Model E112-LJ / F112-LJ
SERVICE MANUAL
Manual No. 513656 Mar. 2010
This manual provides basic information about the machine. Instructions and suggestions are
given covering its operation and care.
The illustrations and specif cations are not binding in detail. We reserve the right to make
changes to the machine without notice, and without incurring any obligation to modify or provide new parts for machines built prior to date of change.
DO NOT ATTEMPT to operate the machine until instructions and safety precautions in this
manual are read completely and are thoroughly understood. If problems develop or questions
arise in connection with installation, operation, or servicing of the machine, contact Stoelting.
stoeltingfoodservice.com
Stoelting Foodservice Equipment
502 Highway 67
Kiel, WI 53042-1600
U.S.A.
Main Tel: 800.558.5807
Fax: 920.894.7029
Customer Service: 888.429.5920
Fax: 800.545.0662
Email: foodservice@stoelting.com
© 2014 PW Stoelting, LLC
A Few Words About Safety
Safety Information
Read and understand the entire manual before
operating or maintaining Stoelting equipment.
This manual provides the operator with information
for the safe operation and maintenance of Stoelting
equipment. As with any machine, there are hazards
associated with their operation. For this reason safety
is emphasized throughout the manual. To highlight
specif c safety information, the following safety def nitions are provided to assist the reader.
The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and
their explanations, deserve your careful attention
and understanding. The safety warnings do not by
themselves eliminate any danger. The instructions
or warnings they give are not substitutes for proper
accident prevention measures.
If you need to replace a part, use genuine Stoelting
parts with the correct part number or an equivalent
part. We strongly recommend that you do not use
replacement parts of inferior quality.
Safety Alert Symbol:
This symbol Indicates danger, warning or caution.
Attention is required in order to avoid serious personal injury. The message that follows the symbol
contains important information about safety.
Signal Word:
Signal words are distinctive words used throughout
this manual that alert the reader to the existence and
relative degree of a hazard.
WARNING
The signal word “WARNING” indicates a potentially
hazardous situation, which, if not avoided, may result
in death or serious injury and equipment/property
damage.
CAUTION
The signal word “CAUTION” indicates a potentially
hazardous situation, which, if not avoided, may result
in minor or moderate injury and equipment/property
damage.
CAUTION
The signal word “CAUTION” not preceded by the
safety alert symbol indicates a potentially hazardous
situation, which, if not avoided, may result in equipment/property damage.
NOTE (or NOTICE)
The signal word “NOTICE” indicates information or
procedures that relate directly or indirectly to the
safety of personnel or equipment/property.
TABLE OF
CONTENTS
Section Description Page
1 Description and Specifications
1.1 Description ................................................................................................. 1
1.2 Specifications .............................................................................................2
1.3 Modes of Normal Operation ........................................................................ 4
1.4 Operation During an Error Mode ................................................................. 5
2 Installation Instructions
2.1 Safety Precautions..................................................................................... 7
2.2 Shipment and Transit ................................................................................. 7
2.3 Machine Installation....................................................................................7
2.4 Auto Fill Pump Installation .......................................................................... 8
3 Initial Set-Up and Operation
3.1 Operator’s Safety Precautions .................................................................... 9
3.2 Operating Controls and Indicators ............................................................... 9
3.3 Removing Mix From Machine ..................................................................... 10
3.4 Disassembly of Machine Parts ...................................................................10
3.5 Cleaning and Sanitizing the Machine Parts................................................. 11
3.6 Assembly of Machine ................................................................................. 12
3.7 Sanitizing ................................................................................................... 13
3.8 Freeze Down and Operation ....................................................................... 13
3.9 Mix Information........................................................................................... 14
3.10 Routine Cleaning ........................................................................................ 14
3.11 Preventative Maintenance ........................................................................... 14
3.12 Extended Storage.......................................................................................16
4 Maintenance and Adjustments
4.1 Machine Adjustment................................................................................... 17
4.2 Product Consistency Adjustment ...............................................................17
4.3 Drive Belt Tension Adjustment ....................................................................17
4.4 Auto Fill Pump Maintenance ...................................................................... 17
Section Description Page
5 Refrigeration System
5.1 Refrigeration System ..................................................................................19
5.2 Refrigerant Recovery and Evacuation.......................................................... 19
5.3 Refrigerant Charging ................................................................................... 20
5.4 Compressor ................................................................................................20
5.5 Condenser .................................................................................................. 22
5.6 Valves ........................................................................................................ 22
A. Thermostatic Expansion Valve (TXV) .................................................................. 22
B. High Pressure Cutout .........................................................................................23
C. Evaporator Pressure Regulaotr (EPR) ............................................................... 24
D. Water Valve (Water Cooled Models Only)........................................................... 24
5.7 Capillary Tube ............................................................................................25
5.8 Filter Drier .................................................................................................. 26
6 Electrical and Mechanical Control Systems
6.1 Control Board ............................................................................................. 27
6.2 Contactor ................................................................................................... 27
6.3 Drive Motor ... ..............................................................................................28
6.4 Capacitors ..................................................................................................29
6.5 Gearbox ..................................................................................................... 30
6.6 Condenser Fan Motor (Air Cooled Models Only) .........................................30
6.7 Switches .................................................................................................... 31
A. Spigot Switch ......................................................................................................31
B. Torque Switch ..................................................................................................... 31
7 Troubleshooting
7.1 Light Indicators........................................................................................... 33
7.2 Troubleshooting - Machine.......................................................................... 33
7.3 Troubleshooting - Auto Fill System .............................................................34
8 Replacement Parts
8.1 Decals, Lubrication, Panels & Legs ............................................................35
8.2 Auger Shaft and Faceplate Parts ................................................................36
8.3 Hopper Parts ..............................................................................................38
8.4 Machine Front & Spigot Switch Assembly.................................................. 39
8.5 E112-LJ Parts ............................................................................................ 40
8.6 F112-LJ Parts............................................................................................. 42
8.7 Auto Fill Parts ............................................................................................44
8.8 Refrigeration Diagram ................................................................................. 45
8.9 E112-LJ Wiring Diagram............................................................................. 46
8.10 F112-LJ Wiring Diagram............................................................................. 47
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1.1 DESCRIPTION
The Stoelting E112-LJ /F112-LJ counter machines are
gravity fed. The machines are equipped with fully automatic
controls to provide a uniform product. This manual is
designed to help qualified service personnel and operators
with the installation, operation and maintenance of the
Stoelting E112-LJ /F112-LJ gravity machines.
Figure 1-1 Model F112-LJ
Figure 1-1 Model E112-LJ
1
1.2 SPECIFICATIONS
E112
F112
Figure 1-2 Specifications
2
1.2 SPECIFICATIONS - CONTINUED
Model E112 Model F112
Dimensions Machine with crate Machine with crate
width 15-1/4'' (38,7 cm) 17-1/2'' (44,5 cm) 17-1/4'' (43,8 cm) 29'' (73,7 cm)
height 30-1/2'' (77,5 cm) 35'' (88,9 cm) 33'' (83,8 cm) 44'' (111,8 cm)
depth 32'' (81,3 cm) 36-1/2'' (92,7 cm) 30-1/4'' (76,8 cm) 39'' (99,1 cm)
Weight
Electrical
running amps
connection type
International Option
Compressor
Dri v e M o t o r
Ai r Fl ow
Plumbi ng Fi t t i ngs
Hopper Volum e
Freezing Cylinder
Volume
Production
Capacity
205 lbs (92,9 kg) 215 lbs (97,5 kg) 288 lbs (130,6 kg) 315 lbs (142,8 kg)
1 Phase, 115 VAC, 60Hz 1 Phase, 208-240 VAC, 60Hz
approximately 16A approximately 10A
NEMA5-20P power cord provided NEMA6-15P power cord provided
1 Phase, 220-240 VAC, 50Hz 1 Phase, 220-240 VAC, 50Hz
6,000 Btu/hr 8,600 Btu/hr
1/3 hp 3/4 hp
Air cooled units require 3" (7,6 cm) air
space on both sides or 4"
(10,2 cm) air space in back
for side-by-side installati on
N/A
3.625 gallon (13,73 liters) 5.375 gallon (20,35 liters)
1.25 gallon (5 quart), 4,73 liters 2.125 gallon (8.5 quart), 8,04 liters
18 GPH (68,15 liters) 24 GPH (90,87 liters)
Air cooled units require 6" (15,24 cm)
air space on both sides
Water cooled units require 3/8" N.P.T.
water and drain fittings.
Refrigerant
Charge
Sucti on Pressur e
(at 72°F)
Discharge Pressure
EPR Valve
Refrigerant
Charge
Sucti on Pressur e
(at 85°F)
Discharge Pressure
EPR Valve
E112-LJ
R-404A
20 oz
30-32 psig
200-205 psig
59-61 psig
F112-LJ
R-404A
(W/C) 20 oz
(A/C) 28 oz
40 psig
280 psig
59-61 psig
3
1.3 MODES OF NORMAL OPERATION
Following is an explanation of the normal operation modes
on the E112-LJ and F112-LJ (Refer to Figure 1-3).
NOTE
Slush mode has two options: normal and continuous drive. With the continuous drive option selected,
the drive motor will run at all times, including standby .
T o change the control between the two options, refer to Section 4.3.
A. PRE STIR
When the CLEAN-OFF-ON is moved into the ON position
or when the spigot is opened, the drive motor will start a 4second pre stir. A consistency check will determine if a
freezing cycle will begin.
B. FREEZING CYCLE
After the pre stir, a freezing cycle begins. The freezing cycle
continues until the torque rod closes the torque switch and
keeps the switch closed for 3 seconds. If product consistency is not met within 22 minutes, the machine will operate
in the compressor time out mode (See Section 1.4).
NOTE
If the spigot is pulled during a freezing cycle, the 22minute timer will restart.
C. POST STIR
After the freezing cycle ends, the drive motor will continue
to run for an 18 second post stir. The post stir ensures the
product does not freeze to the cylinder. If the spigot is
opened during the post stir, the machine will check consistency. If the product is at consistency, the machine will
move into standby. If the product is not at consistency, the
machine will start a freezing cycle.
D. STANDBY
After the post stir, the machine will be in standby. It will
remain in standby for 7 minutes or until the spigot is opened.
E. DEFROST MODE
If the spigot is not opened for 3 hours, defrost mode will
begin. The drive motor will run for 90 seconds every 7
minutes and the diagnostic light will remain lit.
After 8 hours or if the spigot is opened, normal operation
mode will begin.
F. CLEAN MODE
When the CLEAN-OFF-ON switch is in the CLEAN position, the drive motor starts and will run for 20 minutes. After
the 20 minutes expire, the drive motor will stop and the
diagnostic light will flash three times every 4 seconds. It will
continue to flash until the CLEAN-OFF-ON switch is moved
out of the CLEAN position.
Figure 1-3 Modes of Normal Operation
4
Figure 1-4 Compressor Time Out Mode
1.4 OPERATION DURING AN ERROR
MODE
A. COMPRESSOR TIME OUT MODE
If the freezing cycle exceeds 22 minutes, the machine will
operate on timers. The diagnostic light will flash once every
4 seconds (Refer to Figure 1-4).
B. LOW MIX MODE
If the mix level falls below the sensor probe, the auto fill
system will attempt to fill the hopper. The ADD MIX light will
flash for a couple of seconds while the solenoid opens and
fills the hopper. If the bag in box (BIB) is empty, the vacuum
shutoff on the auto fill pump will automatically shut the
pump off and the ADD MIX light will continuosly flash. The
machine will continue to operate on timers until the empty
BIB is replaced and the mix in the hopper is above the
sensor probe (Refer to Figure 1-5).
NOTE
After the BIB is replaced the vacuum shutoff on the
auto fill pump will automatically reset. The solenoid
may have a max runtime error. Turn the Clean/Off/
On switch Off and back On.
Figure 1-5 Low Mix Mode
5
Figure 1-6 Drive Motor Error Mode
C. DRIVE MOTOR ERROR MODE
If the control does not sense current from the drive motor
during a pre stir, the machine will go into standby mode for
7 minutes. After standby, the control will repeat the pre stir
and attempt to sense drive motor current. After the third pre
stir without sensing drive motor current, the machine will
operate on timers and the diagnostic light will flash twice
every four seconds (Refer to Figure 1-6). The attempts to
sense the drive motor current can be substituted by pulling
the spigot.
6
SECTION 2
INSTALLATION INSTRUCTIONS
2.1 SAFETY PRECAUTIONS
Do not attempt to operate the machine until the safety
precautions and operating instructions in this manual are
read completely and are thoroughly understood.
Take notice of all warning labels on the machine. The
labels have been put there to help maintain a safe working
environment. The labels have been designed to withstand
washing and cleaning. All labels must remain legible for
the life of the machine. Labels should be checked periodically to be sure they can be recognized as warning labels.
If danger, warning or caution labels are needed, indicate
the part number, type of label, location of label, and
quantity required along with your address and mail to:
STOELTING
A TTENTION: Customer Service
502 Hwy . 67
Kiel, Wisconsin 53042
Figure 2-2 Space and Ventilation Requirements
E. Correct ventilation is required. The E112-LJ requires
3” clearance on both sides. If the machine is placed
side-by-side next to other equipment, there needs
to be at least 4” clearance at the back of the
machine. The air-cooled F112-LJ requires 6”
clearance on both sides for proper air flow.
2.2 SHIPMENT AND TRANSIT
The machine has been assembled, operated and inspected at the factory. Upon arrival at the final destination,
the entire machine must be checked for any damage
which may have occurred during transit.
With the method of packaging used, the machine should
arrive in excellent condition. THE CARRIER IS RESPONSIBLE FOR ALL DAMAGE IN TRANSIT, WHETHER
VISIBLE OR CONCEALED. Do not pay the freight bill until
the machine has been checked for damage. Have the
carrier note any visible damage on the freight bill. If
concealed damage and/or shortage is found later, advise
the carrier within 10 days and request inspection. The
customer must place claim for damages and/or shortages
in shipment with the carrier. Stoelting cannot make any
claims against the carrier.
2.3 MACHINE INSTALLATION
Installation of the machine involves moving the machine
close to its permanent location, removing all crating,
setting in place, assembling parts, and cleaning.
A. Uncrate the machine.
B. Determine the location of the machine. The location
must be able to hold 350 lbs.
C. Accurate leveling is necessary for correct drainage
of machine barrel and to insure correct overrun.
Place a bubble level on top of the machine at each
corner to check for level condition. If adjustment
is necessary, level the machine by turning the
bottom part of each leg in or out.
D. The F112-LJ has a base gasket that must be
installed. Separate the gasket and install it with the
seam to the back. Make sure the angled side of the
gasket is facing up.
CAUTION
Failure to provide adequate ventilation will void warranty.
F. Connect the drip tray bracket by loosening the two
screws at the front of the machine. Install the
bracket so that it rests on the nylon washer
between the two metal washers. Tighten the screws.
Figure 2-3 Drip Tray Bracket
G. Place the CLEAN-ON-OFF switch in the OFF
position.
7
WARNING
Do not alter or deform electrical plug in any way .
Altering the plug to fit into an outlet of different configuration may cause fire, risk of electrical shock,
product damage and will void warranty.
H. Connect the power cord to the proper power
supply. The plug on the E112 is designed for
115VAC / 20 amp duty and the plug on the F112 is
designed for 208-240VAC / 15 amp duty. Check
the nameplate on your machine for proper supply.
The unit must be connected to a properly grounded
receptacle. The electrical cord furnished as part of
the machine has a three prong grounding type
plug. The use of an extension cord is not
recommended, if necessary use one with a size 12
gauge or heavier with ground wire. Do not use an
adapter to get around grounding requirement.
2.4 AUTO FILL PUMP INSTALLATION
The auto fill pump is powered by water and has a fixed orifice
that delivers water and syrup to the machine at an exact
ratio. The auto fill kit is designed for use with Bag In Box
(BIB) concentrated syrup.
Follow these instructions to properly install the brix pump
A. Route the clear tubing with the BIB connector to
the BIB. If there is excess tubing, trim it and
reconnect it to the BIB connector.
B. Route the water line tubing to the shutoff valve of the
water supply. Trim excess tubing and connect it to
the shutoff valve.
C. Route the water line and syrup line tubing (3/8”
braided tubing) from the pump to the machine.
water inlet
from shutoff
valve
syrup inlet
from BIB
Figure 2-5 Top View of Pump
D. Route the water line tubing to the tube exiting the
rear panel. Trim excess tubing and connect.
E. Route the syrup line to the tubing connected to the
adapter on the hopper cover. Trim excess tubing
and connect.
F. Check that the clear tubing coming out of the rear
panel is connected to the plug in the hopper cover.
If not, connect it using a clamp in the kit.
G. Check that all tubing connections are properly
clamped, fittings are tightened and the tubing is not
kinked.
water outlet
to machine
this side of
pump is
mounted to
the BIB shelf
syrup outlet
to machine
to
machine
water
inlet
Figure 2-4 Auto Fill Pump Tubing Layout
to
BIB
Figure 2-6 Auto Fill Pump Kit
8
SECTION 3
INITIAL SET-UP AND OPERATION
3.1 OPERATOR’S SAFETY PRECAUTIONS
SAFE OPERATION IS NO ACCIDENT; observe these
rules:
A. Know the machine. Read and understand the
Operating Instructions.
B. Notice all warning labels on the machine.
C. Wear proper clothing. Avoid loose fitting garments,
and remove watches, rings or jewelry that could
cause a serious accident.
D. Maintain a clean work area. Avoid accidents by
cleaning up the area and keeping it clean.
E. Stay alert at all times. Know which switch, push
button or control you are about to use and what
effect it is going to have.
F. Disconnect electrical cord for maintenance. Never
attempt to repair or perform maintenance on the
machine until the main electrical power has been
disconnected.
G. Do not operate under unsafe operating conditions.
Never operate the machine if unusual or excessive
noise or vibration occurs.
3.2 OPERATING CONTROLS AND
INDICATORS
Before operating the machine, it is required that the
operator know the function of each operating control. Refer
WARNING
High voltage will shock, burn or cause death. The
OFF-ON switch must be placed in the OFF position
prior to disassembling for cleaning or servicing. Do
not operate machine with cabinet panels removed.
to Figure 3-1 for the location of the operating controls on the
machine.
A. Spigot Switch
The spigot switch will automatically start the auger
drive and refrigeration systems when the spigot is
opened to dispense product. When the spigot is
closed, the drive motor and compressor will remain
on until the product in the freezing cylinder reaches
the proper consistency..
Consistency
Adjustment
Screw
Diagnostic
Light
Add Mix
Indicator
Clean/Off/On
Switch
Figure 3-1 Controls
9
B. CLEAN-OFF-ON Switch
The CLEAN-OFF-ON switch is used to supply
power to the control circuit. When the switch is in
the OFF (middle) position, power will not be
supplied to the control board or refrigeration
system. When the switch is in the ON position, the
machine will operate in the freezing mode. When
the switch is in the CLEAN position, all refrigeration
will stop and the auger will start rotating.
C. ADD MIX Light
The ADD MIX light will flash to alert the operator
to a low mix condition. It does so by monitoring the
mix level in the hopper. If the ADD MIX light is
flashing, check the auto fill system to determine
the issue. Refer to the troubleshooting section for
details
D. Diagnostic Light
The Diagnostic Light will remain lit for defrost
mode. It will flash if an error occurs. The light will
flash once if there is a compressor error. There will
be two quick flashes if there is an auger error. And
there will be three quick flashes if the machine is
left in clean mode for more than 20 minutes. Refer
to the troubleshooting section for details.
E. Consistency Adjustment Screw
The Consistency Adjustment Screw increases or
decreases product consistency. A tension spring
is connected to the screw and changes the amount
of torque needed to complete a refrigeration cycle.
Turn the knob clockwise to increase consistency
or counterclockwise to decrease consistency.
F. Front Door Safety Switch
The front door safety switch prevents the auger
from turning when the front door is removed. The
switch is open when the door is not in place and
closed when the door is properly installed.
G. Hopper Probes
The mix level in the hopper is controlled by two
probes. When mix in the hopper gets below the
long probe, the solenoid opens and the hopper fills.
When the mix level reaches the short probe, the
solenoid closes.
3.3 REMOVING MIX FROM MACHINE
To remove the mix from the machine, refer to the following
steps:
A. Wash, rinse, dry and sanitize hands before starting.
B. Turn the water line lever to the Off position.
C. Place the Clean/Off/On switch to Clean and drain
the mix from the freezer into a utility bucket and
turn off the machine. Discard mix into the second
compartment of a 3-compartment sink.
D. Fill the hopper with 2 gallons of clean, cold water
using the clean white utility bucket.
E. Place the Clean/Off/On switch to Clean. Run the
machine in Clean mode for approximately 5
minutes. Continue to the next step while the
machine is cleaning.
F. Prepare Stera-Sheen Green Label Sanitizer
according to manufacturer’s instructions to provide
a 100ppm strength solution. In the blue cleaner/
sanitizer bucket, mix 1 packet of sanitizer and 2
gallons of cold water. Check the chlorine content
with a test strip to ensure 100ppm strength.
G. After 5 minutes, drain the water from the machine
into the red utility bucket and discard the water.
NOTE
If the water does not drain clear, repeat the step s.
H. Place the Clean/Off/On switch Off.
I. Fill the hopper with the 2 gallons of sanitizer
solution from the blue bucket.
J. Place the Clean/Off/On switch to Clean. Run the
machine in Clean mode for approximately 5
minutes.
K. After 5 minutes, drain the sanitizer solution from
the machine into the red utility bucket and discard
the solution.
3.4 DISASSEMBLY OF MACHINE PARTS
Inspect for worn or broken parts each time the machine is
disassembled. Replace any worn or broken parts to ensure
safety to both the operator and the customer and to
maintain good machine performance and a quality product.
Frequency of cleaning must comply with the local health
regulations.
To disassemble the machine, refer to the following steps:
CAUTION
Hazardous Moving Parts.
Revolving auger shaf t can grab and cause injury .
Place the switch in the OFF (middle) position before disassembling for cleaning or servicing.
10
Figure 3-2 Remove Spigot Pin
A. Pull out the spigot pin by its ring. Remove the
spigot handle.
NOTE
Place all parts into the lemonade parts basket immediately after removing from the machine. Place
small parts onto the small parts rod in the basket.
B. Remove front door by turning the circular knobs
and then pulling door off the studs.
NOTE
When removing front door, entire door and stator
assembly will come out as well.
C. Remove the torque rod from the stator assembly.
D. Remove the quad ring from the groove in front door.
E. Remove the stator bar. Remove the small white
bushing.
Figure 3-4 Removing O-Ring
F. Remove the o-rings at the front and back of the
stator bar by first wiping off the lubricant using a
clean paper towel. Then squeeze the o-ring upward
with a dry cloth. When a loop is formed, roll the oring out of the groove.
G. Remove the auger support bushing.
H. Turn the spigot body until the ice breaker bar can
be removed. Remove breaker bar.
I. Remove the spigot body from the front door.
J. Remove the o-rings (2) from the spigot.
K. Remove the auger assembly from the freezing
cylinder and remove the auger blade. Remove the
rear seal and o-ring from the auger.
L. Remove the drain tray, drip tray and drip tray grid.
M. Remove the hopper cover and disconnect the auto
fill adapter from the cover by pulling out the retaining
clip.
Figure 3-3 Spigot and Ice Breaker Bar Removal
3.5 CLEANING AND SANITIZING THE
MACHINE PARTS
Place all loose parts in a pan or container and take to the
wash sink for cleaning. Local and state health codes dictate
the procedure required. Some health codes require a foursink process (pre-wash, wash, rinse, sanitize, and air-dry),
while other codes require a three-sink process (without the
pre-wash step). The following procedures are a general
guideline only. Consult your local and state health codes for
procedures required in your location.
A. Set up a 3-compartment sink with wash, rinse and
sanitize compartments. Use only Stera Sheen
Green Label or Kay-5 Green. Prepare sanitizer
according to manufacturer’s instructions to provide
a 100ppm strength solution. Set aside a small
amount of sanitizer
B. Clean all parts using brushes provided.
C. After cleaning, remove the parts and let air dry.
11
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