipment), the presence of the above symbol on the product or on its packaging indicates that this item must not be disposed of together with the other normal unsorte d municipal waste. Instead, it is the user’s responsibility to dispose of this product by returning it to a collection point designated for the recycling of electrical and electronic equipment waste. Separate collection of this waste helps to optimise the recovery and recycling of any reclaimable materials and also reduces the impact on human health and the environment. For more information concerning the correct disposal of this product, please contact your local authority or the retailer where this product was purchased.

Troubleshooting Bacteria Contamination

Product samples should be taken periodically by a qualified expert in order to asses the bacteria count in the product. The bacteria count in the samples should be below the figures given below:

Standard Plate Count (SPC)……………...50,000 Coliform …………………………………………10

Should the bacteria counts exceed the figures listed above then there is a source of bacterial contamination. The source of contamination must be identified and corrected. High bacteria counts are indicate that a product is not safe for consumption. You must inform the machine operator on how to prevent bacterial contamination of the product.

Note: Soft serve yogurt product. However, COLIFORM bacteria contamination is NOT ACCEPTABLE in any food product. The information given below will help prevent coliform bacteria contamination problems.

The following is a list of possible bacteria contamination sources together with methods of prevention.

will generally have high bacteria counts – this is normal and helps define the

SOURCE OF CONTAMINATION

1 - Operator contact.

2 - Mix residue/deposits (milkstone

build-up).

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PREVENTION

1a - Wash hands and forearms thoro ughly. 1b - Wear rubber gloves if cuts or skin conditions exist. 1c - Wash hands periodically throughout the day.

2a - Provide the proper brushes. 2b - Thoroughly brush clean all parts and components to

prevent the formation of milkstone, a porous substance which will house bacteria and contaminate fresh mix.

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Carpigiani K 3 User’s guide

SOURCE OF CONTAMINATION

3 - Worn or damaged parts.

4 - Incorrect cleaning and sanitation

procedures.

PREVENTION

3a - Lubricate all rubber parts contacting the mix with a food

grade lubricant.

3b - Inspect o-rings for damage. Only replace with factory

approved parts.

3c - Regularly check drip troughs for excessive leakage.

4a - Sink must be perfectly clean and contain enough solution

to cover the biggest component. Brush clean and sanitize the freezer on a regular basis .

4b - Use the correct brushes, lubricants, and single service

towels.

4c - Store and use chemicals as directed by the instructions on

their labels.

4d - Use a few good employees to follow the cleaning

procedure correctly and consistently. Allow the employee uninterrupted time to complete the cleaning procedure.

4e - Allow the sanitizing solution to stand in the hopper and

freezing cylinder for five minutes .

4f - Wash and sanitize the lubricant tube after each use.

Always replace the cap on the tube.

4g - Machine components and brushes should be air-dried

overnight. Never store them in the storage cooler.

4h - Always follow daily cleaning procedures. Regularly wipe

down the outside of the machine and dispensing spouts with a sanitized towel.

5 - Improperly stored mix

5a - Use mix stock with oldest date first. Observe expiration

dates.

5b - Place the mix directly in the cooler. Do not stack mix

outside or under direct sunlight before placing it in the cooler.

5c - Always leave one inch between the mix and other products

in the cooler to allow air to circulate.

5d - Mix must not remain at room temperature for long periods

of time.

5e - Hopper storage must maintain a temperature of 40°F

(4,4°C). Storage temperatures above 45°F will allow bacteria to multiply to dangerous levels in less than one hour.

5f - Once the mix is placed in the hopper, the ho pper covers

must be used to maintain the correct temperature and minimize mix contamination.

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Carpigiani K 3 User’s guide

1. Introduction

1.1 GENERAL INFORMATION

1.1.1 MANUFACTURER'S IDENTIFICATION DATA

The machine has a data plate carrying manufacturer data, machine type and serial number, assigned when it is manufactured.

LEGEND:

A= Serial number B= Machine type C= Voltage D= Fuss/Breaker size E= Gas type and weight F= Frequency

1.2 INFORMATION ABOUT THE MACHINE

1.2.1 GENERAL DATA

Electronic, self-heat-treatment, floor machine, for the production and immediate distribution of milkshake/ice cream having the following main features:

 Refrigerated upper tanks;  Cylinder feeding pumps (to control product overrun);  Automatic system to dispense the milkshake with a 4 flavours syrup selection;  Two containers for hot toppings, with pasteurisation temperature control;  Two containers for room temperature toppings;  Automatic pasteurisation system to heat-treatment the product inside the mix tank and inside the

cylinder during pause periods (for instance, during nig ht time);

 Electronic consistency control system hard-o-matic.

1.2.2 INTENDED USE

The K 3 machine must only be used for the production of ice cream and milkshake, within the fu nctional limits listed below:

 Voltage: ±10%  Min. ambient temperature: 50°F (10°C)  Max. ambient temperature: 109°F (43°C)  Max relative ambient humidity: 85%

This machine has been designed for its use in closed places not subject to explosion-proof standards; consequently, it shall be used in places complying with normal atmosphere..

1.2.3 NOISE

The continuous level of acoustic radiation pressure, which has been weighed and called A on working place, turns to be lower than 70 dB(A), both by air-cooled and water-cooled units.

B A

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Carpigiani K 3 User’s guide

1.2.4 TECHNICAL FEATURES

60 in

58 in

Hou rly Prod u ction * Hopper capacity Flavors Electrical supply

Model

K 3

K3/E

SUNDAE SHAKE

3,5 oz. / 100 gr

lb /kg

82 / 38 380 88 / 40 160

portions

lb / kg

1.2.5

MACHINE ASSEMBLY IDENTIFICATION

LEGEND:

1 Syrup tanks cabinet 2 Hopper cover 3 Hot toppings 4 Room temperature toppings 5 Dispensing head shake side 6 Dispensing head soft side

7 Air condenser

13,5 oz. / 400 ml

portions

SUNDAE

Gallons

Liters

5,25 gal

20 l

TTS

SUNDAE SHAKE Volt - V Phase Cycle - Hz kW Amps

Galons

Liters

5,25 gal

20 l

1 5

208 - 230 3 60 5,5 30

380 - 415 3 50 5,5 20

Installed

power

Full

load

Net

weight

lb / kg

871 / 395

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Carpigiani K 3 User’s guide

1.2.6 AUTOMATIC PASTEURISATION CYCLE

The machine has been pre-set in the factory to start automatically the pasteurisation cycle every night at 2 am. (the automatic pasteurisation time can be re-set at a different time by a trained technician.

1.2.7 TEMPERATURE CONTROL When the machine is set to STOP, the tank temperature is controlled: if it is higher or equal to 59°F (15°C),

the execution of the pasteurisation program is forced. So, by pressing the PROD. button, the pasteurisation program will automatically start.

NOTE:

After the machine’s brush cleaning, it is necessary to press the PROD. button within 60 minutes after the front lid closing. During this 60 minutes the test at 59°F (15°C) is masked and Production is accepted. After 60 minutes, the machine does not accept the PROD. button any more and it sets to pasteurisation function.

1.2.8 TANK LIDS HOLDER

When you need to refill the mix tank, lift the lid and turn it upside down. Insert the handle of the lid in the slot of the holder placed on the other lid. You need not to remove the holder.

LID HOLDER

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Carpigiani K 3 User’s guide

1.2.9 MIXER (OPTIONAL)

Operating procedure

1. Hold a cup under soft-serve dispensing nozzle.

2. Pull draw lever completely forward and fill up the cup.

3. Place a dome lid on top of the cup. Tip: Set the cup on a level surface.

6. Push the cup onto the blender mixing spoon, hold the cup with one hand and push the switch on with the other hand. Using one hand, blend the cup for 7 seconds. While blending, move the cup from side to side and up and down.

4. Hold the cup under the requested inclusion dispenser. Slide the mix-in dispenser’s handle, to dispense the product

5. Snap mixing spoon onto blender connector (be careful not to touch spoon)

7. Once blender stop rorating, hold the cup in one hand and release the mixing spoon from the blender with the other hand.

8. Serve the cup.

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Carpigiani K 3 User’s guide

2. INSTRUCTIONS FOR USE

2.1 CONTROLS

The K 3 is equipped with two front push-button panels, one for the controls related to the SHAKE side and one for the controls related to the SUNDAE side.

MILK SHAKE DISPENSING BUTTONS

WHITE BASE DISPENSING BUTTON (for SMOOTHY)

- OPEN PISTON TO EMPTY THE MACHINE (CLEANING)

LCD back lights flashing for

warni ng :

“read info on display”

Warning light for LOW

mix level (reserve)

MAIN FUNCTIONS:

- Stop

- Production

Pasteurisation Led

lights on from start Past. till Past. End “+” increase button for manager menu

Agitation Button/Lock button

Storage Led

lights on from Past. End “-” decrease button for manager menu Alarm and warning restore

IMPORTANT

Push-buttons are activated keeping the finger (not the nail) pressed on it for at least 1/2 second

(safety feature).

WARNING

TO REDUCE WEARING OF THE BEATER BLADE (POS. 430) USE AGITATION FUNCTION JUST FOR

THE TIME STRICTLY NECESSARY.

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Carpigiani K 3 User’s guide

2.1.1 MILK SHAKE FUNCTIONS

STOP BUTTON

By pressing this button during operation, the machine stops (LED on).

DISPLAY Comments

16:29:27 Tue

When the machine is in STOP, the display shows Time and Date.

PRODUCTION BUTTON

Preparatio n (startup) :

machine is freezing the product. For that time, dispensing is not allowed.

Production (LED is always on):

desired consistency by the Hard-o-Tronic system. If the machine has been in the production mode and then placed in Stop, the 15 minutes start up procedure will be automatically bypassed if the time in Stop does not exceed 60 minutes; otherwise the start up procedure will be repeated. By pressing this button when in STOP, the display indicates:

KEY

DISPLAY comments

Do Not Serve !

TEV +19°C W-14

Hopper  +14°C

Cylinder  +13°C

In this box the display shows in the first line (above):

Set=065 Hot=035 Lev=00000

Cones today

12345 Total Cones

0923456780 TEV+010 TGV-022

TEC+013 TE1-012

Pushing PROD again, we return to first display (1).

On pushing this button, its LED will blink for 15 minutes while the

The product is ready to be dispensed and it is kept at the

When the Milk Shake is not ready, the display shows: “DO NOT SERVE“

In this box the display shows the Hopper’s temperature in the first line (above) and the Cylinder’s temperature in the second one.

Set=065: the shake consistency to be reached Hot=035: the shake consistency actually detected in the cylinder Liv=00000 for technician

In this box the display shows the daily quantity of cones (starting from 0:00 until 23:59).

In this box the display shows the total quantity of cones

In this box the display shows various probes of the SHAKE part ( no °C nor °F are displayed).

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Carpigiani K 3 User’s guide

Machines equipped with “LONWORKS” device, Service Pin:

Activation of the service pin, proceed as follows:

1. Place one side of the machine in STOP

2. Press PROD

At the end of the procedure put the side in standard function (Production or Storage)

AGITATION BUTTON (CLEANING)

button for 10 seconds (a beep signal is activated)

By pressing this button from STOP, the led turns on and the display indicates:

KEY DISPLAY Comments

HOT=058 TEC+014 Beater + Pump ON

Pressing Production again we return to first display.

HOT=058 TEC+014 Pump ON

HOT=058 TEC+014 Beater ON

HOT=058 TEC+014 Beater + Heating

Pressing this button one time, the beater motor and the mix pump motor will turn ON. HOT (consistency) and TEC (cylinder’s temperature) are displayed in the first line.

Pressing this button for the second time we arrest the beater motor but the mix pump remains on.

Pressing this button for the third time we activate the beater motor and the mix pump motor stops.

Pressing this button for the fourth time we activate both the beater motor and the mix pump motor and the heating as well to help the product to melt.

LOCK BUTTON

To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows:

Keep the the keyboard is locked. At this point you can clean the keyb oard safely. To restart it, just keep the same key pressed for 3 seconds and the led will turn off.

button pressed for 3 seconds, the respective led will flash indicating that

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PASTEURISATION FUNCTION / INCREASE FUNCTION

The pasteurisation function can be activated only if the mix in the hopper is a bove the Medium Level (“ADD MIX” message on display must be off). AUTOMATIC PASTEURISATION CYCLE:

(pasteurisation LED on) and the mix is above the medium level, the heat-treatment cycle starts automatically at a certain time (as programmed in the Mana ger Menu normally at 2:00 AM). During the display indicates “HEAT-TREATMENT CYCLE” the mix in the hopper and in the cylinder is heated up to 65°C, k ept at 65°C for 30 minutes and finally cooled down to 2°C. At the end of the cycle, the display shows “PASTO END” followed by date and hour of termination. The machine passes automatically to STORAGE function. To serve shake, press STOP, then the PROD button, but only if the machine hasn’t passed automatically in PRODUCTION yet.

Note: Once the pasteurisation cycle has started, it can not be interrupted. The complete pasteurisation cycle will take less than 4 hours to be completed.

During the pasteurisation and Pause cycles, the mix in the machine is very hot. Do not attempt to recover the mix nor to disassemble the machine.

WARNING

Do not dispense sundae nor dismount the machine during the pasteurisation

because the product is very hot and under pressure.

while the machine is in production

STORAGE / DECREASE FUNCTION / RESET ALARM MESSAGES

The Storage Led lights ON as soon as the Pasteurisation cycle ends. The machine preserves the mix at +2°C (35°F) in the hoppe r and in the cylinder.

- this button is also used to decrease the value in the Manager menu

- this button is also used to RESET the ALARM MESSAGES on the display.

MIX LEVEL SIGNAL

In each hopper we have 2 level sensors: MEDIUM level and LOW level.

- When the MIX LEVEL LED flashes, it means that the mix level in the hopper is lower than the medium mix level sensor.

- When the MIX LEVEL LED is on, it means that the mix level in the hopper is lower than the minimum mix level sensor.

The display indicates ADD MIX or MIX OUT.

Maximum filling level indicator

Mix level sensor

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When the LCD back light is blinking, that means an alarm has tripped.

When it becomes still, the alarm which has previously tripped, has automatically reset and

the indication on the display must be reset by pressing RESET button

EVENTS

In order to read the events, the machine must be in STOP, so keep the pressed until ****READ EVENTS**** is displayed.

02:00:00 06 APR

The first event will appear on the display. Push or in order to scroll UP or DOWN the events list.

START PASTEUR

PUSH TO EXIT THE EVENTS READING AND GO TO STOP.

MILK SHAKE DISPENSING BUTTONS

Every “coloured cup” button corresponds to a milk shake flavour. In PRODUCTION, the product is disp e nsed ac co rd ing to the flavou r selected. If, while dispensing milk shake, you push any “coloured cup” button, the milk shake will immediately stop without reaching its automatic level; this function may be used to dispense small portions. (tasting function).

When in STOP, by pushing th e button pushing again it closes. When in STOP, the “coloured cup” button are used for calibration of syrup quantity.

the piston opens and remains opened; by

SYRUP QUANTITY CHECK AND SYRUP SYSTEM CLEANING

While the machine is in STOP:

- Push one time only the “coloured cup” button.

- Syrup will be dispensed for 5/7 seconds.

- Check the quantity of the syrup using the calibration cup.

- If the quantity of syrup is not satisfactory then modify the calibration as explained in

the manager menu.

- By pushing a second time while the syrup pump is ON, the pump will run at MAX speed in order to flush and clean the syrup tubes.

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MANAGER MENU

1) To access the Manager Menu press simultaneously both and keys, then release them immediately.

On the display you will read the first step of the Manager Menu:

The first row indicates the step number, and the second row indicates the description and value.

Time Step U01 10

2) Push

3) Push STOP to move to the next step.

4) To exit the Manager Menu push

The following table illustrates all steps of the Manager Menu:

 U01 -> 06 Time and date settings  U07 Language selection.  U08 Start Production time.  U09 Start Pasteurisation time.

or in order to increase or decrease the value.

button.

STEP N° (first row) U01 Hours 00 23 U02 Minutes 00 59

U03 Day of Week SUN SAT U04 Day of Month 01 31 U05 Month Jan Dec U06 Year 2000 2099 U07 Language ITA DEU

U08 Start Prod. Hour 00 U09 Start Past .Hour 00 23+no U10 Beeper Lev. Enabled No Yes+Man U11 Syrup 1 pump speed 010 240 U12 Syrup 2 pump speed 010 240 U13 Syrup 3 pump speed 010 240 U14 Syrup 4 pump speed 010 240

Display

(second row)

Min Max

23+no+auto

 U10 Disables/ enables the sound alarm when mix level is low..

U11 -> 14 Syrup pumps speed to calibrate the syrup quantity (1 oz fluid ounce in 5 or 7 sec)



THE MACHINE IS READY FOR START-UP ONLY AFTER IT HAS BEEN PERFECTLY

FOR HYGIENIC AND SAFETY REASONS, HANDS SHOULD

NEVER BE PLACED INSIDE THE MIX HOPPER WHILE THE MACHINE IS WORKING.

CLEANED AND SANITIZED.

Default

ENG

02 Yes 150 120 100 090

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2.1.2 SUNDAE FUNCTIONS

STOP BUTTON

By pressing this push-button during operation, the machine stops (LED on).

DISPLAY Comments

10:33:21 Fri

When the machine is in STOP, the display shows Time and Date.

PRODUCTION BUTTON

Press PROD button to start the production mode (LED on). The motor and compressor are automatically controlled by HARD-O-TRONIC system.

By pressing this button from STOP, the display indicates:

KEY DISPLAY comments

Do Not Serve!

TEV +19°C W -14

Sundae Ready!

TEV +19°C W -14

Do Not Serve!

Beater HT Sensor Hopper  +14°C

Cylinder  +13°C

In this box the display shows in the first line (above):

Set=100 Hot=085

Cones today

12345

Total Cones

0923456780

TEV+010 TGV-022

TEC+013 TE1-012

Topping +057

Set Topping +055

Pushing PROD again, we return to the initial display.

When the sundae is not ready , the display shows: “DO NOT SERVE“

When the sundae has re ached the desired consistency the display shows “SUNDAE READY”.

In case of ALARM, this will be displayed in the second row

In this box the display shows the Hopper’s temperature in the first line (above) and the Cylinder’s temperature in the second one.

Set=100: set HOT SOFT HOT=085: the consistency actually detected in the soft cylinder.

In this box the display shows the daily quantity of cones (starting from 0:00 until 23:59).

In this box the display shows the total quantity of cones.

In this box the display shows various probes of the SHAKE part ( no °C nor °F are displayed).

In this box the display shows the Topping probe ( no °C nor °F are displayed), with the respective temperature sets.

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Machines equipped with “LONWORKS” device, Service Pin:

Activation of the service pin, proceed as follows:

1. Place one side of the machine in STOP

2. Press PROD

button for 10 seconds (a beep signal is activated)

At the end of the procedure put the side in standard function (Production or Storage)

TOPPING HEATER

In PROD. function the two hot topping containers are heated automatically to reach the desired temperature. In case the water level in the bain-marie is too low the display will indicate an alarm in order to refill it with water.

AGITATION BUTTON (CLEANING)

By pressing this button from STOP, the led turns on. The beater and the mix pump motor get ON until you press STOP or after 3 minutes. The display indicates:

KEY

DISPLAY comments

HOT=058 TEC+014 Beater + Pump ON

Pressin

this button one tim e , the beater motor and the

mix pump motor will turn ON. HOT (consistency) and TEC (cylinder’s temperature) are displayed in the first line.

HOT=058 TEC+014 Pump ON

HOT=058 TEC+014 Beater ON

HOT=058 TEC+014 Beater + Heating

Pressin

beater motor but the mix pump remains on.

Pressin

beater motor and the mix pump motor stops. Pressing this button for the fourth time we activa te both

the beater motor and the mix pump motor and the hea tin g

this button for the second time we arrest the

this button for t he th i r d tim e w e activate the

as well to help the product to melt.

Pressing Cleaning again we return to the initial display.

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dicato

LOCK BUTTON

To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows:

Keep the the keyboard is locked. At this point you can clean the keyboard safely. To restart it, just keep the same key pressed for 3 seconds and the led will turn off.

button pressed for 3 seconds, the respective led will flash indicating that

PASTEURISATION FUNCTION / INCREASE FUNCTION

The pasteurisation function can be activated only if the mix in the hopper is a bove the Medium Level (“ADD MIX” message on display must be off). AUTOMATIC PASTERUSATION CYCLE:

(PASTEURISATION LED on) and the mix is above the medium level, the pa steurisation cycle starts automatically at a certain time (as programmed in the Manager Menu normally at 2:00 AM). During the display indicates “HEAT-TREATMENT CYCLE” the mix in the hopper and in the cylinder is heated up to 65°C, k ept at 65°C for 30 minutes and finally cooled down to 2°C. At the end of the cycle, the display shows “PAST. END” followed by date and hour of its termination. The machine passes automatically to STORAGE function. To serve shake, press STOP, then the PROD button, but only if the machine hasn’t passed automatically in PRODUCTION yet.

Note: Once the pasteurisation cycle has started, it can not be interrupted. The complete heat-treatment cyc le wi ll tak e less than 4 hours to be com ple te d.

During the pasteurisation and Pause cycles, the mix in the machine is very hot. Do not attempt to recover the mix nor to disassemble the machine.

WARNING

Do not dispense sundae nor dismount the machine during the pasteurisation

because the product is very hot and under pressure.

while the machine is in production

STORAGE / DECREASE FUNCTION / RESET ALARM MESSAGES

The Storage Led lights ON as soon as the Pasteurisation cycle ends. The machine preserves the mix at +2°C (35°F) in the hoppe r and in the cylinder.

- this button is also used to decrease the value in the Manager menu

- this button is also used to RESET the ALARM MESSAGES on the display.

MIX LEVEL SIGNAL

In each hopper we have 2 level sensors: MEDIUM level and LOW level.

- When the MIX LEVEL LED flashes, it me ans that the mix level in the hopper is lower than the medium mix level sensor.

- When the MIX LEVEL LED is on, it means that the mix level in the hopper is lower than the minimum mix level sensor.

The display indicates ADD MIX or MIX OUT

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Maximum filling level in

Mix level sensor

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When the LCD back light is blinking, that means an alarm has tripped.

When it becomes still, the alarm which has previously tripped, has automatically reset and

the indication on the display must be reset by pressing the RESET

EVENTS

In order to read the events, the machine must be in STOP, so keep the EVENTS**** is displayed.

02:00:00 06 APR

The first event will appear on the display. Press or in order to scroll UP or DOWN the events list.

Press

to exit the events reading and go to STOP.

START PASTEUR

pressed until ****READ

button.

MANAGER MENU

1) To access the Manager Menu press simultaneously both and keys, then release

them immediately.

On the display you will read the first step of the Manager Menu:

The first row indicates the step number, and the second row indicates the description and value.

2) Press

3) Press STOP to move to the next step.

4) To exit the Manager Menu press the

Step Hour U01 10

or in order to increase or decrease the value.

key.

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The following table illustrates all steps of the manager menu:

Step

(first row) U01 Hours 00 23 U02 Minutes 00 59

U03 Day of Week Sun Sat U04 Day of Month 01 31 U05 Month Jan Dec U06 Year 2000 2099 U07 Language Eng DEU

U08 Start Prod. Time 00 U09 Start Past. Time 00 23+no U10 Lev. Beep Enable No Yes U11 Speed Pump 1 No No

Display ENG

(second row)

Min Max

23+no+auto

Default

ENG

08 02

Yes

 U01 -> 06 Time and date settings  U07 Language selection.  U08 Start Production time.  U09 Start Pasteurisation time.

 U10 Disables/enables the sound alarm when mix level is low.

U11 Unused



THE MACHINE IS READY FOR START-UP ONLY AFTER IT HAS BEEN PERFECTLY

FOR HYGIENIC AND SAFETY REASONS, HANDS SHOULD

NEVER BE PLACED INSIDE THE MIX HOPPER WHILE THE MACHINE IS WORKING

CLEANED AND SANITIZED.

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2.2 OPERATIONS

2.2.1 DISPENSING MILK SHAKE

 Once the milk shake has completed the freezing cycle and the LED is on solid, place a cup on the cup

holder and press one of the “coloured cup” buttons (brown, red, yellow or blue) in order to dispense milk shake.

 The machine automatically dispen ses the milk shake in the cup, placed on the cup holder, up to the

level set by the sensor.

 The dispensing may be stopped at anytime by pressing any of the “coloured cup” buttons.

WARNING

It is important to keep the sensor clean and to use a fresh clean

cup of the recommended type.

The vertical joint of the cup (with double pasteboard layer)

must be always placed away from the sensor.

2.2.2 DISPENSING SUNDAE

In order to dispense sundae, place a cup or a cone under the spout and slowly pull down the dispensing handle. As soon as the sundae comes out, twist the cup or the cone to form a cone-shaped serving. When the portion has reached the desired size, close the dispensing handle and quickly pull the cone or the cup down in order to sharpen the tip.

2.3 PROGRAMMED CLEANING CYCLE

The machine is equipped with an automatic system that calls for washing of the parts in contact with the product at least every 14 days.

In PROD. the second row of the display indicates the days remaining to the next cleaning.. Sundae Ready!

TEV +19°C W -14 --> Indicates cleaning within 14 days.

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2.4 POWER BLACK- OUT

In the event of a black-out with the machine in:

 AGITATION  PASTEURISATION (HEATING or PAUSE stage)

the machine will resume operating in the same function where it was when the power went off. If the machine was in one of the following functions:

 STORAGE  PRODUCTION  PASTEURISATION (COOLING stage)

Upon the return of power, the temperature at the time of failure and the duration of the black-out will be automatically checked and the machine will resume operating in the same function or it will start a new PASTEURISATION cycle, in accordance with the applicable safety standards.

CAUTION

If the blackout exceeds four hours, in order to avoid health hazards

in the dispensed product, it is necessary to disassemble, wash, rinse and

sanitize the parts, as indicated in Section 4 of this manual.

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3. DAILY CLOSING PROCEDURES

NOTE:

The machine is equipped with an automatic system wich calls for washing of the parts in contact with the product every 14 days. This system disables the dispensing function at the end of the fourteenth day (see cap. 6)

3.1 SHAKE SIDE

Make sure your hands are clean and sanitized before performing the following procedures.

3.1.1 DISASSEMBLING AND CLEANING THE COMPONENTS:

Remove cup holder, drip tray, drip troughs and hopper covers to wash, rinse, sanitize them at the sink and replace them on the machine. Before replacing the tank covers, clean the upper area inside the tanks with a sanitised cloth.

3.1.2 SANITIZING THE DOOR AREA:

a) Fill an empty pail with McD Sanitizer prepared in water at 70-90°F (21-32°C) (1 packet

in 2-1/2 gallons (9-1/2 litres) of water = 100 PPM ) and mix the powder. b) Return to the machine with some McD sanitizing solution in the container. c) Immerse the brushes in the sanitising solution and wipe several times the dispensing

area of the door, the small cover underneath the door, the dispensing hole, the area

above the same door and everywhere inside the door. d) Spray the sanitising solution on the dispensing part, on the door area, underneath the piston cover and all

around the door. e) Using a clean, sanitized towel, wipe the freezer door, the front panel area around the freezer door and all

other surrounding areas.

SYRUP LINE CLEANING / SANITIZING

3.1.3

Syrup suction tubes/ connectors cleaning :

a) Remove the syrup tubes from their jugs or disconnect the syrup connectors from the bags, b) Clean the outer surface of the syrup tubes/connectors with a clean, sanitized towel. c) Remove the syrup jugs/syrup bags from the syrup compartment.

Sanitizing the syrup lines:

a) Fill an empty pail with McD sanit izer prepare d in water at 122-140°F (50-60°C) (1 packet in 2-1/2 gallons (9-

1/2 litres) of water = 100 PPM) and mix the powder. b) Place the syrup tubes’ connectors in the sanitizing solutio n. Press the STOP button, then the corresponding

“coloured cup” button twice to run the syrup pump at maxim um speed and let the sanitizing solution flow for

1 minute. Press the STOP button to stop the syrup pump.

c) Leave the sanitizing solution in the syrup line for 10 minutes.

d) Repeat for all syrup lines.

Removing the sanitizing solution from syrup lines

a) Remove the connectors from the pail containing the sanitizing so lution and put them on a clean to wel . b) Press the corresponding “coloured cup” button twice to run the syrup pumps at maximum speed in order to

empty the tube from the remaining sanitizing solution c) Press STOP button to stop the syrup pump d) Repeat for all syrup lines

Loading the syrup lines with syrup

a) Connect the syrup tubes to their jugs or connect the syrup connectors to the syrup bags. b) Place empty bucket under the spout. c) Press the “coloured cup” button twice until the syrup is dispensed and discard it. d) Press STOP button to stop the syrup pump. e) Repeat for all syrup lines.

f) Using a clean, sanitized towel, wipe the door compartment.

NOTE

It’s possible to be displayed the message “why in stop". This message reminds you to return the machine in production mode at the end of the syrup lines cleaning.

E Z

I T

N A S

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3.1.4 PREPARING THE MACHINE FOR THE OVERNIGHT HEAT TREATMENT CYCLE.

a) Open the hopper cover to verify the mix level. b) Fill th e hopper with McD shake mix to the Max level. The “ADD MIX” message on the display must be off. c) Keep the machine in PROD mode.

If the mix in the hopper is below the medium level ("ADD MIX" MESSAGE ON DISPLAY), the pasteurisation cycle

The heat treatment cycle is automatic and starts during the night (set time). Both sides of the machine should be in production mode to perform properly the heat-treatment cycle.

3.1.5 FRONT PANEL CLEANING

To clean the keyboard panel with a clean sanitized towel is recommended to lock the keys as follows: Press

for 3 seconds, light will flash in dicating that the front panel is now locked. Clean the front panel

and the keybord panel with a clean sanitized towel.

WARNING

will not start.

After cleaning press

for 3 seconds, to unlock t he keyboard.

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3.2 SUNDAE SIDE

Make sure your hands are clean and sanitized before performing the following procedures.

3.2.1. SANITIZING THE DOOR AREA SURFACE:

a) Fill an empty pail with McD Sanitizer prepared in water at 70-90°F (21-

32°C) (1 packet in 2-1/2 gallons (9-1/2 litres) of water = 100 PPM) and mi x

the powder. b) Return to the machine with a small amount of McD sanitizing solution c) Immerse the brushes in the sanitising solution and wipe several times the

dispenser of the door, the same door, the area of the le ver and all around

the door, including the holes of the knobs. d) Spray the sanitising solution on the dispenser of the door, on the

surrounding area and on the same door. e) Clean the front of the machine with a clean and sanitized towel.

3.2.2 TOPPING PUMPS CLEANING:

a) Remove the topping covers and pumps. Protect the exposed topping containers with a cover, in

order to avoid the product’s exposure to the air.

b) Wash the covers and the external part of the motor carefully using water and detergent. c) Fill the container with water at 50-60°C (122-140°F), place the pumps inside, press the

distribution pistons and rinse them until the outflowing water is clean.

d) Fill the container with the sanitizing solution, place the pumps inside and push the

distribution pistons to sanitize them ( hold on for 1 minute).

e) Place the covers and pumps on the clean, dry surface and leave them drying in the air

overnight.

PREPARING THE MACHINE FOR THE OVERNIGHT PASTEURISATION CYCLE.

3.2.3

a) Open the hopper cover to check the mix level. b) Fill the hopper with McD shake mix to the Max level. The “ADD MIX” message on the display must be off. c) Keep the machine in PROD mode.

WARNING

If the mix in the hopper is below the medium level ("ADD MIX" MESSAGE ON DISPLAY),

the pasteurisation cycle will not start.

3.2.4 FRONT PANEL CLEANING

To clean the keyboard panel with a clean sanitized towel is recommended to lock the keys as follows: Press

for 3 seconds, light will flash in dicating that the front panel is now locked. Clean the front panel

I N

A S

and the keybord panel with a clean sanitized towel.

After cleaning press

for 3 seconds, to unlock t he keyboard.

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4. DAILY OPENING PROCEDURES

 Check that pasteurisation cycle has been successfully completed and the disp lay indicates the messag e "PAST. END",

followed by the time and day of i ts comp letio n.

 If the pasteurisation cycle wasn’t completed successfully ,the machine will be locked out. Check the reason

reading the alarm messages and press PROD. button to run pasteurisation cycle manually. Once the pasteurisation cycle is completed successfully, the lock out resets automatically and the machine is ready to go in production. No product can be dispensed during the pasteurisation cycle (approximately three hours).

in order to reset the message on the display. Press STOP then

4.1 MILK SHAKE SIDE

Make sure your hands are clean and sanitized before performing the following procedures.

4.1.1 SANITIZING THE DOOR AREA:

a) Fill an empty pail with McD Sanitizer prepared in water at 70-90°F

(21-32°C) (1 packet in 2-1/2 gallons (9-1/2 litres) of water = 100

PPM) and mix the powder. b) Immerse the brushes in the sanitising solution and wipe several

times the dispensing area of the door, the small cover underneath

the door, the dispensing hole, the area above the same door and

everywhere inside the door. c) Spray the sanitising solution on the dispensing part, on the door

area, underneath the piston cover and all around the door. d) Cle an the external parts of the machine with a clean an d sanitizing

towel.

4.1.2 STARTING UP THE MACHINE:

The machine is in STOP function. Press the PROD button in order to start it up. The led will blink and the starting up process is carried out for 15 minutes. During this time, you CANNOT dispense the Shake. When “PROD” LED stays STILL, the Milk Shake is ready to serve.

WARNING

Do not keep any syrup line empty. In case you are using only 3 syrup flavours, you must close the hole

of the front lid using the tap delivered with the accessories as indicated in sect. 6.4.2.1 of the user’s

manual.

R E

N A S

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4.2 SUNDAE SIDE

Make sure your hands are clean and sanitized before performing the following procedures.

SANITIZING THE DOOR AREA:

4.2.1

a) Fill an empty pail with McD Sanitizer prepared in water at 70-90°F (21-

32°C) (1 packet in 2-1/2 gallons (9-1/2 litres) of water = 100 PPM) and mix the powder

b) Return to the machine with some McD sanitizing solution in the

container.

c) Immerse the brushe s in the sanitising solution and wipe several times th e

dispenser of the door, the same door, the area of the lever and all around the door, including the holes of the knobs.

d) Spray the sanitising solution on the dispenser of the door, on the

surrounding area and on the same door.

e) Clean the front parts of the machine with a clean and sanitized towel.

4.2.2 PREPARING HOT TOPPINGS:

a) Remove the topping container s and check the water level. Fill the hot topping hopper with water

until the indicated level is reached. There is a level sensor inside the topping hopper, therefore when the water level is low, an alarm message will be displayed. The alarm will persist until the

correct water level is reached. b) Fill the containers with toppings, if necessary, c) Place the covers and topping pumps in their seats (press the distribution pistons and disca rd the

first dispensed product). Once the machine is in PROD and the water level is sufficient, the

toppings will start to warm up. d) As soon as the machine is in PROD. and the water level is satisfied the topping heaters will be

automatically on.

4.2.3 STARTING UP THE MACHINE:

The machine is in STORAGE mode. Press the STOP and then the PROD butto ns to start up the machine. You will be able to serve the sundae just in few minutes.

R E

I T

N A S

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5. WEEKLY CLEANING

On a weekly basis, certain machine parts must be disassembled, washed, sanitized and reassembled. The following is the list of operations to be performed weekly in addition to the regular daily cleaning procedure.

Make sure your hands are clean and sanitized before performing the following procedures.

5.1 WASHING AND SANITIZING OF THE TOPPING CONTAINERS

5.1.1 CLEANING OF THE TOPPING BINS:

a) Remove the topping pumps and bins from the machine and bring them to the back sink. b) Discard the toppings weekly to break the bacterial life cycle. c) Wash the bins thoroughly with the McD All Purpose Super Concentrate (APSC) and hot water 122-

140°F (50-60°C) (or with of hot McD APSC from the KayStar dispenser at the back sink), eliminating any product’s residue.

d) Place the bins into the McD Sanitizer diluted with water at 70-90°F (21-32°C) [1 packet in 2 -1/2 gal.

(9-1/2 liters) of water = 100 PPM] for 1 minute.

e) Make sure that the bins are empty and leave them out to air-dry.

5.1.2 CLEANING OFTHE TOPPING HOPPER

a) Place an empty container under the drain tap inside the syrup compartment. b) Open the tap and drain the water completely from the tap. (caution: water is hot) c) Close the tap.

5.2 DISASSEMBLING, WASHING AND SANITIZING OF THE HOT TOPPING PUMPS

Clean the hot-topping pumps:

Place the lower end of the pump into a container with clean warm water and operate the pump until the discharged water is clear.

 DISASSEMBLY

step 1

Loosen the locking collar until the plunger assembly can be removed from the pump cylinder.

NOTE

The plunger spring is slightly compressed so be careful when removing the knob.

step 2

Remove the discharge tube assembly by rotating it counter clockwise until the flats on the discharge tube move away from the valv e bo dy loc k ing groov es , then pull the discharge tube assembly away from the valve body carefully.

step 3

Separate the O-ring from the discharge tube by pressing the O-ring and sliding it in the joint groove until the O-ring can roll out from the groove.

step 4

Remove the cylinder assembly from the valve body by pressing downwards the valve and rotate it counter clockwise at the same time until the tabs of the cylinder assembly leave the locking grooves on the valve body .

step 5 Remove the O-ring from the valve body. step 6

Place all parts in a clean container .

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 WASHING NOTE

DO NOT use tools that can scratch polished surfaces. Do use clean and sanitized brushes instead.

step 1

Wash all pump components with the McD All Purpose Super Concentrate (APSC) and hot water at 122 140°F (50-60°C) (or with hot McD APSC from the KayStar dispenser at the back sink).

step 2

Rinse them with clear water. Use the supplied brushes to clean the discharge tube assembly and the valve body. It is recommended to wash the small parts in a pan or in any other similar container so they will not get lost.

step 3

Sanitize the pump components immerging them in a container with McD Sanitizer diluted in water at 7090°F (21-32°C) [1 packet in 2-1/2 gal. (9-1/2 litres) of water = 100 PPM] (and mix the powder) ] then, hold on for 1 minute.

step 4

Allow the pump parts to air-dry after sanitizing.

 REASSEMBLY

step 1

Lubricate and position the knob O-ring in its groove on the knob. Put the knob apart.

step 2

Assemble the washer, the spring, the head insert, and the head tube on the piston and stem assembly.

step 3

Slip the cone shaped collars (if used) onto the head tube, then place the locking collar on the head tube.

step 4

Hold the head tube and push the piston and stem assembly inside th e head tu be, comp ressing the spring at the same time. When the threaded end of the stem projects through the head tube, thread the knob onto the piston and onto the stem assembly. Put the assembled plunger assembly apart.

step 6

Lubricate the O-ring with the appropriate lubricant and install the O-ring in its groove on the discharge tube assembly joint. Temporarily put the discharge tube assembly apart.

step 7

Lubricate the O-ring with food grade lubricant and install the O-ring in its groove inside the valve body.

step 8

Align the tabs on the cylinder flange with the notches in the valve body. Tilt the cylinder assembly slightly and slide the widest section of the flange under the centre locking groove of the valve body. Rotate the cylinder assembly clockwise and press it downwards at the same time the flange tabs fully engage the locking grooves of the valve body.

step 9

Position the discharge tube assembly on the valve body, aligning the flats on the discharge tube assembly’s joints with the locking tabs on the valve body. Push down the discharge tube assembly until it is seated. Rotate the discharge tube assembly clockwise to lock it in place.

step 10

Slide the lid onto the discharge tube assembly and onto the cylinder assembly and secure the lid with the discharge tube nut.

step 11

Apply food grade lubricant on to the disch arge fitti ng O-ring and in stall the O-ri ng on the pla nt. Install the plant on the discharge tube by pushing it inside and rotating it in a clockwise direction.

step 12

Apply a small amount of food grade lubricant to the seal flare, install the plunger assembly in the pump body assembly, and tighten the locking collar.

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5.3 CHECK TOPPING P UMP TEMPE RATURE A ND VOLUM E

NOTE

This procedure should be performed in the morning when the pumps are disassembled and cleaned.

step 1

Dispense one serving of topping into a sundae cup and discard this portion of material.

step 2

Dispense the second serving into a sundae cup in the same way.

step 3

Insert the digital thermometer into the topping. Let the digital thermometer stabilize for 20 seconds.

: Topping temperature must be between 115 and 125F (46 and 52C) and must remain in this

NOTE



range before the calibration pump starts. The water temperatur e of the bath must be between 135



F (57 and 63C).

145

step 4

If the temperature is too cold or too warm, call service to adjust it.

step 5

Hold the small chamber of the calibrating cup exactly under the dispensing nozzle.

step 6

Push the dispensing lever down firmly. The topping must come to the bottom of the calibrating cup. Do not allow the topping to slide down on the sides of the cup.

NOTE: The amount of dispensed topping should be one fluid ounce (29.6 ml).

step 7

If the amount of dispensed topping is not correct, consult the troubleshooting section of your equipment’s manual.

step 8

Repeat for the other topping pump.

and

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6. EVERY 14 DAYS CLEANING

After exactly 14 DAYS from the last brush cleaning, the machine must be thoroughly washed and restarted. It automatically locks out and must be disassembled, washed, sanitized and reassembled before operations can resume. Every time product is dispensed the display indicates the number of days to the next brush cleaning. THE FOLLOWING IS THE LIST OF OPERATIONS TO BE PERFORMED ON THE 14 ADDITION TO THE REGULAR DAILY AND WEEKLY CLEANING PROCEDURE.

NOTICE

MAKE SURE YOUR HANDS ARE CLEAN AND SANITIZED.

6.1 DISASSEMBLING AND CLEANING THE MILK SHAKE SIDE

NOTICE

ALL PARTS REMOVED FROM THE MACHINE SHOULD BE PLACED INTO A CONTAINER, AND

TRANSPORTED TO THE SINK FOR CLEANING, RINSING AND SANITIZING.

6.1.1 CLEANING THE SHAKE SYRUP SYSTEM Wiping pick up tubes:

a) Remove the syrup pick up tubes from the syrup jugs or disconnect the syrup connector from the

syrup bag.

b) Wipe the outside of the pick up tubes with a clean, sanitized towel. Remove the syrup jugs/syrup

bags from the syrup compartment.

Cleaning the syrup lines:

a) Remove the cup holder and place an empty pail under the door spout.Fill a pail with the McD All

Purpose Super Concentrate (APSC) and hot water 122-140°F (50-60°C) (or refill a pail of hot McD

APSC from the KayStar dispenser at the back sink).

b) Place the pick up tubes inside. Press STOP then push the corresponding “coloured cup” button

two times to run the syrup pump at maximum speed and let the water flow for 1 minute. Press STOP button to stop the syrup pump.

c) Repeat for all syrup lines.

Rinsing the syrup lines:

a) Fill a pail with tap water and place the pick up tubes inside. Push the corresponding “coloured cup”

button two time and let the water flow for 1 minute. Press STO P button to stop the syrup pump.

b) Repeat for all syrup lines.

DAY IN

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6.1.2 DRAINING AND CLEANING THE MILK SHAKE SIDE

WARNING

Every time the display shows “WASH TODAY” alarm, you have to push

once the

button in order to reset the ala r m me ss a g e.

Drain the Milk Shake step 1 Put an empty pail under dispensing spout. step 2

Push the “STOP” button. step 3

Push the

button then push button to allow the milk shake to flow out until it becomes liquid.

step 4

Push the “STOP” button to close the pist on, stop the beate r motor and the mix pump.

step 5 Remove the pressure tube:

In the hopper, disconnect the pressure tube from the pump, turn it sideways and remove it by pulling it up from its seat. Remove the mix pump: Grasp the pump and turn it in a clockwise direction of 45° then pull it out towards you. Make sure that the pump drive shaft and seal are taken out with the pump.

Remove the mix agitator:

Remove the agitator from the hopper by pulling it upwards.

step 6

Pump body

Push the

button in order to open the piston and dr ain the rest of

the liquid mix.

step 7

Use the

button to open and close the piston when necessary while still in STOP. Drain the hopper completely. To close the piston, press the “STOP” button.

step 8 Rinse the machine

Feeding tube

Pour 2,5 gallons (9.5 liters) of cool, clean water into the mix hopper. Use the white hopper brush to scrub the mix hopper, mix le vel sensor and the outside the agitator shaft. Use the small brush to clean the mix inlet hole and the drive hub of the mix pump.

step 9 Drain rinse water from hopper and cylinder

Place an empty pail under the milk shake spout.

Push the

button to open the spigot piston and let the water drain out. Press the button and let the beater run for about 10 seconds. Press the “STOP” button to stop the beater; the piston closes automatically.

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Push the button to open the spigot piston and let the water flow completely out.

Repeat steps 8 and 9 until the rinse water being dispensed is clear. step 10 Clean the machine

Fill the tank with 2-1/2 gallons (9-1/2 litres) of warm water APSC solution.

step 11

Press the

button and let the beater run for about 10 seconds.

step 12

Push the “STOP” button.

step 13

Use the appropriate hopper brush to scrub the mix hopper, mix level sensor and the outsid e the agitator shaft. Use the small brush to clean the mix inlet hole and the drive hub of the mix pump.

step 14

Push the

button and let the liquid flow completely out.

step 15

Then push the “STOP” button to close the piston.

step 16 Rinse the machine

Rinse with clear water, push the

button and let the water flow completely out. Press the “STOP”

button to close the piston.

step 17 Sanitizing the machine

Fill the hopper with McD Sanitizer prepared in water 70-90°F (21-32°C) [1 packet in 2-1/2 gal. (9-1/2 liters) of water = 100 PPM].

step 18

Press the

button and let the beater run for 10 seconds then push STOP. Use the appropriate hopper brush to scrub the mix hopper, mix level sensor and the outsid e the agitator shaft. Use the small brush to clean the mix inlet hole and the drive hub of the mix pump.

step 19

Leave the solution of McD Sanitizer for a minimum of 1 minute.

step 20

Push the “

” button and let the sanitizer flow completely out.

step 21

Push the “STOP” button.

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6.1.3 DISASSEMBLING OF THE SHAKE MIX PUMP step 1

Remove the pump drive shaft and seal from the pump. step 2 By holding the feeding tube (#271A) upwards turn it counter-clockwise and pull it out.

Pos. Description

8B Hand screws 31 Check valve-slit 32A Pressure pipe 38 Driving gear 38A Driven gear 39A Pump body 96 Pump shaft 100 Shake chamber tube 202A Pump housing 206 Spring 207 Connection tube 271A Feeding tube 243 Seal-mix pump shaft 245 Pressure relief valve 1104 O-ring 1117 O-ring 1131 O-ring 1178 O-ring 1412 O-ring 1416 O-ring

step 3

Using the O-ring extractor, remove the O-ring (#1412). Remove the spring (#206A) and the back flow valve (#245).

step 4

Unscrew the 2 knobs (#8B) and separate the cover (#202A) from the pump body (#39A).

step 5

Using the or-ring extractor, remove the large O-ring (#1178). tapping the pump body against the palm of your hand, remove the pump gears (#38 and 38A).

step 6

Pull out the connection tube (#207) from the pressure pipe(#32A).. Remove the O-rings (#1131 and 1117) and the duck bill valve (#31).

243

39A

1178

38A

202A

1117

207

245

206A

1412

271A

1131

1117

32A

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6.1.4 DISASSEMBLING OF THE SHAKE DISPENSING DOOR

CAUTION

Before disassembling the dispensing head, make sure that the hopper and

the cylinder are completely drained.

Pos. Description 7A Dispensing door

8A Hand screws 30A Piston 31A Syrup duck bill valves 369 Spinner 370 Spout cap 377 Syrup valves support 1109 O-ring 1195 O-ring 1130 O-ring 1142 O-ring 1240 O-ring 1246 O-ring

step 1

1195

1130

1109

30A

1240

369

1253

370

With the machine in STOP mode, push to open the piston

step 2

button

Open the protection cover (ref. C).

step 3

Slide the cylinder up with the fingers (ref. A) and turn the bracket clockwise (ref. B).

Step 4

Remove the cup holder.

Step 5

Twist the spout cap (#370) clockwise then pull it down in order to remove it (the warning IMSB OPEN

flashs on the display)

step 6

Slide the spinner out (#369).

CAUTION

Be careful not to drop the spinner: it may be seriously damaged.

step 7

Unscrew the four knobs retaining door (#8A) and remove the dispensing door from the four studs by pulling it towards you. (Fig. 4)

step 8

Remove the valve block (#377) sliding it down.

step 9

Remove the 4 o-rings (#1109) from syrup outlet on the front of the machine

step 10

Holding the dispensing door (#7A) straight up, remove the piston by pulling it upward (Fig. 5).

4 5

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step 11

Using the O-ring extractor, remove: a) the piston O-ring (#1130). b) the door O-ring (#1195). c) the 2 piston housing O-rings (#1240) located inside the dispensing door.

d) the spout cap plate O-ring (#1253). e) Remove the duck bill valves and the 8 o-rings (#1246) of the syrup valve block.

6.1.5 DISASSEMBLING OF THE SHAKE CYLINDER’S BEATER step 1

Remove the shake beater (#21) from the cylinder pulling it towards you.

CAUTION!

Be careful not to hit the c ylinder walls with the shaft of the beater when pulling it out.

step 2

Slide the beater seal (#28) out of the beater shaft.

CAUTION!

Make sure that the beater seal is in its place and be careful not to lose it and to reassemble it after

washing.

step 3

Remove the idler (#24A) from the beater frame (#21A).

step 4

Remove the beater blade pin (#726) pulling it upward and remove the blade (#430). Carpigiani suggests to replace the blade once a year (please see the tune-up kit card).

step 5

Remove the pin O-ring (#1271)..

726

1271

430A

Beveled blade

Rubber stoppers

28A

21A

24A

Pos. Description 21 Beater

24A Counter beater 28A Stuffing box (beater seal) 430A Beater blade 726 Beater blade pin 1271 O-ring

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6.2 DISASSEMBLING AND CLEANING OF THE SUNDAE SIDE

6.2.1 DRAINING AND CLEANING OF THE SUNDAE SIDE

Drain the machine step 1 Place an empty pail under the SUNDAE spout. step 2 Press the “STOP” button. step 3

Pull the dispensing lever and drain the ice cream.

step 4

Press the

step 5

When the product coming out becomes liquid, push the “STOP” button and leave the spout open.

step 6 Remove the pressure tube

In the hopper, disconnect pressure pipe from the mix pump, turn it sideways, remove it pulling it up from its seat and let the product flow completely out. Remove the mix pump: Grasp the pump and turn it in a clockwise direction of 45° then pull it out towards you. Make sure that the pump drive shaft and its seal are taken out with the pump.

Remove the mix agitator:

Remove the agitator by pulling it upwards

button.

step 7 Rinse the machine

Close the spout handle, pour 2,5 gallons (9.5 liters) of cool, clean water into the mix hopper. Use the appropriate hopper brush to scrub the mix hopper, mix level sen sor and the outside axe of the agitator shaft. Use the small brush to clean the mix inlet hole and the drive hub of the mix pump.

Drain rinse water from hopper and cylinder

Place an empty pail under spout. Open the spigot piston and let the water drain out.

step 8

Rinse with warm water until the solution runs clear.

step 9

Press the

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button and let the beater run for 10 seconds.

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step 10

Turn the machine off by pushing the “STOP” button and let the water flow out.

step 11 Clean the machine

Fill the hopper with 2-1/2 gallons (9-1/2 litres) of warm APSC solution.

step 12

Clean the hopper walls, the level sensor and outside of the agitator shaft using the supplied brushes.

step 13

Pull the dispensing handle and let the liquid flow out completely.

step 14 Rinse the machine

Rinse with clear water, pull the spigot handle and let the water flow out.

step 15 Sanitize the machine

Fill the hopper with McD Sanitizer prepared in water 70-90°F (21-32°C) [1 packet in 2-1/2 gal. (9-1/2 liters) of water = 100 PPM].

step 16

Press

button and let the beater run for 10 seconds. Use the appropriate hopper brush to scrub the mix hopper, mix level sensor and the outside of the agitator shaft. Use the small brush to clean the mix inlet hole and the drive hub of the mix pump.

step 17

Push the “STOP” button. Let the McD Sanitizer solution stand for at least 1 minute.

step 18

Pull the dispensing handle and let the water flow completely out.

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6.2.2 DISASSEMBLING OF THE MIX PUMP

step 1

Remove drive shaft (#96) and seal (#243).

step 2

Keeping the feeding tube (#271) upward turn it counterclockwise and pull it out.

step 3

Pull the spring (#206) and the back flow valve (#2 45) out. Using the o-ring extractor, remove the O-ring (#1412).

step 4

Unscrew the 2 knobs (#8B) and separate the cover (#202) from the pump body (#39).

step 5

Using the o-ring extractor, remove the larg e O-ring (#1178). Tapping the pump body against the palm of your hand, remove the pump gears (#38-#38A).

step 6

Pull the connection tube (#207) from the pressure pipe (#32). Remove the O-rings (#1131 and 1117) and the duck bill valve (#31).

243

1178

38A

202

1117

Pos. Description 8B Hand screws

31 Check valve-slit 32 Pressure pipe 38 Driven gear 38A Driving gear 39 Pump hosing – rear 96 Pump drive shaft 202 Pump hosing - front 206 Spring 207 Connection tube 243 Seal mix pump drive shaft 245 Pressure relief valve 271 Feeding tube 1117 O-ring 1412 O-ring 1416 O-ring

245

206

1412

271

207

1131

1117

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6.2.3 DISASSEMBLING OF THE SUNDAE DISPENSING DOOR

CAUTION

Before disassembling the dispensing head, make sure that the hopper

and the cylinder are completely drained.

Pos. Description 5 Dispensing handle

6 Handle pin 7 Soft serve door 8 Handscrews 30 Dispensing piston 43 Piston lever 1153 O-ring 1188 O-ring 1289 O-ring

1188

1153

1289

step 1

With the machine in STOP mode, remove two retaining knobs (#8) and pull the door assembly towards you sliding it off the two front panel studs.

step 2

Remove the pivot O-ring (#1289)

step 3

Pull the dispensing handle (#5) so the piston (#30) raises in its housing and pull the pivot pin (#6) out releasing the dispensing handle (#5).

step 4

Using the dispensing handle lever, pull the piston (#30) out completely .

step 5

Using the o-ring extractor, rem ov e:

a) the 2 piston O-rings (#1153) b) the large dispensing door O-ring (#1188).

6.2.4 DISASSEMBLING OF THE SUNDAE BEATER

step 1

Pull the beater (#21) out of the cylinder.

step 2

Slide the beater seal (#28) out of the beater shaft.

step 3

Pull out and remove the end pusher (#25P) and the idler (#24).

step 4

Remove the 3 beater blades (#430). Carpigiani suggests to replace the blades each 6 months (please see the tune-up kit card).

CAUTION

The beater seal is very important. It must be checked regularly for wear and tear. It must always be

on the beater shaft and properly lubricated, during operation, otherwise mix will leak in the drip

tray.

430

214

25P

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6.3 WASHING AND SANITIZING OF COMPONENT PARTS

step 1

Fill a clean sink with the McD All Purpose Super Concentrate (APSC) and hot water 122-140°F (50-60°C) (or with hot McD APSC from the KayStar dispenser at the back sink).

step 2

Wash the disassembled parts with the APSC solution and scrub them thoroughly with the brushes provided with the machine. As you proceed, rinse with hot water. Make sure all lubricant and mix film is removed from parts.

step 3

Fill another sink with McD Sanitizer prepared in water 70-90°F (21-32°C) [1 packet in 2-1/2 gal. (9-1/2 litres) of water = 100 PPM].

step 4

Place the parts in the sanitizing solution. Leave them there for at least 1 minute.

step 5

Place the components on the milk shake tray to air-dry.

step 6

Place the sundae components on the sundae tray to air-dry.

step 7

Return to the machine with a small amount of McD Sanitizer.

step 8

Dip a brush into the sanitizer and thoroughly brush both freezing cylinders.

step 9

Dip a brush into the sanitizer and thoroughly brush clean the mix inlet hole and the pump drive hub openings in the rear of both mix hoppers.

Step 10

Spray the back of cylinder with sanitizer.

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step 11

Dip a brush into the sanitizer solution thoroughly brush clean the syrup injectors located on the front panel just under the milk shake cylinder.

Repeat steps 8 , 9 and 10 several times.

We recommend not to wash the sundae and shake components together.

1) Wash

4) Air-Dry

3) Sanitize

2) Rinse

IMPORTANT!!

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6.4 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS

6.4.1 REASSEMBLY OF THE SHAKE CYLINDER BEATER step 1

Lubricate the blade pin O-ring (#1271) and slide it onto the pin (#726).

726

1271

Beveled blade

430A

28A

21A

Pos. Description 21A Beater

24A Counter beater 28A Beater seal

24A

430A Beater blade 726 Beater blade pin 1271 O-ring

CAUTION!

Check the rubber stoppers onto the blade for integrity. Replace if worn or damaged.

Carpigiani suggests to replace the blade once a year (please see the tune-up kit card).

Rubber stoppers

WARNING

Like all moving parts, the complete beater is also subject to wear and tear.

For this reason, we recommend checking the amount of wear to parts in

direct contact with one an-other (beater/beater idler and beater/cylinder

walls) on a regular basis during scheduled cleaning operations and in any

case, every six months of machine operation.

In particular, make sure that the wear on the bushing on the beater idler is

no more than 2 mm, as indica ted by th e mar king on the bushi ng itself. I f

Marking line

there is more than 2 mm wear, it is necessary to replace the beater idler.

step 2

Place the blade (#430A) in its housing on the beater (#21A) aligning the pin hole with the hole on the beater. Secure the blade (#430A) onto the beater (#21A) inserting the beater blade pin (#726) into the blade and the beater hole. The head of the rubber stoppers should rest on the beater frame.

step 3

Replace the idler (#24A) in the beater frame (#21A) first inserting the front shaft into the slot of the beater front housing and then inserting t he idler shaft int o the rear housin g. Push it towards th e back, otherw ise the idler ma y fall out.

step 4

Lubricate the sides of the beater seal (#28A) and slide it onto the beater shaft.

CAUTION!

The beater seal is very important. It must be checked regularly for wear and tear. It must always be

on the beater shaft and properly lubricated, during operation, otherwise mix will leak in the drip

tray.

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step 5

Insert the beater assembly into the cylinder, push it to the end and rotate it slightly until its shaft enters the rear hub: the self adjusting blade should be inside the rim of the cylinder.

6.4.2 REASSEMBLY OF THE SHAKE DISPENSING DOOR step 1

Lubricate and replace the 4 syrup outlet o-rings (#1109) on the front panel of machine.

step 2

Lubricate the O-rings and replace them in their respective position i.e.:

a) Replace the 8 o-rings (#1246) on the syrup distribution block (#377), b) Replace the 4 duck bill valves (#31A) on the syrup distribution block (#377), c) Replace the syrup distribution block (#377) in its position on the front panel of the machine, d) Replace the 2 piston housing O-ring (#1240) in the dispensing door, e) Replace the O-ring (#1130) on the piston, f) Replace the O-ring (#1195) on the dispensing door, g) Replace the O-ring (#1142) on the spinner plate

step 3

Holding the dispensing door (#7A) upward, lubricate and replace the piston (#30A) in its position in the front door.

step 4

Fit the dispensing door (#7A) in the four front panel studs and fasten it w ith the fou r kn ob s (#8A ) hand-tightening them in alternate sequence.

step 5

Lubricate the spinner shaft and insert the spinner (#369) into its housing.

step 6

Mount the spinner plate (#370).

step 7

Move up the spigot piston, slide up the cylinder (ref. A) and close the bracket (ref. B) on the piston.

step 8

Close the protection cover (ref. C). Ensure cover is closed properly otherwise the machine will not operate.

step 9

With the machine in STOP mode push the

button to close the piston.

30A

Pos. Description 7A Dispensing door

8A Hand screws 30A Piston 31A Syrup duck bill valves 369 Spinner 370 Spout cap 377 Syrup valves support 1109 O-ring 1195 O-ring 1130 O-ring 1142 O-ring 1195 O-ring 1240 O-ring 1246 O-ring

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1195

1130

1109

1240

369

1253

370

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6.4.2.1 Shake side warning – When using only 3 syrups.

In case you are using only 3 syrup flavours, you should close the hole of the front lid using the tap ref. 1 delivered with the accessories. This step can fit only in the hole indicated by X in the fig. To block it firmly use the key ref. 2. By doing so, the forth syrup flavour that corresponds to the blue cup button becomes disabled. The tap and its o-ring should be disassembled, cleaned and sanitized during the periodical cleaning.

6.4.3 REASSEMBLY OF THE SHAKE MIX PUMP step 1

Lubricate and replace the O ring (#1117) on the connection tube (#207).

step 2 Lubricate and replace the O-ring (#1131) and the duck bill valve (#31) on the pressure pipe (#32A). step 3

Insert the connection tube assembly in the pressure pipe (#32A).

step 4

Place the pressure pipe in a sanitizing solution.

step 5

Insert the pump gears (#38-#38A) into the pump body (#39A).

step 6

Lubricate and replace the pump body O-ring (#1178).

step 7

Lubricate and replace the drive shaft seal (#243) into the pump body (#39A).

step 8 Lubricate and replace the O-ring (#1412) on the feeding tube (#271A). step 9

Hold the pump cover (#202A) upside down and insert the back flow valve (#245) and spring (#206 A) in their pump cover housing.

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step 10

Insert the feeding tube (#271A) in the pump cover: push and turn it clockwise.

step 11

Lubricate the drive shaft (#96). Position drive shaft into the rear of mix hopper, pushing it to wards the back and rotating it slightly until it enters the drive hub. Hold the pump body assembly, with the blocking pin hook on the right, keep your thumbs over the pump gears so that they remain in place, push and turn the pump clockwise until the drive shaft mates with the driving gear. Now turn the pu mp cou nter clockwise until it locks onto the blocking pin.

step 12

Assemble the pump cover (#202A) with the feeding tube downwards on to the pump body a nd turn the two knobs (#8B) tightly

243

39A

1178

38A

202A

1117

207

245

206A

1412

271A

1131

1117

32A

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6.4.4 REASSEMBLY OF THE MIX HOPPER AGITATOR

step 1

Relocate the agitator back in its seat, pay attention to engage it onto its shaft correctly

6.5 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS

6.5.1 REASSEMBLY OF THE SUNDAE BEATER step 1

Insert the 3 beater blades (#430) onto the beater frame. Carpigiani suggests to replace the blades each 6 months (please see the tune-up kit card).

step 2

Insert the end pusher (#25P) onto the beater frame. step 3 Insert the end of the idler shaft (#24) in the rear housing of the beater, through the end push er. Push the idler into position.

step 4

Lubricate the sides of the beater seal (#28) and slide it onto the beater shaft.

IMPORTANT

Check the beater seal for integrity. Replace if worn or damaged.

It should be replaced rather frequently.

step 5

Insert the beater assembly into the cylinder. Push it while turning it clockwise until it engages in its rear hub, otherwise the dispensing head cannot be fastened properly, mix can flow out and ser ious damage may occur.

6.5.2 REASSEMBLY OF THE SUNDAE DISPENSING DOOR step 1

Lubricate and slide the 2 piston O-ring (#1153) into their seats.

step 2

Lubricate the piston (#30) and insert it, pointed end down, in the dispensing head (#7) making sure that the piston square notch lines u p with the rectangular opening on the spigot front.

step 3

Position the dispensing handle (#5) on the door (#7) and insert the pivot pin (#6) in its housing through the handle lever hole. Lubricate and slide the O-ring (#1289) into its seat on the pivot pin. Lubricate and slide into its seat the large dispensing door O-ring (#1188).

step 4

Insert the dispensing door assembly onto the two front panel studs and fasten it with the two knobs (#8) hand tight.

25P

430

1188

1153

1289

214

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6.5.3 REASSEMBLING OF THE SUNDAE MIX PUMP step 1

Lubricate and replace the two O-rings (#1117) on the connection tube (#207).

step 2 Lubricate and replace the O-ring (#1131) and the duck bill valve (#31) on the pressure pipe (#32). step 3

Insert the connection tube assembly in the pressure pipe (#32).

step 4

Place the pressure pipe in a sanitizing solution.

step 5

Insert the pump gears (#38-#38A) into the pump body (#39).

step 6

Lubricate and replace the pump body O-ring (#1178).

step 7

Lubricate and replace the drive shaft seal (#243) into the pump body (#39).

step 8

Lubricate and replace the O-ring (#1412) on the feeding tube (#271).

step 9

Hold the pump cover (#202) upside down and insert the back flow valve (#245) and spring (#206) in their pump cover housing.

step 10

Insert the feeding tube (#271) in the pump cover: push and turn it clockwise.

step 11

Lubricate the drive shaft (#96). Position drive shaft into the rear of mix hopper, pushing it towards the back and rotating it slightly until it enters the drive hub. Hold the pump body assembly, with the blocking pin hook on the right, keep your thumbs over the pump gears so that they remain in place, push and turn the pump clockwise until the drive shaft mates with the driving gear. Now turn the pump counter clockwise until it locks onto the blocking pin.

step 12

Assemble the pump cover (#202) with the feeding tube downwards onto the pump body and turn the two knobs (#8B) tightly.

Pos. Description 8B Hand screws

31 Check valve-slit 32 Pressure pipe 38 Driven gear 38A Driving gear 40 Pump hosing – rear 96 Pump drive shaft 202 Pump hosing - front 206 Spring 208 Connection tube 243 Seal mix pump drive shaft 245 Pressure relief valve 272 Feeding tube 1117 O-ring 1178 O-ring

1412 O-ring

1416 O-ring

243

1178

38A

202

1117

207

245

206

1412

271

1131

1117

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6.5.4 REASSEMBLING OF THE MIX TANK AGITATOR step 1

Relocate the agitator back in its seat: pay attention to engage it onto its shaft correctly.

6.6 SANITIZING OF THE ENTIRE MACHINE

The machine must be sanitized before mix is poured in.

Carry out the following operations for both shake side and sundae side of the machine.

NOTE

After the machine’s brush cleaning, and more precisely from the moment you close the front door (lid) of the machine, it is necessary to run the machine in production (by pushing PROD. button) within 60 minutes. After the 60 minutes, the machine does not accept the PROD. button any more and it sets to pasteurisation function automatically. In other words, you should make the “Sanitization of the whole machine“ and the “Mix Priming“ within 60 minutes, then push PROD. button.

6.6.1 SANITIZE THE HOPPER

 Fill the hopper to the maximum level with

packet in 2-1/2 gal. (9-1/2 litres) of water = 100 PPM] and allow it to drain into the cylinder.

 Using the brush, clean the mix level probes, the entire surface of the mix hopper, the surface of the

mix pump and the outside of the hopper agitator.

6.6.2 SANITIZE THE PUMP AND FREEZING CYLINDER

McD Sanitizer prepared in water 70-90°F (21-32°C) [1

 Press the push-button

“STOP”. The cylinder and the pump are now filled with the sanitizing solution.

 Return to the machine with a small amount of McD sanitizer solution in a pail.  Dip the door spout brush in the pail of sanitizer and brush clean the dispensing spout. Repeat the

operation 2 times.

 Wipe the exterior of machine with clean sanitized towel. Repeat the operation 2 times.  Wait for at least 5 minutes before proceeding with the next instructions.

6.6.3 DRAIN THE SANITIZER

 Place an empty pail under the draw spout and pull the handle (for SUNDAE side).

 Or press the “  Allow all of the sanitizer to drain.

 If the sanitizing solution does not flow out completely, keep the spigot open and press the

button, keep the beater running for 5 seconds so that the last solution residues flow out then push STOP.

Do not keep the beater running for mor e than the ti m e stri ctly n eed ed to com p lete washing and

sanitization. Without the lubrication of mix butterfat the beater blades wear out quickly.

” button (for the SHAKE side).

and let the beater run for about 10 seconds. Press the push-button

CAUTION

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6.7 SYRUP SANITIZING, PRIMING AND CALIBRATION (SHAKE SIDE)

Make sure your hands are clean and sanitized before performing the following procedures.

Sanitizing the syrup lines:

a) Fill an empty pail with McD sanitizer prepared in water 122-140°F (50-60°C) [1 packet in 2-1/2

gallons (9-1/2 liters) of water = 100 PPM] (and mix the powder).

b) Place the pick up tubes inside. Push STOP button, then the corresponding “coloured cup” button

two times to run the syrup pump at maximum speed and let the sanitizing solution flow for 1 minute. Press STOP button to stop the syrup pump.

c) Repeat for all syrup lines.

Drain the sanitizer from the syrup lines

a) Remove the syrup pick up pipes from the pail and put them on a clean towel . Place an empty pail

under the draw spout and push STOP button, then press twice each “colo ured cup” button to run the syrup pumps and drai n the re si dues of sanitizer.

b) Push STOP button to stop the pump.

Priming the syrup lines with syrup:

a) Place each syrup pick up pipe in its syrup jug or connect the syrup connector to the syrup bag. b) Place empty bucket under the spout. c) Press the “colour ed cup” button twice until the syrup is dispensed, and then discard this portion of

syrup. d) Press STOP button to stop the syrup pump. e) Repeat for all syrup flavors. f) Using a clean, sanitized towel, wipe the door cabinet.

WARNING

TO AVOID POTENTIAL BACTERIA GROWTH IN THE SYRUP SYSTEM DURING OPERATIONS,

ALL THE SYRUP LINES MUST ALWAYS BE FILLED WITH SYRUP

Calibrate syrups as follows:

 Press “STOP” button, LED will light.  Place calibration cup under the spout.  Press “coloured cup” button to start the syrup pump and dispense syrup for 5 seconds (milk shake )

or 7 seconds (TTS). The pump will automatically stop. During the syrup dispensing, the display

indicates the “syrup number” and the speed of the pump.

 Check syrup quantity; it should be 1 fluid ounce (30 ml), 1/8 ounce.  As soon as the piston closes and the syrup pump stops, the display blinks and shows the pump’s

speed. The

buttons flash for 3 seconds; acting upon those buttons we may increase

or decrease the pump’s speed. This adjustment becomes effective from the next time you push the

syrup buttons.

REPEAT THE CALIBRATION FOR EACH FLAVOUR.

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6.8 MIX PRIMING

Reminder

Prime Hopper:

 Retrieve 1 bag of McD shake or sundae mix from the walk-in refrigerator.  With the both sides of the machine in STOP mode, place an empty pail under the draw spouts.

 Pull the handle (for SUNDAE sides) or press the

button (for the SHAKE side).

 With the draw handle (SUNDAE side) or piston (SHAKE side) open, pour one ba g of mix into the

hoppers allowing it to drain into the freezing cylinders.

 When only full strength mix (not mix and sanitizer) is flowing from the draw spouts, close the draw

handle (for SUNDAE side) or press the

button (for the SHAKE side).

Connect the mix pressure pipe:

 When the mix stops bubbling from the bottom of the hopper, take the mix pressur e pipe from the

sanitizing solution and insert it in its position in the bottom of the hopper. Make sure your hands

are clean and sanitized. Press the

button and let run the beater for only five seconds just to

check the pumps work well, the push STOP.

 Turn the pressure pipe clockwise towards the pump and connect the tube to the pump.  Press PROD. button to start the Automatic freezing operation.  Replace the hopper cover.

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7. MONTHLY CLEANING

7.1 CLEAN MESH FILTERS (ON LY FOR AIR COOLED VERSION)

It is necessary to clean the air filter every month, as follows:

step 1

Locate and remove the filter from the equipment (see fig.).

step 2

At the back sink, prepare a warm solution of McD All Purpose Super Concentrate (APSC) (HCS) using the meter placed on the sink.

step 3

Wash the filter thoroughly in the warm McD All Purpose Super Concentrate (APSC) (HCS) solution.

step 4

After having washed the mesh filter, rinse it thoroughly using the hot water from th e hose at the back sink.

NOTE: Flush in the opposite direction to normal air flow direction in the filter.

step 5

Shake all the water off the filter.

step 6

Using a clean, sanitized towel, wipe out any remaining moisture from the filter.

step 7

Place the filter into the filter’s track.

step 8

Push the filter in until it is seated.

step 9

Cleaning of the mesh filter is completed.

CAUTION

Never use sharp metal objects to execute this operation;

a regular operation of the freezing system mostly depends on condenser cleanout.

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

8. PREVENTATIVE MAINTENANCE

8.1 CHECK OUT LIST

During daily, weekly and fortnightly cleaning operations, check carefully the integrity of parts subject to wear: if they appear worn, torn or not totally functional replace them. The manufacturer offers programmed maintenance plans that include the periodical replacement of parts subject to wear.

CHECK SUGGESTED ACTION

SHAKE SIDE

PUMP

 Integrity of O-ring and overflow valves.  Dry smoothness of gears in their seats.

DISPENSING DOOR

 Check O-ring integrity, check smoothness of

piston.

 Check syrup duck bill valves

TANK MIXER

 Check if it rotates freely.

CYLINDER BEATER

 Check if beater idler and scraper blade show

dents and check their integrity.

 Check integrity of beater seal (# 28).  Check that the wear on the bushing on the beater

idler is no more than 2 mm, as indicated by the marking on the bushing itsel f. If th ere is more than 2 mm wear, it is necessary to replace the beater idler

PERISTALTIC PUMP TUBE (# 385)

 Check the integrity

 If they show cuts, replace them.  If they do not turn well or turn too

freely, replace them or have them checked by a technician.

 Replace if they show damage.  Replace if they show damage

Reassemble

 Replace if broken or cracked.  Replace if damaged

 Replace the idler

The peristaltic pump tube should be

replaced at least once per year: in case of heavy use, replacement is suggested every 6 months. Replacement is necessary in case of inconsistence syrup delivery.

SUNDAE SIDE

PUMP

 Integrity of O-ring and overflow valves.  Dry smoothness of gears in their seats.

DISPENSING LID

 Check integrity of O-ring, check smoothness of

piston.

CYLINDER BEATER

 Check if scraper blades show dents and crack.  Check if end-pusher and beater idler show

dents and check their integrity.

 Check integrity of beater seal (# 28).

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 If they show cuts, replace them.  If they do not turn well or turn too

freely, replace them or have them checked by a technician.

 Replace if they show damage.

 Replace if broken or cracked.  Replace if broken or cracked.

 Replace if damaged

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8.2 PERIODICAL CHECK-UP AND MAINTENANCE

 Replace the syrup pump hose (#385) every 12 months or needed, for example in case of heavy use,

replacement is suggested every 6 months. Replacement is necessary in case of inconsistent syrup delivery.

 Replace the mix pump gears (#38 and 38A) every 12 months.  Replace rubber parts (O-ring, beater seal) every 6 months.  Replace beater scraper blades (please refer to “tune-up kit” card).  Check the correct operation of syrup pumps (dispensed syrup quantity: 1 fl. Once in 5” for EU / in 7”

for USA)

8.2.1 PERISTALTIC PUMP TUBE REPLACEMENT INSTRUCTION

PUMP TUBE REMOVAL

step 1

Remove the syrup feed pipes or connectors from the syrup containers. Wipe the outside of the pipes with a clean, sanitized towel.

step 2

Remove the syrup bags (jugs).

step 3

Place the syrup feed tubes into the pail con taining McD All Purpose Super Concentrate (APSC) (HCS) [1 packet in 2-1/2 gal. (9-1/2 litres)

of water = 100 PPM.] To avoid any contamination, cover the syrup containers with a plastic wrap.

step 4

Press STOP button. (LED On)

step 5

Press twice the “coloured cup” button to start the flow of McD All Purpose Super Concentrate (APSC) (HCS) through the syrup line.

step 6

Allow the McD All Purpose Super Concentrate (APSC) (HCS) to flow until all of the syrup is flushed out from the line.

step 7

Once the line is free of syrup, remove the syrup fe ed tube from the McD All Purpose Super Concentrate (APSC) (HCS) and run the pump until the

syrup line is free from liquid. step 8

Repeat steps 3 through 8 using McD Sanitizer (HCS) [1 packet in 2-1/2 gal. (9-1/2 liters) of water = 100 PPM].

step 9

Press the quick coupling connector (ref. 1a) to disconnect the syrup pickup tube from the pump tube.

step 10

Push on the quick coupling connector (ref. 1b) to disconnect the syrup feed tube from the pump tube.

step 11

Open the pump by pushing downwards the hinged cover (ref. 2).

step 12

Grasp the pump tube (ref. 385) from one end, pull it up and pull out the second end, then remove the pump tube.

Rif. 1a

Rif. 2

385

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Pump Tube Installation fase 1

Sanitize the new pumps tubes (ref.385) and lubricate the o-rings on the syrup line fittings.

fase 2

Place the pump tube into the pump body.

Fase 3

Pull up the pump cover to close it.

fase 4

Connect the syrup feed tube into the pump tube fitting.

fase 5

Connect the syrup pickup tube into the pump tube fitting.

fase 6

Replace the syrup jugs.

fase 7

Prime the syrup lines. Dispense one serving of syrup into a cup and discard this portion.

fase 8

Calibrate the syrup system according to the instructions in the equipment manual.

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9. TROUBLESHOOTING

9.1 ALARMS

The machine issues possible alarm messages on the display and makes the writing blink. In case of alarm which has reset, the writing will be on display in a fixed way (it will not blink).

To reset the writing, press Storage/Reset key

The machine can be used in ice cream production even if an alarm is active; if it is a critical alarm, the machine will not allow you to select ice cream production program; should this be the case, press STOP and do not use the machine till it is repaired.

Following find the alarm list:

DISPLAY DESCRIPTION CORRECTIVE ACTION Add Mix

Mix Out Spigot Opened Power on Wash In n days

Do Not Serve! No Topping Water

(Soft side only) Pasto needed!

Why in STOP ??

Hopper Temp Warm

Barrel Temp Warm

Hopper Temp High

Barrel Temp High

WINK (only machine with

Lonworks device)

Mix level is lower than the medium level sensor Mix level is lower than the low level sensor The back spigot is opened or out of seat Close the pigot A black out has occurred It indicates the days remaining for next cleaning; when “ Wash

today!” appears the machine must be disassembled, cleaned and sanitized. Press RESET button to reset the message on the display.

Product under process; please wait and don’t serve yet The Water in the topping bin is lower than the sensor level

The pasteurisation is not completed efficiently. run a pasteurization cycle until PASTO

If the machine is in Stop with the level covered, the blinking message “Why in Stop” will be displayed after 30’ and the acoustic intermittent alarm will be heard.

The timer activates in Production and Storage every 4 hours. If the temperature remains over 4°C for too long, the following message is displayed:

The timer activates in Production and Storage every 4 hours. If the temperature remains over 4°C for too long, the following message is displayed.

When on the second line on the display soft side appears the message “WINK”, it means that the restaurant manager checks the correct connection of the machine to the computer network. This message is displayed for a minute and it is accompanied by a beep. At the end of the minute the display returns to standard view.

Pour the mix in the hopper Pour the mix in the hopper

Add water in the topping bin

END appears to unlock the machine.

Push STOP then PROD .

Set the machine in Production,

Pasteurisation or Storage.

It may be cancelled by pressing the

Storage key. It’s an advise only.

It may be cancelled by pressing the

Storage key. It’s an advise only.

It may be cancelled by pressing the

Storage key. It’s an advise only.

It may be cancelled by pressing the

Storage key. It’s an advise only.

Wait 1 minute

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Following find the ALARM’S list:

WARNING

The technician’s intervention is necessary when the ALARM message occurs.

DISPLAY DESCRIPTION Safety Therm. Cyl

Safety Therm. Hop

Overload Beater Pressure Switch Overload Compres Al. Hopper Probe Al. Cylind. Probe Al. IceHop. Probe Al Evapor.Probe

Ice Cylinder

Timeout Prd. Belt Alarm

Invert Phases!

Al. Topping Probe (Soft side only)

Overload Mixer (Shake side only)

IMSA Open (Shake side only)

IMSB Open (Shake side only)

Level failure (Shake side only)

The safety thermostat of the cylinder intervened. The machine passes to STOP and doesn’t complete the pasteurisation cycle. The mix IS NOT pasteurised.

The safety thermostat of the hopper intervened. The machine passes to STOP and doesn’t complete the pasteurisation cycle. The mix IS NOT pasteurised.

The thermal relay intervened upon the beater’s motor. The pressure switch intervened. The thermal relay of the compressor’s motor intervened. The temperature probe of the hopper doesn’t work. The temperature probe of the cylinder doesn’t work. The sensor of the hopper’s vaporizer doesn’t work. The sensor of the cylinder’s vaporizer doesn’t work. This alarm may appear due to the scarce supply of the cylinder. Freezing problems, the product doesn’t harden. The beater in the hopper doesn’t work. It’s necessary to invert 2 phases in the three-phase supply line in order to make the beater’s rotation

direction correct. The temperature topping probe doesn’t work.

The thermal relay of the mixer intervened. The machine doesn’t pass to Stop but displays the alarm that remains on display only momentarily.

Carter of the actuator’s cover is opened.

The spinner’s cover is opened.

Indicates the anomalous functioning of the cup’s level sensor.

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Carpigiani K3-E Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual