MDH-302/402 & GENI/GENII
Series
Ice & Beverage Dispensers
Installation, Use & Care Manual
This manual is updated as new information and models are released.
Visit our website for the latest manual. www.manitowocfsg.com
Leader in Ice & Beverage Dispensers
Part Number 020002839 10/09
Safety Notices
! Warning
!
Caution
Important
!
Caution
Important
! Warning
Read These Before Proceeding:
As you work on Manitowoc equipment, be sure to pay
close attention to the safety notices in this manual.
Disregarding the notices may lead to serious injury and/
or damage to the equipment.
Throughout this manual, you will see the following types
of safety notices:
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
Text in a Caution box alerts you to a situation in
which you could damage the equipment. Be sure to
read the Caution statement before proc eeding, and
work carefully.
Procedural Notices
As you work on Manitowoc equipment, be sure to read
the procedural notices in this manual. These notices
supply helpful information which may assist you as you
work.
Proper installation, care and maintenance are
essential for maximum performance and troublefree operation of your Manitow oc equipment. Read
and understand this manual. It contains valuable
care and maintenance information. If you encounter
problems not covered by this manual, do not
proceed, contact Manitowoc Foodservice Group.
We will be happy to provide assistance.
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
NOTE: SAVE THESE INSTRUCTIONS.
Throughout this manual, you will see the following types
of procedural notices:
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will
not cause damage or injury, but it may slow you
down as you work.
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about th e pr oce dur e yo u
are performing.
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
Section 1
General Information
Read This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Installation Instructions
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MDH-302 & 402 Footprint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Location Requirements for Top Mounted Ice Machine Installations. . . . . . . . 2-3
Pre-installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
How To Read A Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Baffle for Manitowoc
Manual Fill Lid for Dispensers with aN Ice Machine . . . . . . . . . . . . . . . . . . 1-1
Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Bulk Syrup System also: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Double Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Also Consider The Location Of The Following Items Before Installation: . . 2-5
Additional Checks for Top Mounted Ice Machine Installations . . . . . . . . . . 2-5
Installing Baffle for Ice Machine Installations . . . . . . . . . . . . . . . . . . . . . . . 2-6
“S” Series Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
"Q" Series Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Minimum Circuit Amperage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pump Deck Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
®
Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Wat er Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Recommended Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Diagram Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
MDH-302 12 Valve Plumbing DIagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
MDH-302 12 Valve Flex Manifold (1 PER SIDE) . . . . . . . . . . . . . . . . . . . . . 2-10
MDH-402 16 Valve Plumbing DIagramS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
MDH-402 16 Valve Flex Manifold (1 PER SIDE) . . . . . . . . . . . . . . . . . . . . . 2-11
MDH-402 20 Valve Plumbing DIagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
MDH-402 20 Valve Flex Manifold (1 PER SIDE) . . . . . . . . . . . . . . . . . . . . . 2-12
CO2 System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Routing Internal Carb Tank Purge Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Step by Step Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Specifications Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
System Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Starting Your Beverage System & Dispenser. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Section 3
Operation
General System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
MDH-402 Cold Carbonation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Ice Recommended for Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Non-Adjustable Agitation Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Ice Storage and Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Carbonation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Syrup Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
B-I-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operation Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Ice Delivery Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Section 4
Maintenance
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Daily Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Monthly Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cleaning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Disassembly for Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Disassemble the Rocking Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Disassemble the Ice Crusher Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Monthly Ice Crusher Assembly Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
reassemble the Ice Crusher assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Gear Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Sanitizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Beverage System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Bag-In-Box System Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figal Beverage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Shipping, Storage and Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Section 5
Before Calling for Service
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
IcePic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Pump Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drink Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Liquid Level Control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table of Contents
Part Number 020002839 10/09 4
Section 1 General Information
!
Warning
S = Ice Only
SV = Ice/Beverage
NGF = Ice/Beverage
FRP = Ice/Beverage &
Integrated Flavor Shots
i = Intellicarb
CI = Ice Crusher (IcePic)
SCI = Selectable
Crushed Ice
Ice Capacity
Model Prefix
Model Suffix
Model Base
MDH–302– i
Section 1
General Information
Read This Manual
Manitowoc Beverage Equipment (MBE) developed this
manual as a reference guide for the owner/oper ator a nd
installer of this equipment. Please read this manual
before installation or operation of the machine. A
qualified service technician must perform inst allation and
start-up of this equipment, consult Section 5 within this
manual for service assistance.
If you cannot correct the service problem, call your MBE
Service Agent or Distributor. Always have your model
and serial number available when you call.
Your Service Agent ____________________________
Service Agent Telephone Number_________________
Your Local MBE Distributor ______________________
Distributor Telephone Number____________________
Model Number _______________________________
Serial Number ________________________________
Installation Date ______________________________
Unit Inspection
Thoroughly inspect the unit upon delivery. Immediately
report any damage that occurred during tr ansportation to
the delivery carrier. Request a written inspection report
from a claims inspector to document any necessary
claim.
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
Model Numbers
This manual covers the following models:
Beverage/Ice Dispensers
MDH-302, MDH-402, MDH-302 CI, MDH-402 CI
HOW TO READ A MODEL NUMBER
Accessories
BAFFLE FOR MANITOWOC® ICE MACHINE
When installing a Manitowoc Ice Machine on a
dispenser, a baffle kit is required for proper installation.
The baffle kit is designed to prevent ice from lying
against the front of the ice machine, and melting down
the front of the dispenser. There are two different baffle
kits available for “S” series ice machines, one kit is for
the 30" wide machine, and the other kit is for the 22"
wide machine. There is also a kit for “Q” series ice
machines.
Kits are available through your local distributor. List
prices may be subject to change without notification.
Please call your local parts distributor for current pricing
before ordering.
Part Number 020002839 10/09 1-1
MANUAL FILL LID FOR DISPENSERS WITH AN ICE MACHINE
If you are top mounting your dispenser with a ice
machine, you will require a lid for the manual fill area at
the top, front of the dispenser.
If you ordered a dispenser and a ice machine at the
same time, the manual fill lid was included with the unit.
The manual fill lid can be ordered from your local
distributor.
General Information Section 1
Label
LEGS
Legs are optional equipment with most MBE dispen sers.
Sta ndard legs a re 4" ( 10.2 cm) t a ll st ainless stee l legs. If
an ice machine is installed on top of the dispenser, legs
must not be installed. We do not recommen d using legs
when an ice machine is mounted on the dispenser. The
combined weight of the dispenser , ice and ice machine
is more evenly distributed when the base area of the
dispenser is in contact with the counter top.
Serial Number Location
This number is required when requesting information
from your local distributor. The serial number is listed on
the SERIAL NUMBER DECAL affixed to the dispenser.
Warranty Information
Consult your local MBE Distributor for terms and
conditions of your warranty. Your warranty specifically
excludes all beverage valve brixing, general
adjustments, cleaning, accessories and related
servicing.
Your warranty card must be returned to MBE to activate
the warranty on this equipment. If a warranty card is not
returned, the warranty period can begin when the
equipment leaves the MBE factory.
No equipment may be returned to MBE without a written
Return Materials Authorization (RMA). Equipment
returned without an RMA will be refused at MBE’s dock
and returned to the sender at the sender’s expense.
Please contact your local MBE distributor for return
procedures.
Serial Number Location
1-2
Part Number 020002839 10/09
Section 3 Operation
Section 3
Operation
General System Overview
NOTE:
This is a simplified schematic to
MDH Series
Internal Carbonation
Beverage Dispensing System
Tap Water
Tap Water
1
3
Dispenser
Carbonated/Non-carbonated
Beverage Manifolds
Carbonator Tank
SYRUP
75
1800
2
CO
2
CO
Cylinder
2
60
CO
2
show the basic operation of the
beverage system.
Countertop
BIB
Syrup Pump
SYRUP
Bag-In-Box
4
Syrup
Carton
Typical Internal Carbonation Beverage Dispensing System
NOTE:
This is a simplified schematic to
show the basic operation of the
SYRUP
SYRUP
beverage system.
Countertop
BIB
Syrup Pump
4
Bag-In-Box
Syrup
Carton
Typical MDH Ambient
System Overview
Tap Water
1
Tap Water
5
3
Carbonator
Tank
NON-CARBONATED WATER
CARBONATED WATER
Dispenser
w/Coldplate
SYRUP
SYRUP
90-
1800
100
60
CO
2
Cylinder
2
CO
CO
2
CO
2
2
Typical External Carbonation (Ambient) Beverage Dispensing System
Part Number 5010330 10/09 3-1
Operation Section 3
MDH-402 Cold Carbonation System
3-2
Typical MDH-402 Cold Carbonation Beverage Dispensing System
Part Number 5010330 10/09
Section 3 Operation
Merchandiser
Nozzles
Key Switch
Drainpan Grid
Drainpan
Splash Panel
Nozzles
Ice Chute
(Crushed Ice on
Nozzles
RECOMMENDED ICE OTHER ICE SIZES AND SHAPES
Dice
7/8" x 7/8" x 7/8"
(2.2 x 2.2 x 2.2 cm)
Half Dice
3/8" x 1-1/8" x 7/8"
(1.0 x 2.9 x 2.2 cm)
Contour
3/8" x 1-1/4" x 1-1/4"
(1.0 x 3.2 x 3.2 cm)
Mini
7/8" Dia. x 3/4" Long
(2.2 cm Dia. x 1.9 cm Long)
Gourmet-Small
1" Dia. x 3/4"
(2.5 cm Dia. x 1.9 cm)
Crescent Cube
0.75"
(1.9 cm)
0.38"
(1.0 cm)
1.13"
(2.9 cm)
1
RED
NO
2
3
6
4
5
COM NC
Component Identification
Sequence of Operation
ICE RECOMMENDED FOR DISPENSING
Dispensers are designed to dispense hard, cube ice up to
one-inch square. The ice shapes and sizes listed above are
recommended for dispensing. W arm “Sup er Cooled” Ice
Before Dispensing: “Super Cooled” ice is not recommended
for dispensing. “Super cooled” ice is ice th at has been stored
in freezers below 32°F. must it be necessary to temporarily
use “super cooled” ice, allow the ice to warm at room
temperature for 25 to 30 minutes before placing the ice in the
dispenser.
NOTE: Manitowoc Half Dice Ice has been shown to give the
best performance in the IcePic dispenser . Hoshizaki
America, Inc., ice machines with cresent-style shape cubes
are compatible with this dispenser but not recommended.
Part Number 5010330 10/09 3-3
NON-ADJUSTABLE AGITATION TIMER
The timer is non-adjustable and is set to agitate the ice for 3
seconds every 3.5 hours. Activating the dispenser will reset
the timer. After 3.5hours of non-use, the timer will energize
the dispenser motor .
The LED tells the technician in which mode the timer is
operating. Rather than a jumper pin, this timer has a female
spade connector that must be connected to terminal number 6.
When this jumper is in place, the LED will blink at one
second intervals, this is the run mode.
When the jumper is open, the LED will flash every
0.4 second. This is the test mode and the timer will cycle
every 55 seconds in test mode. If the timer is left in test
mode, it will automatically reset to run mode.
Operation Section 3
ICE STORAGE AND DISPENSING
As the customer presses the rocking chute, the arm at the
top left rear of the chute pushes upward on the door lock.
The door opens until it contacts the sto ps in the mounting
brackets. The plastic arm on the ice chute also activates the
lever of the ice dispensin g switch. When activated, the micro
switch starts the gear motor. The gear motor turns the
paddle wheel and agitator arm.
The paddlewheel carries ice. Periodic agitation is standard
on the 30" and larger dispensers. During periodic agitation,
the paddle wheel and agitator turn for approximate ly three
seconds every three and one half-hours. The door lock
prevents ice from being dispensed during the ag itation cycle.
Rocking Chute Ice Dispensing
As the customer presses the rocking chute, the arm at
the top left rear of the chute pushes upward on the door
lock. The door opens until it contacts the stops in the
mounting brackets. The plastic arm on the ice ch ute also
activates the lever of the ice dispensing switch. When
activated, the micro switch starts the gear motor. The
gear motor turns the paddle wheel and agitator bar.
Crushed Ice Dispensing
As a customer presses the ice chute the rocking chute
door lifts and actuates micro switch which initiates the
crushed ice dispensing process. When activated, the
micro switch starts the gear motor and ice crusher motor .
The gear motor turns the paddle wheel and U-bar
agitator. The paddle wheel carries ice to the crusher
assembly. Once the ice reaches the crusher housing,
four stationary blades and three rotating blades crush
the ice and push it through the opening in the ice crusher
housing. The crushed ice then falls through the opening
into the ice chute, and into the customer’s cup.
Operation
Carbon Dioxide (CO
) leaves the storage tank and
2
arrives at the carbonator tank through the gas inlet.
Water supply enters the carbonator pump inlet at regular
street water line pressure (minimum 20 PSI, maximum
80 PSI, dynamic or flowing pressure). The water pump
increases the pressure of the water, which allows the
water to flow into the carbonator tank. The CO
and the
2
water mix together in the carbonator to produce the
carbonated water that is then sent to the soda dispenser.
The agitation of the water and CO
together in the tank
2
under high pressure creates the soda water. The quality
of carbonation (percent of CO
mixed in the water)
2
increases as the water temperature decreases and
exposure time increases.
The water level in the carbonator tank is controlled by a
water level control in the tank. This control turns the
pump motor off and on to maintain a preset level of liqu id
in the tank. The water level control may be electronic
probes or a mechanical float.
SYRUP DELIVERY SYSTEM
Your syrup location can vary depending on the volume of
beverages served and ease of accessibility. Your beverage
system may set in a back storage room or under the
counter of the dispenser. Configurations are almost
limitless. Check the temperatures expected for the storage
location. Adverse temperatures can affect the storage and
quality of beverage products. It is recommended the
temperature of storage location should not fall below 40°F
(4°C) or rise above 90°F (32°C).
CARBONATION
The purpose of the carbonator is to take regular tap
water at street water pressure (minimum 20 PSI,
maximum 80 PSI, dynamic or flowing pressure) 1/2"
water line and increase the water to beverage system
pressure (usually 100 PSI). This water is then combined
with the CO
same pressure, the CO
gas. Because the water and gas are at the
2
will dissolve into the water.
2
Chilling the mixture before dispensing will assist in
locking the carbon dioxide into the water. After
dispensing, the CO
The CO
will gradually leave the liquid due to pressure
2
may be unlocked from the liquid.
2
and temperature changes.
Components
The components of the carbonator are: water pump, an
electric motor to operate the pump, carbonator tank
where the water and CO
mix, and a water level control.
2
3-4
Part Number 5010330 10/09
Section 3 Operation
From Water Supply
T o Noncarbonated W ater Inlet Barb
Water to Carbonator Pump
Filter
Water Regulator 40–70 PSI
Booster System (If Required)
To CO
2
Manifold (BIB
Pumps) from
CO
2
Supply
70 PSI
To Syrup Inlet
Barbs on Unit
To BIB Pumps
from BIB
To BIB
Pump
BIB
Back Room Package
1. Incoming tap water - should be at a minimum
dynamic pressure of 40 psi and maximum static
pressure of 70 psi.
2. Carbonator Water pump motor - Powers the water
pump. The water pump motor is part of the
carbonator pump deck.
3. Carbonator Water pump - Pumps t ap water into the
carbonator tank. The water pump is part of the
carbonator . The incoming water for the carbonator
must be first run through the pump before
connecting to the proper cold plate inlet.
4. Internal/External Carbonator tank - Combines
CO
gas and tap water to form carbonated water.
2
The “carbonator” is the carbonator tank, water pump
and water pump motor.
5. CO
6. BIB pressure gauge - Set for 75 psi. Indicates CO
7. Primary pressure regulator - Lowers the CO
cylinder - Holds highly pressurized carbon
2
dioxide (CO
aluminum cylinder tank. CO
primary pressure regulator.
pressure going to B-I-B pumps.
pressure, to 100 psi, so the CO
proper pressure to enter the carbonator regulator.
). The CO2 cylinder is a steel or
2
gas flows through the
2
gas will be at the
2
gas
2
8. Lowered outgoing pressure - Set for 75 psi.
Gauge indicates lowered outgoing pressure from the
CO
cylinder after being routed through the primary
2
pressure regulator at 100 psi.
9. Secondary pressure regulator - Lowers the CO
gas pressure before the CO
pump. CO
pressure activates the syrup pump.
2
gas flows to the syrup
2
10. Syrup pump - Draws syrup out of the bag-in-box
syrup package. Syrup flows through the syrup lines
to the dispenser for chilling, then dispensing. There
is a syrup pump for each bag-in-box syrup system.
11. Bag-In-Box syrup cartons - Box which contains a
plastic bag, filled with syrup.
Racking
Regardless if you are working on a B-I-B or Figal system, a
place will be designated for placement of the product. A rack
(or shelf) system affords systematic placement and
complete usage of the beverage paid for. The B-I-B rack
allows the boxes to lay properly for syrup dispersal. Please
check with your B-I-B syrup supplier. Some boxes must be
2
slightly tilted down, while others may be in virtually any
position. The Figal tank rack keeps the newer an d full tanks
organized at one end of the beverage line with the partial
tanks at the other .
2
Part Number 5010330 10/09 3-5
Operation Section 3
Carbonated Water to
3/8 Syrup Lines to
Incoming
Water
Carbonato
100
CO
2
Soda Water
Pump
Door
Stops
Door Lock
Door
Ice
Delivery
Switch
Door
Stops
Door
Door Lock
1/16"
to
1/4"
Tab
Switch Arm
B-I-B
The Bag-In-Box system refers to a plastic disposable bag.
The B-I-B normally contains 5 gallons of syrup, however
some locations offer 2-1/2 gallon B-I-B unit s. This plastic bag
is then held inside a cardboard or other container. B-I-B
systems are for post-mix applications only .
Pumps
The syrup in a B-I-B system is delivered to the beverage
system through gas operated pumps. These pumps extract the
syrup out of the bags, forcing the syrup throughout the system.
Auto Bag Selectors
These are used on higher volume B-I-B systems where two
or more bags of the same product are connected to one
pump and one system. An auto bag selector is essentially a
valve that automatically changes from one bag (or series of
bags) to another bag (or series of bags) of syru p as the bags
empty, allowing a constant flow of product.
FIGAL SYSTEM
Figal refers to the stainless steel tanks of pre-mix bevera ge
or post-mix syrup. A small CO
tank pushes the beverage
2
out of the figal tank.
Most Figal tanks have a self-closing valve on the tank as well as
the gas and syrup connectors. This allows the operator of the
system to change tanks without having to shut down the entire
system. With this type of connector, push dow n on the
connector while pulling up on the snap ring around the opening
of the connector. Then simply pull the connector off the tank.
Operation Checks and Adjustments
ICE DELIVERY SWITCH ADJUSTMENT
To properly adjust the switch, first unplug the power cord
to the unit then remove the merchandiser. This will give
you access to the ice delivery switch located on the left
side of the rocking chute.
Tanks
The stainless steel Figal beverage tanks are easy to store
and connect. When using the Figal tanks:
• Use a gas connector for the inlet fitting of the tank.
• Use a syrup connector for the outlet fitting of the tank.
• If more than one Figal tank is connected in series, when
changing tanks, remove the tank closest to the original
gas inlet while adding the new tank to the connector
closest to the syrup outlet.
3-6
Begin by observing the chute by slowly pushing against
the rocking chute. When the ice delivery switch clicks,
measure the distance from the door stop s on the rocking
chute bracket to the door. The distance between the two
must be no more than 1/4" (0.64 cm), but no less than
1/16" (0.16 cm).
The left side of the rocking chute has a tab that pu shes up on
the ice delivery switch. T o adjust it, use needle nose pliers and
bend the arm of the switch up or down in order to change the
point where the tab makes contact with the switch arm.
Part Number 5010330 10/09
General
Important
Section 2
Installation Instructions
These instructions are provided to assist the qualified
installer. Contact your Manitowoc Beverage Equipment
Service Agent or call Manitowoc Beverage Equipment
for information regarding start-up service s.
Dimensions
Failure to follow these installation guidelines may
affect warranty coverage.
MODELABCDE
MDH-302* 42.75"
(108.59 cm)
MDH-402* 60.00"
(152.40 cm)
* Applies to IcePic models also (MDH-302 CI & MDH-402 CI)
Part Number 5010330 10/09 2-1
30.50"
(77.47 cm)
30.50"
(77.47 cm)
22.50"
(57.15 cm)
22.50"
(57.15 cm)
38.75"
(98.43 cm)
56.50"
(143.51 cm)
20.50"
(52.07 cm)
21.25"
(53.98 cm)
Installation Instructions Section 2
Minimum Area
for Cutout
Maximum Area
for Cutout
D
C
B
A
!
Caution
MDH-302 & 402 Footprint
Model
MDH-302* 38.75"
MDH-402* 56.50"
ABCD
(98.43 cm)
(143.51 cm)
Maximum Minimum
Cutting the countertop may decrease its strength.
Counter must be braced to support the dispenser
countertop weight plus ice storage capacity and
weight of icemaker, if applicable.
* Applies to IcePic models also (MDH-302 CI & MDH-402 CI)
(52.07 cm)
(54.36 cm)
20.50"
21.40"
3.00"
(7.62 cm)
3.00"
(7.62 cm)
32.00"
(81.28 cm)
48.00"
(121.92 cm)
2-2
Part Number 5010330 10/09
Section 2 Installation Instructions
!
Warning
Location
The location selected for the beverage dispenser must
meet the following criteria. If any of these criteria are not
met, select another location.
• The air temperature must be at lea st 50°F (10°C), but
must not exceed 95°F (35°C).
• The location must not be near heat-generating
equipment or in direct sunlight and must be protected
from weather.
• The countertop must be level. V erify that the
countertop can support the weight of the dispe ns er,
or the dispenser/ice machine combination plus the
weight of the stored ice.
• Wate r lines, drains and power outlet must be within 6'
(1.8 m) of location.
Carbon Dioxide (CO2) displaces oxygen. Exposure
to a high concentration of CO
which are followed rapidly by loss of con sciousness
and suffocation. If a CO
particularly in a small area, immediately ventilate the
area before repairing the leak. CO
must not be installed in an enclosed space. An
enclosed space can be a cooler or small room or
closet. This may include convenience stores with
glass door self serve coolers. If you suspect CO
may build up in an area, venting of the B-I-B pumps
and / or CO
monitors must be utilized.
2
gas causes tremors,
2
gas leak is suspected,
2
lines and pumps
2
2
Location Requirements for T op Mounted Ice Machine Installations
Location — Avoid placing the dispenser and/or ice
machine near heat sources such as radiators, ovens,
refrigeration equipment and direct sunlight.
Clearances — Refer to the ice machine installation
manual for clearances.
Front of ice machine to be flush with front of
dispenser — Some ice machines may overhang at the
back of the dispenser.
Drains — A separate drain line is required for the ice
machine, in addition to a drain line for the ice/beverage
dispenser.
Dispensers may require an adapter kit to install some
top-mounted ice machines. Contact your local distributor
for the correct adapter kit.
For full information about ice machine installation,
including clearances, plumbing lines, connections,
and electrical requirements, see the ice machine
installation manual.
Part Number 5010330 10/09 2-3
Installation Instructions Section 2
Pre-installation Checklist
When installing any system, first make sure the major components are available. Generally the major components
necessary for an installation are:
Pre-mix System:
Post Mix System:
regulator set
CO
2
Product connectors for Figal tank
Gas connectors for Figal tank
Beverage dispenser
Beverage tubing
tank
CO
2
Figal beverage tanks
Stepless (Oetiker) clamps
CO2 regulator set
Beverage dispenser
Beverage tubing
tank
CO
2
Carbonator
Stepless (Oetiker) clamps
Chain for CO
Figal System also:
tank
2
Chain for CO
B-I-B System also:
B-I-B connectors
B-I-B regulator set
B-I-B rack
B-I-B syrup boxes
2-4
tank
2
Syrup connectors for Figal tank
Gas connectors for Figal tank
Figal syrup tanks
Bulk Syrup System also:
Syrup connectors for Bulk tank
Gas connectors for Bulk tank
Bulk syrup tanks
Part Number 5010330 10/09
Section 2 Installation Instructions
6" (15.2 cm)
clearance
for cuber
cuber
6"
(15.2 cm)
6"
(15.2 cm)
6" (15.2 cm)
6" (15.2 cm)
DOUBLE CHECK:
Do you have enough space to install the
dispenser or a dispenser and top mounted ice
machine?
Does top mounted ice machine (if utilized) have
a minimum of 6 inches (15.3 cm) clearance on
all sides?
Is the countertop level?
Can the countertop support the weight of the
dispenser, or the dispenser/ice machine
combination plus the weight of the stored ice?
ALSO CONSIDER THE LOCATION OF THE FOLLOWING ITEMS BEFORE INSTALLATION:
Water line
Drain
ADDITIONAL CHECKS FOR TOP MOUNTED ICE MACHINE INSTALLATIONS
Location — Avoid placing the dispenser and/o r
ice machine near heat sources such as
radiators, ovens, refrigeration equipment and
direct sunlight.
Clearances — Six inch (15.2 cm) clearance on
all sides of the icemaker is needed.
Front of icemaker to be flush with front of
dispenser — The front of the icemaker must be
flush with the front of the dispenser. When the
icemaker is flush with the front of the dispenser,
some icemakers may overhang at the back of
the dispenser.
Drains — A separate drain line is required for
the ice machine, in addition to a drain line for
the ice/beverage dispenser.
Dispensers may require an adapter kit to install
some top-mounted icemakers. Contact your
local distributor for the correct adapter kit.
Power outlet
Heating and air conditioning ducts
For full information about icemaker installation,
including plumbing lines connections and electrical
requirements, see the icemaker installation manual.
Part Number 5010330 10/09 2-5
Installation Instructions Section 2
Backing Plate
to Be Inserted
Into Side
Pocket of
Bulkhead
Screws
Screws
New Ice Baffle
Backing Plate
to Be Inserted
Into Side
Pocket of
Bulkhead
Baffle, Manitowoc Ice
Machine
0.69"
(1.7 cm)
Ref.
6.32"
(16.0 cm)
Ref.
7.22"
(18.3 cm)
Ref.
Assembly
INSTALLING BAFFLE FOR ICE MACHINE INSTALLATIONS
“S” Series Baffle
1. Remove both front panels.
2. Examine the ice machine to see if the machine has
four screws on the lower front plastic panels.
3. If there are screws, remove the m from the
countersunk holes on the front surface of the
machine, save the screws.
4. Install the deflector, using the four screws removed
in step three.
5. Four screws and two backing plates are in the kit.
6. If there are no screws on the ice machine (step 2),
pierce the thin plastic countersunk holes, install the
backing plates and install the deflector using the
screws from the kit.
7. Replace the front panels.
"Q" Series Baffle
1. Position baffle on top of water well with tab on the
front and the other tab inside the water well.
2. Mount the baffle on the left side of the ice machine
using the hole and screw provided.
"Q" Series Ice Machine
"S" Series Ice Machine
2-6
Part Number 5010330 10/09
Section 2 Installation Instructions
!
Warning
Important
!
Warning
!
Warning
Electrical
GENERAL
All wiring must conform to local, state and national codes.
MINIMUM CIRCUIT AMPACITY
The minimum circuit ampacity is used to help select the
wire size of the electrical supply. (Minimum circuit
ampacity is not the beverage/ice machine’s running amp
load.) The wire size (or gauge) is also dependent upon
location, materials used, length of run, etc., so it must be
determined by a qualified electrician.
ELECTRICAL REQUIREMENTS
Refer to Ice Machine Model/Serial Plate for voltage/
amperage specifications.
VOLTAGE
The standard voltage for MDH Series dispensers is
120VAC-60Hz. A power cord is provided with 120VAC60Hz models only. MDH Series dispensers use a 1/7 hp
gearmotor.
MINIMUM CIRCUIT AMPERAGE CHART
Due to continuous improvements, this information is
for reference only. Please refer to the dispenser
serial number tag to verify electrical data. Serial tag
information overrides information listed on this page.
Grounding Instructions
Risk of electrical shock. Connect to a properly
grounded outlet only.
This appliance must be grounded. In the event of
malfunction or breakdown, grounding provides a path of
least resistance for electric current to reduce the risk of
electric shock. This appliance is equipped with a cord
having an equipment-grounding conductor and a
grounding plug. The plug must be plugged into an
appropriate outlet that is properly installed and grounded
in accordance with all local codes and ordinances.
Improper connection of the equipment-ground ing
conductor can result in a risk of electric shock.
The conductor with insulation having an outer
surface that is green with or without yellow stripes
is the equipment grounding conductor. If repair or
replacement of the cord or plug is neces sary, do
not connect the equipment-grounding conductor
to a live terminal. Check with a qualified electrician
or serviceman if the grounding instructions are
not completely understood, or if in doubt as to
whether the appliance is properly grounded. Do
not modify the plug provided with the appliance —
if it will not fit the outlet, have a proper outlet
installed by a qualified electrician.
Dispenser Voltage/Cycle
MDH-302
MDH-302 w/EM
MDH-402
MDH-402 w/24" EM
MDH-402 w/34" EM 220-240/50 5.0 FLA
Part Number 5010330 10/09 2-7
115/60 3.5 FLA
220/50, 220/60,
240/50, 240/60
220-240/50 4.5 FLA
Minimum
Circuit Amps
4.0 FLA
Installation Instructions Section 2
!
Warning
PUMP DECK WIRING
The supply cord is equipped with a three prong 5-15P.
When using electric appliances, basic precautions
should always be followed, including the following:
a. Read all the instructions before using the
appliance.
b. To reduce the risk of injury, close
supervision is necessary when an
appliance is used near children.
c. Do not contact moving parts.
d. Only use attachments recommended or
sold by the manufacturer.
e. Do not use outdoors.
f. For a cord-connected appliance, the
following shall be included:
• Do not unplug by pulling on cord. To
unplug, grasp the plug, not the cord.
• Unplug from outlet when not in use and
before servicing or cleaning.
• Do not operate any appliance with a
damaged cord or plug, or after the
appliance malfunctions or is dropped or
damaged in any manner. Contact the
nearest authorized service facility for
examination, repair, or electrical or
mechanical adjustment.
g. For a permanently connected appliance —
Turn the power switch to the off position
when the appliance is not in use and before
servicing or cleaning.
h. For an appliance with a replaceable lamp —
Always unplug before replacing the lamp.
Replace the bulb with the same type.
When a Ground Fault Circuit Interrupter (GFCI) is
required by code, a breaker type protector must be
used. We do not recommend GFIC outlets as they are
known for more intermittent nuisance trips than panel
breakers. To ensure both the safety and proper
operation of this equipment, be certain th at the electrical
receptacle is a proper design so as to accept this plug,
ensuring that the carbonator assembly is properly
grounded.
If the pump deck is to be installed in an area or
community whose local codes require permanent wiring,
the following procedure must be followed.
1. The three wires (white, black and green) must be fed
through the cable connector and brought into the
wiring compartment. The cable must be secured into
the connector.
2. The green wire from the cable must be connected to
the green screw that attaches to the inside panel of
the wiring compartment. Be sure to use a ring torque
terminal for connecting the wire to the screw.
3. The white wire from the cable must be joined to the
N terminal of the liquid level control board by a
suitable U.L. listed insulated cable connector.
The black wire from the cable must be joined to the L1
terminal of the liquid level control board by a suitable
U.L. listed insulated cable connector.
2-8
i. For a grounded appliance — Connect to a
properly grounded outlet only. See
Grounding Instructions.
Part Number 5010330 10/09
Section 2 Installation Instructions
Splash Panel
Plumbing
Diagram
Plumbing
Diagram
Water Supply
RECOMMENDED PLUMBING
The plumbing diagram is printed on a white vinyl label,
normally located above the inlet tubes for syrup and
water. The plumbing diagram label can be accessed by
removing the splash panel of the dispenser. The
plumbing diagram label explains which inlet coldplate
fittings supply which dispenser valves and water
manifolds.
The water supply must first be connected to the
carbonator pump (not shown) before plumbing to
connection “A” shown on plumbing diagram. The
carbonator pump deck must be within six feet of the
dispenser for optimum performance. See BIB inst allation
diagram for system pressure settings.
A check valve must be installed in the water supply
line 3 feet from the noncarbonated water connect ion
“PW”. Contact factory if not installed.
DIAGRAM LOCATION
PLUMBING
DIAGRAM
PLUMBING
DIAGRAM
Part Number 5010330 10/09 2-9
Installation Instructions Section 2
MDH-302 12 VALVE PLUMBING DIAGRAM
MDH-302 12 VALVE FLEX MANIFOLD (1 PER SIDE)
2-10
Part Number 5010330 10/09
Section 2 Installation Instructions
LEFT RIGHT
MDH-402 16 VALVE PLUMBING DIAGRAMS
MDH-402 16 VALVE FLEX MANIFOLD (1 PER SIDE)
Part Number 5010330 10/09 2-11
Installation Instructions Section 2
LEFT RIGHT
MDH-402 20 VALVE PLUMBING DIAGRAM
MDH-402 20 VALVE FLEX MANIFOLD (1 PER SIDE)
2-12
Part Number 5010330 10/09
Section 2 Installation Instructions
Rear of Unit
90° Elbow Fitting
Radiator Clamp
Flexible Tubing
Straight Fitting
Radiator Clamp Flexible Tubing
Holes for beverage lines
Drainage Through Bottom Drainage Through Back
Rear View
Radiator Clamp
Holes for drain pan drain
CO2 System
ROUTING INTERNAL CARB TANK PURGE TUBE
Some models are equipped with an internal carbonation
tank.These models require that the purg e/pressure relief
tubing be routed to a drain.
1. Remove the splash panel.
2. Uncoil tubing and route between the front of the
dispenser and the drain pan.
3. Depending on drain location route the tubing
through the tubing bundle cutout or out the back of
the dispenser.
4. Verify the tubing is not kinked and then secure
tubing to maintain a minimum 1" (2.5 cm) air gap at
the drain. Follow any applicable local or national
codes.
DRAINS
Part Number 5010330 10/09 2-13
Installation Instructions Section 2
Important
Important
Step by Step Installation
GENERAL
MDH series dispensers have a stainless steel cabinet and
lighted merchandiser standard.
Beverage valves, coldplate connections, drain
connections and electrical components are front
serviceable.
CAPACITIES
Dispenser Valves Ice Storage
MDH-302 10 or 12 300 lbs
MDH-302 w/EM 10 or 12 300 lbs
MDH-402 16 or 20 400 lbs
MDH-402 w/24" EM 16 or 20 400 lbs
MDH-402 w/34" EM 16 or 20 400 lbs
SPECIFICATIONS CHART
MIN. MAX
Incoming Plain
Water Pressure
Plain Water Pressure
to Carb Tank
Ambient
Temperature
Co
2 Pressure
(Primary)
Electrical 115V/60 Hz/1 230V/50-60 Hz/1
Pre-mix Pressure
Normal 60 psi*
Diet 40 psi*
B-I-B (Secondary) 75 psi or according to line run
Flavor Shots 30 psi or according to line run
* This is the optimal pressure. For high foam, decrease the pressure,
for spitting/popping, increase the pressure.
UNIT INSTALLATION
1. Place the dispenser in the desired location.
NOTE: The unit must be placed and operated in a
horizontal, level position. This unit is not suitable for areas
cleaned with a water jet, pressure washers or water hoses.
40 psi dynamic 70 psi static
55 psi 65 psi
40°F
(4°C)
90 psi 100 psi
105°F
(41°C)
4. Fill bin with ice.
5. Set flexible manifold for correct drink settings.
6. Turn water supply on to the dispenser.
7. Purge air from the carbonator tank. Lift the pressure
relief valve tab on the carbonator tank until water
comes out of the relief valve.
8. Connect the pump deck control lead to the pump motor .
9. Connect power supply cords. (There are (2) two cords
that need to be connected to a 115V power supply.)
10. Brix beverage valves.
SYSTEM PRESSURES
1. Incoming tap water - must be at a minimum
dynamic pressure of 40 psi and maximum static
pressure of 70 psi.
If incoming water pressure is under 40 psi dynamic, a
water booster is recommended. If incoming water pressure
is over 55 psi, a water regulating valve is recommended.
NOTE: For water booster setups, connect directly to the
incoming water to the unit. A regulator may be n eeded to
maintain 40 - 55 psi to the carb onator or water may be
routed around the booster to the carbonator. If water
pressure is too high to the carbonator poor drink
carbonation can result.
Water boosters are preset to turn on a t 65 psi and o ff
at 85 psi.
2. BIB pressure gauge must be set for 75 psi or
according to your line run.
3. Carbonator Pressure gauge (Use Preset Regulator):
- Cold Carbonation set for 75 psi.
- Ambient systems must be set at 90 psi to 105 psi.
NOTE: For models with flavor shots you want to achieve
.5 oz (14.787 cc) a second dispense, adjust secondary
regulator or flow controls accordingly.
2. Run the beverage lines and water lines; make sure
to install the water connections to the proper inlets.
Connection “A” comes from the brass carbonator
pump and connection “B” is your plain water supply.
3. Install plumbing drains and insulate.
2-14
Part Number 5010330 10/09
Section 2 Installation Instructions
Important
Starting Your Beverage System & Dispenser
Upon completion of the beverage dispenser and / or
system installation, all tubing, dispenser, and system
components must be cleaned and sanitized prior to use.
NOTE: At installation, equipment, dispensers, and tubing
get moved through many environments, dirt, dust, chases,
insulation, drywall, etc. It is an important procedure and
best practice to address cleaning to deliver the best quality
drink to your customer.
Clean and sanitize the water and syrup circuits
according to instructions provided in this manual.
Clean and sanitize the dispenser components
according to instructions provided in this manual.
Seal to counter top when no legs are used with the
unit. Consult and use local health codes if a
discrepancy occurs between this manu al and your
local health codes.
Part Number 5010330 10/09 2-15
Installation Instructions Section 2
THIS PAGE INTENTIONALLY LEFT BLANK
2-16
Part Number 5010330 10/09
Section 4 Maintenance
!
Caution
!
Warning
!
Warning
Section 4
Maintenance
Cleaning
DAILY CLEANING
All cleaning must meet your local health department
regulations. The following cleaning instructions are
provided as a guide.
Use only warm soapy water to clean the exterior of
the tower. Do not use solvents or other cleaning
agents. Do not pour hot coffee into the drain pan.
Pouring hot coffee down the drain pan can
eventually crack the drain pan, especially if the
drain pan is cold or still contains ice.
Electric Shock Hazard
Unplug unit before servicing or cleaning.
Clean the dispensing valves:
6. Remove nozzles and diffusers from beverage
valves.
Nozzle Removal
7. Rinse nozzle and diffuser with warm, clean water.
8. Clean nozzles and diffusers with soapy water and a
soft bristle brush.
9. Clean the underside of the beverage valves with
warm, soapy water. Rinse with clean damp towel.
10. Replace nozzles and diffusers on valves.
When using cleaning fluids or chemicals, rubber
gloves and eye protection must be wor n.
Clean the exterior and drain pan:
1. Turn off the key switch located on either right or left
side of the unit.
2. Lift the grid and remove it from the drain pan.
3. Using mild soap, warm water and a clean cloth, wipe
the drain pan and splash panel. Then, rinse with
clean, warm water. Allow plenty of warm (not hot)
water to run down the drain of the drain pan, to
remove syrup residue that can clog the drain
opening.
4. Wash the grid, then rinse with clean water . Place the
grid back in the drain pan.
5. Wash all exterior surfaces of the unit with warm
water and a clean cloth. Wipe again with a clean, dry
cloth.
11. Turn on the key switch.
Part Number 5010330 10/09 4-1
Maintenance Section 4
!
Warning
!
Warning
MONTHLY CLEANING
Unplug unit before servicing or cleaning ice bin.
Ice bin contains part s tha t can move at any time and
will cause injury if hands are in the way.
When using cleaning fluids or chemicals, rubber
gloves and eye protection must be worn .
Clean and sanitize the ice bin:
1. Unplug unit and remove all ice from the ice bin.
2. Mix a solution of mild detergent to clean the
dispenser bin and components.
3. Wash the ice bin using a sponge and the mild
detergent solution.
4. Using the mild detergent solution and a soft bristle
brush or clean cloth, clean the following dispenser
parts:
• Entire bin
• Paddle wheel
• Paddle wheel area
6. Prepare 2 gallons of sanitizing solution by mixing
1/2 ounce of household bleach (that contains 5.25 %
sodium hypochlorite) with 2 gallons of 120°F water.
The mixture must not exceed 100 PPM of chlorine.
Or mix a solution of any approved sanitizer,
following the directions for mixing and applying the
sanitizer.
7. Sanitize the ice bin and cold plate with the sanitizing
solution for at least 10 seconds.
8. Allow to air dry. Do not rinse.
Re-assembling the dispenser parts:
9. Re-assemble parts in the following order:
• Bin liner
• Paddle wheel
•Agitator
• Paddle wheel pin
• Ice chute
• Merchandiser
10. Hand tighten all knurled fastene rs.
11. Pour in fresh, sanitary ice and replace the plastic lid
on the top of the dispenser.
12. Plug in the unit’s electrical cord.
13. Check for proper ice dispensing.
•Agitator
• Paddle wheel pin
• Ice Chute
• Rear bushing
• Motor shaft
• Strip lids (where applicable)
5. Rinse all the parts in clean, running water.
CLEANING CHECKLIST
•Check CO
the primary regulator gauge will point to a shaded
area that reads “Low CO
Cylinder.”
• Check syrup supply.
• Clean drain pan, grid, and splash panel.
• Clean the valve nozzles and diffusers.
supply . If CO2 supply is low, an arrow on
2
” or “Change CO2
2
4-2
Part Number 5010330 10/09
Section 4 Maintenance
Preventive Maintenance
Preventative maintenance is a vital part of keeping your
dispenser in top condition. Following the guidelines
below will assist you in continued trouble-free operation
of your unit.
1. Conduct daily maintenance of the machine.
2. Perform monthly maintenance of the machine.
3. Perform periodic maintenance and sanitizing of
beverage system.
4. Do not overfill the dispenser bin with ice.
5. Do not allow the dispenser to sit for prolonged
periods of non use with ice in the bin.
6. Most ice dispenser service problems are caused by
low usage of the ice dispenser.
7. Do not allow ice to remain in the bin more than a day
in order to prevent ice from freezing together and/or
stagnant ice.
Possible excess ice storage reasons:
• Storage capacity exceeds daily requirements.
• Low demand during the off season.
• Dispenser oversized with future growth in mind.
Lower ice storage to meet one day’s needs. If you
manually fill ice, fill only with the appropriate amount of
ice. Fill the dispenser with fresh ice each morning. Do
not fill the dispenser at night just before shut down. Ice
cubes can freeze together if not dispensed.
Disassembly
DISASSEMBLY FOR CLEANING AND MAINTENANCE
NOTE: Sanitize the ice dispenser at Initial Start-up in
addition to monthly sanitizing. You will need a slotted
screwdriver in order to disassemb le.
Disassemble parts in the following order:
A. Merchandiser
B. Ice chute
C. Paddle wheel or agitator pins
D. Agitator
E. Paddle wheel
F. Bin liner
G. Paddle wheel area
Beverage/Ice Dispenser
Accessing a Dispenser Bin Top Mounted with a
Manitowoc Ice Machine:
1. Remove the front panel of the ice machine.
2. Remove the ice deflection baffle. This will give you
access to the dispenser bin.
3. If the Manitowoc ice machine is operating, wait for
the sheet of ice to fall into the dispenser bin.
Accessing a Dispenser Bin that is Top Mounted with a
Manitowoc Ice machine and Large Extended
Merchandiser in front of the Ice machine:
4. Access to the bin is possible through the strip lids on
the side of the Dispenser.
Disassembling the Dispenser Parts for Bin Cleaning:
5. Remove the front panel of the Manitowoc ice
machine.
6. If the Manitowoc ice machine is operating, wait for
the sheet of ice to fall into the dispenser bin.
When the ice sheet falls into the dispenser bin,
immediately place toggle switch of the ice machine to
the OFF position. If the Manitowoc ice machine is NOT
operating, place the toggle switch of the ice machine to
the OFF position now.
Part Number 5010330 10/09 4-3
Maintenance Section 4
7. On MDH models without a top mounted ice
machine, remove the plastic lid from the top of the
dispenser.
8. Remove all ice from the dispenser.
9. Disconnect electrical power to the dispenser.
10. Remove the strip lids off the top left and top right of
the dispenser bin.
1 1. There is a left bin an d a right bin on both the 302 an d
402 models. Clean and sanitize one bin, then follow
the same procedures on the second bin.
Non-front Serviceable Motor
a. Rotate the agitator arm so the paddle wheel pin
handle is pointing up, toward the ceiling.
b. Prepare agitator pin for rem oval by removing the
stainless steel split ring.
c. Then remove the paddle wheel pin from the hole
in the agitator.
d. Push the agitator bar toward the back of the unit
until the agitator is free of the paddle wheel hub.
Front Serviceable Motor
a. With agitator arm in any position remove hitch
clip pin from the mushroom bushing on the rear
of the ice bin.
b. Push the agitator bar toward the bushing to
remove it from the paddle wheel hub.
NOTE: If a top mount ice machine is installed, sliding the
ice machine to one side will make bin component
removal easier. If the ice machine is hard plumbed it will
need to be disconnected.
12. Remove paddle wheel, bin liner and paddle wheel area.
13. Move the front of the agitator to one side and slide
the agitator forward until the rear of the agitator shaft
is clear of the bushing.
14. Remove the agitator from the bin area.
15. Slide the paddle wheel from its shaft.
16. Loosen the four knurled fasteners that hold the bin
liner in place.
17. Remove the bin liner.
18. Remove the paddle wheel area from the bin.
19. Discard the remaining ice in the bin.
DISASSEMBLE THE ROCKING CHUTE
1. Loosen the two knurled fasteners that hold the
merchandiser in place.
2. Remove the merchandiser.
3. Remove outer bracket.
4. Remove door lock.
5. Remove door.
6. Remove ice chute.
Front Serviceable
4-4
DISASSEMBLE THE ICE CRUSHER ASSEMBLY
NOTE: These instructions cover both GENI & GENII crushers.
1. Unplug unit before cleaning or servicing the crusher
assembly.
Non-front Serviceable
Part Number 5010330 10/09
Section 4 Maintenance
GENII Only
COTTER PIN
CHUTE ROD
DECORATIVE
CHUTE
GENI
GENII
GENI & GENII drip pans
are the same, GENII is
illustrated on the left.
GENI & GENII blade
assemblies are the
same, GENII is
illustrated on the left.
2. Remove the merchandiser . The merchandiser is
removed by taking out the two (2) screws located at the
top of the merchandiser. Once the screws are removed,
lift and rotate the top of the mer chandiser towards you
and then remove the merchandiser from the unit.
NOTE: When the merchandiser is removed an electrical
safety switch kills power to the entire unit.
3. Remove Rocking Chute Door.
4. Remove the decorative ice chute by pulling the cotter
pin out on the right side of the chute rod and pulling the
chute rod toward the left side of the dispenser.
6. See the following steps to remove the ice crusher
blade assembly from the crusher hous ing .
A. Unlock the crusher hub from the crusher
housing by pulling the locking tab out and
rotating the hub clockwise.
B. Pull the hub and blade assembly out of the
housing approximately one half inch (½”) to
disengage the crusher axle from the motor shaft.
C. Rotate the knob on the crusher axle so it is in a
vertical position. (This will assure the rotating
blades will not interfere with pulling the blade
assembly from the housing.)
D. Now the blade assembly will be free from the
housing and you will be able to completely
5. Remove the crusher drip pan by pulling up slightly on the
remove the blade assembly from unit.
crusher assembly and pulling the drip pan away from the
foam front.
Part Number 5010330 10/09 4-5
Maintenance Section 4
HOUSING DOOR
COSMETIC CHUTE
HOUSING
BLADE/HUB
ASSEMBLY
MOTOR SHAFT
DRIP PAN
GENI
GENII
MONTHLY ICE CRUSHER ASSEMBLY CLEANING
Once the ice crusher hub assembly has been removed the
crusher is ready to be cleaned and sanitized. Follow the
steps below for proper cleaning and sanitizing procedures .
1. Assure the unit is unplugged.
2. Mix a solution of mild detergent to clean the ice
crusher components.
ROCKING CHUTE DOOR
HOUSING
BLADE/HUB
ASSEMBLY
MOTOR SHAFT
4. Rinse all of the parts with clean water.
5. Prepare 2 gallons of sanitizing solution by mixing a ½
ounce of household bleach (that cont ains 5.25% sodium
hypochlorite) with 2 gallons of 120 F water . The mixture
should not exceed 100 PPM of chlorine. Or mix a
solution of any approved sanitizer , following the
directions for mixing and applying the sanitizer.
6. Apply sanitizer to all parts with clean cloth, or by
spraying.
7. Allow to air dry. DO NOT RINSE.
8. Reassemble the Ice Crusher Assembly by following
the instructions in the "Reassembling the Ice
Crusher Assembly" section.
9. Insert the blade assembly into crusher housing.
When inserting blade assembly you must align the
stationary blades with the locating slots in the
crusher housing.
10. When inserting the blade assembly into the crusher
housing you must also make sure the axle knob is in
a vertical position. This will align the rotating blades
with the housing to assure a quick and easy
installation.
11. Once all blades are in the housing you will need to
align the crusher axle with the motor shaft. You can
do this by turning the axle knob and pushing the
blade assembly toward the motor until the cru sh er
hub is flush with the end of the housing.
12. To lock the blade assembly into the housing rotate
the crusher hub counter clockwise until the locking
tab snaps into place and the crusher hub is secure.
13. Replace the crusher drip pan, slide until it snaps into
place.
3. Using the mild detergent solution and a soft bristle
4-6
DRIP PAN
COSMETIC CHUTE
brush or clean cloth, clean the following ice crusher
components.
• Blade / Hub assembly
• Cosmetic Chute
•Drip Pan
• Crusher Housing
• Ice Crusher Motor Shaft
• Rocking Chute Door
14. Reattach the decorative ice chute by inserting the
chute rod through the chute, Housing Mo un t, an d
Motor Mount. Secure the Chute Rod by inserting
cotter pin through the rod on the right side of the
housing mount. Make sure arm of microswitch is in
front of vertical protrusions on top of decorative
chute.
15. Reinstall the Rocking Chute Door.
16. Reinstall the merchandiser, and secure with the two
(2) screws that were removed during disassembly.
17. 110V power may be reapplied when unit is
completely reassembled.
Part Number 5010330 10/09
Section 4 Maintenance
GENI & GENII blade
assemblies are the
same, GENII is
illustrated on the left.
GENI & GENII drip pans
are the same, GENII is
illustrated on the left.
GENI
GENII
GENII Only
REASSEMBLE THE ICE CRUSHER ASSE MBLY
1. Insert the blade assembly into crusher housing.
When inserting blade assembly you must align the
stationary blades with the locating slots in the
crusher housing.
2. When inserting the blade assembly into the crusher
housing you must also make sure the axle knob is in
a vertical position. This will align the rotating blades
with the housing to assure a quick and easy
installation.
3. Once all blades are in the housing you will need to align
the crusher axle with the motor shaft. You can do this by
turning the axle knob and pushing the blade assembly
toward the motor until the crusher hub is flush with the
end of the housing.
6. Reattach the decorative ice chute by inserting the chute
rod through the chute, Housing Mount, and Motor
Mount. Secure the Chute Rod by inserting cotter pin
through the rod on the right side of the housing mount.
Make sure arm of microswitch is in front of vertical
protrusions on top of decorative chute.
COTTER PIN
DECORATIVE
CHUTE
CHUTE ROD
7. Reinstall the Rocking Chute Door.
4. To lock the blade assembly into the housing rotate the
crusher hub counter clockwise until the locking tab
snaps into place and the crusher hub is secure.
5. Replace the crusher drip pan, slide until it snaps into place
by pulling up slightly on the crusher assembly and
pushing the drip pan toward the foam front.
8. Reinstall the merchandiser, and secure with the two (2)
screws that were removed during disassembly.
9. Power may be reapplied when unit is completely
reassembled.
Part Number 5010330 10/09 4-7
Maintenance Section 4
Removable Front
Merchandizer Panel
Agitator
Ice Bin
Ice
Paddle Wheel
Rocking Chute
Ice Dispense Chute
Drain Pan
Gear Motor
Water Line
Beverage Valve
(Option)
GEAR MOTOR REMOVAL
Non-front Serviceable
These instructions are provided as a guide for the
removal of the gear motor. Depending on the model
number of your dispenser, these instructions may vary
slightly.
1. Disconnect power from the electric receptacle.
2. Remove all ice from the ice storage bin of the
dispenser.
3. Remove the paddle wheel pin from the paddle
wheel/agitator assembly inside the dispenser bin.
4. Remove the agitator assembly from the dispenser
bin by pushing the agitator to the back of the bin.
Angle the front of the agitator to the side. Pull the
agitator forward then out of the dispenser.
5. Remove the paddle wheel from the dispenser by
pulling the hub of the paddle wheel to the back of the
bin and off the gear motor shaft.
6. Remove the splash panel from the dispenser and
expose the gear motor.
7. Disconnect the electric connector from the gear
motor wire leads.
8. Remove the pin in front of the gear motor.
9. Y ou m ust be able to remove the gea r motor from the
dispenser.
10. To install a replacement gear motor, reverse this
procedure.
4-8
Part Number 5010330 10/09
Section 4 Maintenance
Front Serviceable
These instructions are provided as a guide for the
removal of the gear motor. Depending on the model
number of your dispenser, these instructions may vary
slightly.
1. Unplug the dispenser.
2. Unplug the motor.
3. Remove motor mount pins.
6. New motor must have the same alignment (within
15 degrees).
7. To get correct alignment you can do one of two
things:
a. Turn drive shaft with an adjustable wrench,
being careful not to damage the drive shaft.
b. Plug in the unit, plug in the motor and use the
ice dispense switch to move the drive shaft into
correct alignment.
8. If you plugged in the unit to help with alignmen t of
drive shaft now unplug the unit.
9. Slide motor up into housing, making sure that the
tabs fit on the bracket.
4. Slide motor towards you.
5. Notice alignment of the chamfered edge of drive
shaft.
10. Install motor mount pins.
11. Plug in motor.
12. Test unit.
Part Number 5010330 10/09 4-9
Maintenance Section 4
!
Warning
!
Warning
Bag
side
connector
Sanitizing
BEVERAGE SYSTEM CLEANING
Flush sanitizing solution from syrup system.
Residual sanitizing solution left in system could
create a health hazard.
When using cleaning fluids or chemicals, rubber
gloves and eye protection must be worn .
Sanitize the beverage system at initial start-up as well as
regularly scheduled cleaning. The drain pan must be in
place under soda valves, to carry away detergent and
sanitizing agents that will be flushed through valves.
BAG-IN-BOX SYSTEM SANITATION
The procedure below is for the sanitation of one
syrup circuit at a time. Repeat to sanitize additional
circuits.
You will need the following items to clean and sanitize
the Bag-in-Box (BIB) beverage system:
• Three (3) clean buckets
2. Disconnect the “syrup-line side” of the bag-in-box
connector.
3. Rinse connector with warm tap water.
4. Connect syrup connector to BIB connector and
immerse both into Bucket 1. A “bag-side” connector
can be created by cutting the connector from an
empty disposable syrup bag.
• Plastic brush or soft cloth
• Mild detergent
• Unscented bleach (5% Na CL O) or
Commercial sanitizer
• Bag-In-Box bag connector
1. Prepare the following in the buckets:
• Bucket 1 — warm to hot tap water for rinsing.
• Bucket 2 — mild detergent and warm to hot
water.
• Bucket 3 — mix a solution of unscented bleach
(5% Na CL O) or commercial sanitizer and warm
to hot water. Mixture must supply 100 PPM
available chlorine (1/4 oz. bleach to 1 gallon
water).
4-10
Part Number 5010330 10/09
Section 4 Maintenance
!
Caution
5. Draw rinse water through system until clean water is
dispensed. Most beverage valves allow the syrup
side to be manually activated by depressing the
syrup pallet.
6. Connect Bucket 2 to system.
7. Draw detergent solution through system until
solution is dispensed.
8. Repeat steps 2-7 until all syrup circuits contain
detergent solution.
9. Allow detergent solution to remain in the system for
5 minutes.
10. Connect Bucket 3 to system.
11. Draw sanitizing solution through system until
solution is dispensed.
12. Repeat step 11 until all syrup circuits contain
sanitizer solution.
13. Allow sanitizer solution to remain in system for 15
minutes.
14. Remove nozzles and diffusers from beverage
valves.
15. Scrub nozzles, diffusers and all removable valve
parts (except electrical parts) with a plastic brush or
a soft cloth and the detergent solution.
16. Soak nozzles, diffusers and removable valve parts
(except electrical parts) in sanitizer for 15 minutes.
17. Replace nozzles, diffusers and valve part s.
18. Connect Bucket 1 to system.
19. Draw rinse water through system until no presence
of sanitizer is detected.
20. Attach syrup connectors to BIBs.
21. Draw syrup through system until only syrup is
dispensed.
22. Discard first 2 drinks.
2. Disconnect all product and water lines from product
tanks and remove carbonator.
3. Locate the Figal syrup tank for the circuit to be
sanitized. Remove both quick disconnects from the
Figal syrup tank. Rinse quick disconnects in tap
water.
4. Connect rinse tank to the syrup line. Draw clean
rinse water through the valve until syrup is flushed
from the system.
5. Connect detergent tank to the syrup line and draw
detergent through the valve for two minutes. Then,
allow remaining detergent to stay in the system for
five minutes.
6. Connect rinse tank to the syrup line. Draw clean
rinse water through the valve until detergent is
flushed from the system.
7. Remove valve nozzle and diffuser as shown in Daily
Cleaning instructions. Using a plastic brush or a soft
cloth and warm water , scrub the nozzle, diffuser,
bottom of the dispensing valve and cup lever, if
applicable.
8. Place removable valve parts (EXCEPT solenoids) in
sanitizing solution for 15 minutes.
9. Replace valve diffuser and nozzle on the beverage
valve.
10. Connect sanitizer tank to the syrup line and draw
sanitizer through the valve for two minutes. Allow
sanitizer to remain in the system for a minimum of
15 minutes.
11. Reconnect syrup and carbonated water lines.
12. Draw syrup through the lines to rins e the sys te m.
Discard drinks until at least two cups of satisfactory
tasting beverage are dispensed through the valve.
Shipping, Storage and Relocation
FIGAL BEVERAGE SYSTEM
1. Prepare the following in three clean Figal tanks:
• Rinse tank - fill with room temperature tap water.
• Detergent tank - mix approved beverage system
cleaner with warm water as directed.
• Sanitizing tank - mix a solution of unscented
bleach (5% Na CL O) or commercial sanitizer
and warm to hot water. Mixture must supply 100
PPM available chlorine (1/4 oz. bleach to
1 gallon water).
Part Number 5010330 10/09 4-11
Before shipping, storing, or relocating this unit,
syrup systems must be sanitized. After sanitizing, all
liquids (sanitizing solution and water) must be
purged from the unit. A freezing environment
causes residual sanitizing solution or water
remaining inside the unit to freeze, resulting in
damage to internal components.
Maintenance Section 4
THIS PAGE INTENTIONALLY LEFT BLANK
4-12
Part Number 5010330 10/09
Section 5 Before Calling for Service
Section 5
Before Calling for Service
Checklist
If a problem arises during operation of your dispenser, follow the checklist below before calling service. Routine
adjustments and maintenance procedures are not covered by the warranty.
Problem Possible Cause To Correct
Dispenser will not dispense ice (and NO
SOUNDS are heard when machine is
activated).
Dispenser will not dispense ice (motor
runs but no ice movement is heard in
bin).
Excessive clustering or bridging of ice. Loaded ice not broken up. (Caution:
Ice dispenses continuously. Misaligned microswitch. Adjust microswitch.
Thumping noise or irregular sound at a
particular area of the dispenser.
Dispensing crushed ice or reduced
dispensing speed.
Door will not close. Ice jammed in chute. Adjust bridge in ice machine or, when
Mounting brackets for rocking chute have
spread too far apart.
No power. Check electrical connection.
Loose wire in electrical system. Thoroughly check all wire connections.
Dispenser overloaded with ice. Remove ice from dispenser until unit will
operate.
Motor not working. Check thermally protected motor.
Replace motor or capacitor if necessary.
No ice in bin. Fill dispenser with ice.
Door not opening. Check rocking chute mechanism or
electric solenoid operation.
Paddle wheel pin slipped from the paddle
wheel.
Super cooled ice is not covered by the
Servend warranty.)
Excessive water spilling from the ice
machine.
Poorly adjusted ice machine. Adjust ice machine to eliminate large
Extremely low usage of the dispenser. Lower the ic e level in the bin.
Agitation timer set incorrectly. Test agitation timer.
Shaved ice clusters in the bitn. Remove clusters, discover why ice is
Water spillage from ice machine into
dispenser bin.
Agitation timer. Test agitation timer.
Bridge of ice sheet is too thick. Adjust ice machine.
Paddle wheel area broken or cracked. Replace paddle wheel area.
Ice clusters in bin. Break up or remove clusters.
Door not fully open. Adjust door.
Door and/or door lock has come out of
place.
Replace paddle wheel pin.
Break ice clusters before manually filling
the dispenser. (See ice
recommendations.)
Adjust ice machine to eliminate water
spillage.
waffle shapes.
shaving, and then repair.
Adjust ice machine.
manually filling, break up clusters.
Replace door and lock into proper
position.
Bend parts into shape.
Part Number 5010330 10/09 5-1
Before Calling for Service Section 5
1. Remove probe electronics.
2. Pass magnetic tip of screwdriver by
lower end of tube extending from
electronics package.
3. Reed switch will close.
4. Carbonator operates.
IcePic Troubleshooting
Problem Possible Cause To Correct
DISPENSER DOES NOT DISPENSE
CRUSHED ICE.
Nothing is heard.
Crusher motor hums but does not turn. Blades obstructed. Check for obstructions in ice crusher
Crusher dispense door does not open. Door solenoid faulty Replace Solenoid
Gear box on motor Gear box on motor faulty. Replace Ice Crusher Motor Assembly
Crusher Motor turns but Gear Motor for
Paddle wheel/Agitator Bar does not turn.
Nothing on dispenser works. No power to dispenser Check power source
Difficulty inserting Blade/Hub Assembly
into Crusher housing
Crushed Ice dispenses continuously, or
by itself.
No flashing lights on keypad, Fluorescent
light was on, crusher and whole ice
dispenser will not function, transformer
breaker blown.
No power. Check power source and power cord.
Loose wire in electrical system. Check wiring.
Dispense switch faulty Replace switch
Crusher Motor Faulty. Replace Motor/Gear Box.
Dispenser Safety Switch Open. Assure Merchandiser is installed
correctly with the safety switch in the
closed position.
housing.
Motor faulty Replace Motor
Faulty start relay/capacitor Check relay/capacitor and replace if bad.
Loose wiring to solenoid Check wiring
Crusher Axle broken Replace Crusher Axle
Agitator Gear Motor faulty. Replace Agitator Gear Motor.
Loose wiring. Check wiring
Obstruction in Ice bin stopping motor Check for obstruction
Dispenser Safety Switch opens Assure Merchandiser is installed
correctly with the safety switch in the
closed position.
Loose wiring Check wiring.
a. Stationary Blades not aligned with
locating slots at top and bottom of
crusher housing
b. Rotating Blades not in vertical position.
c. Check for ice in Crusher Housing.
Ice Dispense Switch Faulty Adjust bridge in ice machine or, when
Water shorted out wiring harness on
valves only.
See ""How to Disassemble for
Maintenance"" section in this manual.
manually filling, break up clusters.
Clean up water and reset transformer.
Pump Troubleshooting
Problem Possible Cause Corrective Action
Pump motor does not
shut off
Pump motor
intermittent
Pump motor does not
pump
Problem with probe or probe harness
Problem with probe or probe harness
Water pressure from water source is not
high enough
5-2
Verify water pressure leading into pump inlet is 40 psi
minimum.
Part Number 5010330 10/09
Section 5 Before Calling for Service
Drink T roubleshooting
Condition Investigation Check Correction
Water only dispensing No pressure Regulator(s) out of adjustment Check/adjust regulator(s).
Install fresh tank.
2
line pinched, kinked or
Check/repair/replace CO2 line.
or reset breaker.
Replace water filter.
Check/clean/replace pump strainer.
Check/clean/repair water check valve.
Check for frozen water line. Internal
carbonator unit only.
motor, electrode or liquid level control.
Install fresh tank.
2
line pinched, kinked or
Check/repair/replace CO2 line.
Adjust CO
pressure due to leaks Repair CO2 leaks.
2
Clean out the lines.
if necessary.
replace regulator if necessary.
pressure or change the tank.
2
pressure or replace regulator
2
supply. Reset pressure or
2
Syrup and CO
only
2
Carbonator No power Check power supply. Plug in carbonator
dispensing
Syrup and plain water
No pressure Out of CO
only dispensing setting
One valve will not
dispense anything
Beverage dispensed is
too sweet
Beverage is not sweet
enough
Is there power to the
valve?
Is the ratio (brix) of the
drink correct?
Is the ratio (brix) of the
drink correct?
Drinks are foaming Are system pressures
correct?
No water, syrup or gas
dispensing
Is there power to the
unit?
Is power coming
through the key
switch?
Is there power to the
key switch?
Out of CO
Defective regulator(s) Check/repair/replace regulator(s).
CO
2
obstructed
Water supply Make sure water is turned “on”.
Defective carbonator Check/repair/replace carbonator pump,
HP regulator out of adjustment Adjust HP regulator to the proper setting.
Defective HP regulator Check/repair/replace HP regulator.
CO
2
obstructed
Broken wire or loose connection Replace/repair wire or connector.
Bad microswitch Replace microswitch.
Flow control out of adjustment Adjust the flow control.
Insufficient soda flow due to low
carbonator pressure
Low CO
Obstruction in the water or soda
line
Flow control out of adjustment Adjust the flow control.
Soda flow too high Reset CO
Obstruction in syrup line Clean out the syrup line.
Over carbonation Check CO
Dirty lines/valves Clean/sanitize entire system.
No power Plug in unit or reset breaker.
Power to control box Replace fuse or control box.
Key switch “off” Turn switch “on”.
Key switch defective Replace key switch.
No power through the transformer Reset/replace transformer.
Part Number 5010330 10/09 5-3
Before Calling for Service Section 5
END
START
Does
Pump
motor
come on?
Remove red
and black
wires from
LLC.
Is pum p
motor
operation
intermittent
?
Does
pump
motor
come
on?
Black and/or red probe
shorted. Remove
probes , s traighten or
replace if necessary.
Short “H” and
“C” terminals
on LLC.
Does
the
pump
motor
shut
off?
Meas ure AC
voltage
across load
terminals on
LLC.
Check pump
motor and
wiring.
Check probe
harness, harness
connections and
water supply.
Is line
voltage
(± 10%)
pres ent
?
Replace
LLC
Yes
No
Yes
Yes
Yes
Yes
No
No
No
No
END
START
Does
Pump
motor
come on?
Remove red
and black
wires from
LLC.
Is pum p
motor
operation
intermittent
?
Does
pump
motor
come
on?
Black and/or red probe
shorted. Remove
probes , s traighten or
replace if necessary.
Short “H” and
“C” terminals
on LLC.
Does
the
pump
motor
shut
off?
Meas ure AC
voltage
across load
terminals on
LLC.
Check pump
motor and
wiring.
Check probe
harness, harness
connections and
water supply.
Is line
voltage
(± 10%)
pres ent
?
Replace
LLC
Yes
No
Yes
Yes
Yes
Yes
No
No
No
No
Liquid Level Control Troubleshooting
5-4
Part Number 5010330 10/09
© 2008 Manitowoc
Continuing product improvements
may necessitate change of
specifications without notice.
Part Number 5010330 10/09
Manitowoc Beverage Equipment
Sellersburg, IN 47172, USA
Ph: 812-246-7000 Fax: 812-246-7024
Visit us online at: www.manitowocfsg.com
2100 Future Drive
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