Stoelting F431 User Manual

Model F431

OWNER'S MANUAL

Manual No. 513604 Feb. 2005, Rev . 1

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STOELTING® OWNER'S MANUAL

FOR

MODEL F431

CAB MODEL SOFT-SERVE PRESSURIZED FREEZER

This manual provides basic information about the freezer. Instructions and suggestions are given
covering its basic operation and care.

The illustrations and specifications are not binding in detail. We reserve the right to make changes
at any time without notice, to the freezer and its components, without incurring any obligation to modify
or provide new parts for freezers built prior to date of change.

DO NOT ATTEMPT to operate the freezer 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 freezer, contact the company at the location listed below.

STOELTING, LLC Tele: 920-894-2293
502 Hwy 67
Kiel, WI 53042-1600 Fax: [phone]

A Few Words About Safety

Safety Information

Read and understand the entire manual before
operating or maintaining Stoelting equipment.

This Owner's Manual provides the operator with
information for the safe operation and maintenance of
Stoelting equipment. As with any machine, there are
hazards associated with their operation. For this
reason safety is emphasized throughout the manual.
T o highlight specific safety information, the following
safety definitions are provided to assist the reader .

The purpose of safety symbols is to attract your
attention to possible dangers. The safety symbols,
and their explanations, deserve your careful attention
and understanding. The safety warnings do not by
themselves eliminate any danger . The instructions or
warnings they give are not substitutes for proper
accident prevention measures.

If you need to replace a part, use genuine Stoelting
parts with the correct part number or an equivalent
part. We strongly recommend that you do not use
replacement parts of inferior quality .

Safety Alert Symbol:

This symbol Indicates danger, warning or caution.

Attention is required in order to avoid serious personal
injury . The message that follows the symbol cont ains
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.

NOTICE

The signal word “NOTICE” indicates information or
procedures that relate directly or indirectly to the
safety or personnel or equipment/property.

TABLE OF CONTENTS

Section 1 .............................................................................................................. 1

1.1 Description.............................................................................................. 1

1.2 Specifications.......................................................................................... 2

Section 2 .............................................................................................................. 3

2.1 Safety Precautions .................................................................................. 3

2.2 Shipment & Transit .................................................................................. 4

2.3 Freezer Installation................................................................................... 4

2.4 Installing Permanent Wiring...................................................................... 4

2.5 Mix Pump ................................................................................................ 5

Section 3 .............................................................................................................. 9

3.1 Safety Precautions .................................................................................. 9

3.2 Operating Controls and Indicators............................................................ 9

3.3 Important Cleaning and Sanitizing Information ......................................... 11

3.4 Disassembly of Freezer Parts................................................................. 12

3.5 Cleaning Disassembled Parts.................................................................. 13

3.6 Sanitizing Freezer Parts .......................................................................... 13

3.7 Cleaning the Freezer ............................................................................... 14

3.8 Assembling the Freezer........................................................................... 14

3.9 Sanitizing Assembled Freezer ................................................................. 16

3.10 Initial Freeze Down and Operation .......................................................... 16

3.11 Mix Information........................................................................................ 17

3.12 Operation of Mix Pump............................................................................ 18

3.13 Mix Pump Cleaning .................................................................................. 18

3.14 Disassembly and Inspection of Removable Parts.................................... 18

Section 4 .............................................................................................................. 21

4.1 Product Consistency Adjustment ............................................................. 21

4.2 Locking Out Control Panel....................................................................... 21

4.3 Overrun Adjustment ................................................................................. 21

4.4 Mix Pump Hose Reposition...................................................................... 22

4.5 Mix Pump Hose Replacement ................................................................. 22

4.6 Drive Belt T ension Adjustment ................................................................. 22

4.7 Condenser Cleaning (Air Cooled Freezers) ............................................. 23

4.8 Preventative Maintenance ....................................................................... 23

4.9 Extended Storage.................................................................................... 23

4.10 Error Codes ............................................................................................ 23

4.11 Troubleshooting....................................................................................... 24

Section 5 .............................................................................................................. 29

5.1 How to Order Replacement Parts ........................................................... 29

5.2 Parts Lists and Reference Drawings ....................................................... 29

ILLUSTRATIONS

Figure 1 Model F431 Freezer ..............................................................1

Figure 2 Specifications........................................................................1

Figure 3 Decal Locations.....................................................................3

Figure 4 Auger Rotation.......................................................................4

Figure 5 Mix Hose Installation..............................................................5

Figure 6 Connections for Standard Mix Container................................7

Figure 7 Connecting Mix Pickup Assembly ..........................................7

Figure 8 Connecting Pump Hose to BCS Manifold...............................8

Figure 9 Completed BCS Hose Assembly ...........................................8

Figure 10 Connecting BCS Mix Bags.....................................................8

Figure 11 Operating Controls ................................................................9

Figure 12 Auger Flight Wear & Front Auger Support Bushing Wear ......12

Figure 13 Front Door Disassembly ........................................................13

Figure 14 Auger Flight Removal.............................................................13

Figure 15 Rear Seal Removal................................................................13

Figure 16 Rear Seal Lubrication ............................................................14

Figure 17 Spring Installation ..................................................................14

Figure 18 Front Door Assembly .............................................................15

Figure 19 Air Bleed Valves ....................................................................16

Figure 20 Clean Control.........................................................................16

Figure 21 Refrigerated Cabinet .............................................................17

Figure 22 Dispensing Product................................................................17

Figure 23 Mix Pumps.............................................................................18

Figure 24 Removable Parts...................................................................19

Figure 25 Removeable Parts for Optional BCS .....................................19

Figure 26 Cleaning Air Tube ..................................................................19

Figure 27 Cleaning Feed Tube...............................................................19

Figure 28 Product Consistency Control .................................................21

Figure 29 Overrun Adjustment ...............................................................21

Figure 30 Belt Adjustment......................................................................22

Figure 31 Removing Condenser Filter....................................................23

SECTION 1

INTRODUCTION

1.1 DESCRIPTION

The Stoelting F431 floor model freezer is pressure fed.
The freezer is equipped with fully automatic controls to
provide a uniform product. The freezer is designed to
operate with almost any type of commercial soft-serve
or non-dairy mixes available, including ice milk, ice cream,
yogurt, and frozen dietary desserts.

This manual is designed to assist qualified personnel and
operators in the installation, operation and maintenance
of the Stoelting Model F431 pressure freezer .

Figure 1. Model F431 Freezer

Figure 2. Specification

1

1.2 SPECIFICATIONS

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2

SECTION 2

INSTALLATION INSTRUCTIONS

2.1 SAFETY PRECAUTIONS

Do not attempt to operate the freezer until the safety
precautions and operating instructions in the manual
are read completely and are thoroughly understood.

Take notice of all warning labels on the freezer (see Fig­ure 2).The labels have been put there to help you 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 freezer. Labels should
be checked periodically to be sure they have not been

painted over , rubbed off, fallen off, and can be recognized
as warning labels.

If you are in need of replacement labels, indicate the part
number, type of label, location of label, and quantity re­quired along with your name and address and mail to:

Stoelting, LLC

Commercial Products

502 Hwy. 67

Kiel, WI 53042

HEAT SENSITIVE THERMISTOR LOCATED
UNDER THIS COVER. TEMPERATURE
MUST NOT EXCEED 220°F NEAR
THERMISTOR. HEAT SINK MUST BE
USED WHEN BRAZING ON EVAPORATOR
OUTLET. CHECK RESISTANCE BEFORE
REMOVAL OF THERMIST OR.
SEE SERVICE MANUAL.

Figure 3. Warning Label Locations

3

2.2 SHIPMENT AND TRANSIT

The freezer has been assembled, operated, and in­spected at the factory. Upon arrival at the final destina­tion, the freezer must be checked for any damage which
may have occurred during final transit.

2.4 INSTALLING PERMANENT WIRING

If, permanent wiring is required by local codes, the
following procedure must be performed:

With the method of packaging used, the equipment 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 freezer 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 ten days and request inspection. The customer
must place claim for damage and/or shortages in ship­ment with the carrier. S toelting, Inc. cannot make any

claims against the carrier.

2.3 FREEZER INST ALLATION

WARNING

Installation must be performed by a qualified electri­cian/refrigeration specialist. Incorrect installation may
cause personal injury , severe damage to the machine
and will void factory warranties.

W

Installation of the freezer involves moving the freezer close
to its permanent location, removing all crating, setting in
place, assembling parts, and cleaning.

A. Uncrate the freezer .
B. Install the four casters. Turn the threaded end into

the freezer until zero threads are showing. To level,
turn out casters no more than 1/4" maximum, then
tighten all jam nuts.

WARNING

Hazardous voltage

High voltage will shock, burn or cause death. Turn off
and lock out main power disconnect before installing
wiring. Do not operate machine with cabinet panels
removed.

A. Refer to the nameplate at the rear of the freezer for

specific electrical requirements. Make sure the power
source in the building matches the freezer name­plate requirements. Bring the wires into the junction
boxes through the access holes in the bottom rear of
the freezer.

B. Remove the lower back panel and the two junction

box covers located at the bottom of the freezer.
C. lnstall permanent wiring according to local code.
D. Check the auger shaft rotation by placing the Main

Freezer Power Switch in the ON position, placing

both Freezing Cylinder OFF/ON switches in the ON

position and then pressing the Clean Switch on each

of the control panels. Auger shaf t rotation is clock

wise as viewed through the clear plastic front door.

If the rotation is not clockwise, turn main electrical

power OFF . Then reverse L1 and L3 electrical power

lines to the junction box (three phase only). Re-

check auger shaft rotation (see Figure 4).

C. The freezer must be placed in a solid level position.

NOTE

Accurate leveling is necessary for correct drainage
of freezer barrel and to insure correct overrun.

CAUTION

Risk of product damage

Air cooled condenser requires proper ventilation. Fail­ure to provide adequate ventilation will void factory
warranties.

D. The freezer must have a minimum of 3" (7,5cm)

of space on all sides and 10" (25cm) at the top for
proper circulation. A minimum of 6" (15cm) clear­ance is required in high ambient conditions.

Figure 4. Auger Rotation

4

2.5 MIX PUMP

A. Mix Pump Hose Installation

Follow the steps below to install the mix pump
hose.

1. Turn pump on.

2. Feed one end of mix pump hose into the
entering or pick-up hose side (left) of black
cover.

6" (15cm)

Figure 5. Mix Hose Installation

9. Turn pump off.

10.Connect free end of mix pump hose to 3-way
Tee as shown in Figure 6. When all connections
are complete the 3- way Tee must be lower than
the black pump housing (see Figure 6).

CAUTION

3. Gently push the hose into the black cover until
it begins to feed.

4. Allow the hose to feed itself thru the pump
until 6" (15cm) remains on the entering side.

5. Turn pump off.

6. Connect mix pump hose to the elbow fiting
(located on the left side of the mix line manifold)
using small hose clamp. Be careful not to twist
the mix hose.

7. Turn pump on.

8. Allow remaining 6" (15cm) of tubing to feed thru
pump until hose adapter prevents further
feeding.

Risk of product damage

Air/mix T ee must remain below the black cover/clamp.
If Tee is above the pump, mix will drain to the air
compressor resulting in pump damage.

B. Mix Pick-up Hose Installation

The F431 freezer may be connected to standard
mix containers or prepacked mix bags. One, 5
gallon mix bag may be connected to each freezing
cylinder or two, 2 1/2 gallon bags may be connected
on each side. Follow the instructions below that
match your configuration.

When Using One Mix Container Per Side:

1. Connect 2 inch (5cm) length of 3/8 inch (9,5mm)
I.D. plastic food grade tubing to the mix pick-up
assembly. Secure with hose clamps. Then
place assembly thru hole in cover and install
retaining clip (see Figure 6 and 7).

5

2. Connect free end of tubing to mix check valve.
Observe direction of check valve flow arrow.
Secure with hose clamp. Connect 24 inch (61cm)
length of 3/8 inch (9,5mm) I.D. plastic food grade
tubing to free end of check valve and secure with
hose clamp.

3. Connect elbow fitting to free end of tubing. Con­nect opposite end of elbow to 1/4 inch I.D. tan
tubing on the left side of pump head. Secure with
hose clamps (see Figure 5 and 6).

When Using Bag Connection System (BCS) with
One Bag Per Side (optional kit):

1. Connect 3/8 inch (9,5mm) I.D. plastic food grade
tubing to a bag adapter. Secure with hose clamps.

2. Connect free end of 3/8 inch (9,5mm) I.D. plastic
food grade tubing to mix check valve. Observe
direction of check valve flow arrow. Secure with
hose clamp. Connect 3/8 inch (9,5mm) I.D. plas­tic food grade tubing to free end of check valve and
secure with hose clamp.

When Using Bag Connection System (BCS) with
Two Bags Per Side (optional kit #2183189):

1. Connect 3/8 inch (9,5mm) I.D. plastic food grade
tubing to a bag adapter. Secure with hose clamps.
This bag adapter will connect to the bag nearest
the front of the freezer.

2. Slide the hose clip over free end of 3/8 inch
(9,5mm) I.D. plastic food grade tubing. Attach
free end of tubing to a manifold adapter. Secure
with large hose clamp or equivalent. Push the
manifold adapter into the left port of the mix inlet
manifold and secure with retaining clip. (see
Figure 9).

3. Connect 3/8 inch (9,5mm) I.D. plastic food grade
tubing to a bag adapter. Secure with hose clamps.
This bag adapter will connect to the bag nearest
the back of the freezer.

4. Attach free end of tubing to a manifold adapter.
Secure with large hose clamp or equivalent. Push
the manifold adapter into the right port of the mix
inlet manifold and secure with retaining clip. (see
Figure 9).

5. Place two mix bags into each mix container as
shown in Figure 10 (left mix container shows two
bag configuration).

3. Connect elbow fitting to free end of tubing. Con­nect opposite end of elbow to 1/4 inch I.D. tan
tubing on the left side of pump head. Secure with
hose clamps (see Figure 5 and 6).

4. Place one mix bag into each mix container as
shown in Figure 10 (right mix container shows one
bag configuration).

5. Connect the bag adapter to the mix bag. (see
Figure 10).

When Using Two Mix Containers or Bag
Connection Systems (BCS) on one Side
(optional kit #2183189):

1. The F431 can be configured to operate with only
one freezing cylinder turned on. This may be done
if only one flavor is being dispensed during slow
times. In this case, running only one freezing
cylinder will help minimize product breakdown,
while reducing mix container filling or mix bag
replacement.

2. Connect two mix containers or two mix bags as
described above, but connect both containers to
the mix line manifold of the freezing cylinder you
will be using.

6. Connect the bag adapter attached to the left side
of the manifold to the mix bag in the front of the mix
container (nearest the cabinet door). Connect the
bag adapter attached to the right side of the
manifold to the mix bag in the back of the mix
container (see Figure 10).

6

O

W

FL

I

E

R

D

I

C

T

N

O

TUBE ROUTING

(ONLY ONE SIDE SHOWN)

Figure 6. Mix Pump Connections for Standard Mix Container

Figure 7. Connecting Mix Pick-up Assembly

7

3-way Tee

ÆÆ

Æ

ÆÆ

Low Mix

ÆÆ

Æ

Indicator

Adjustment

ÆÆ
ÆÆ

Æ

ÆÆ

Knobs

Figure 8. Connecting Pump Hose to BCS Manifold

Figure 10. Connecting BCS Mix Bags (two bag

connection on left, one bag connection on right)

ÌÌ

Ì

ÌÌ

C. Mix Low level Indicator Adjustment

The sensitivity of the "Mix Low" indication that

ÈÈ

È

ÈÈ

displays on the control panel can be adjusted to
operator preference. If more advanced notice of
low mix is required, simply loosen the black adjust­ment knobs located on the sensor brackets at the
back of the freezer cabinet, and slide the bracket
upwards. If the "Mix Low" message appears while
there is still sufficient mix in the container, slide the
bracket downward. Be sure to tighten the adjust­ment knobs after properly positioning the sensor
(see Figure 8).

Figure 9. Completed BCS Hose Assembly

8

SECTION 3

INITIAL SET-UP AND OPERATION

3.1 SAFETY PRECAUTIONS

SAFE OPERATION IS NO ACCIDENT; observe these
rules:

A. Know the freezer. Read and understand the operat-

ing instructions.

B. Notice all warning labels on the freezer.
C. Wear proper clothing. Avoid loose fitting garments,

and remove watches, rings or jewelry which could
cause a serious accident.

D. Maintain a clean work area. Avoid accidents by

cleaning 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 power for maintenance.

Never attempt to repair or perform maintenance on
the freezer until the main electrical power has been
disconnected.

G. Do not operate under unsafe operating condi-

tions. Never operate this freezer if unusual or exces-

sive noise or vibration occurs.

3.2 OPERATING CONTROLS AND INDICA TORS

Before operating the freezer, it is required that the opera­tor know the function of each operating control. Refer to
Figure 1 1 for the location of the operating controls on the
freezer. For the information regarding error codes displayed
on the control panel, refer to the troubleshooting section
of this manual.

A. Spigot Switch

The Spigot switch will automatically actuate 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.

B. Freezing Cylinder Off-On Switch

The Freezing Cylinder Off-On switches are two
position toggle switches used to supply power to
the left or right freezing cylinder control circuit.
When the switch is in the OFF position, the
refrigeration system and auger will not operate.
When the switch is in the ON position, the freezer
can be run in the freezing mode or cleaning mode.
The freezer will be in the sleep mode until a switch
is activated.

C. Main Freezer Power Switch

The Main Freezer Power switch is a two position
rocker switch. that supplies power to the freezing
cylinder circuits and the lower cabinet refrigeration
system. When the switch is placed in the ON
position, the lower cabinet refrigeration system will
run until the preset temperature is reached; then
cycle ON and OFF to maintain that temperature.
Power to individual freezing cylinders can then be
controlled with the Freezing cylinder OFF/ON
switches.

Right Freezing

Cylinder OFF/ON

Left Freezing

Cylinder OFF/ON

Push to Freeze Switch
Clean Switch

Main Freezer
Power Switch

Cab Off
Indicator Light

Figure 11. Operating Controls

WARNING

Hazardous voltage

The Main Freezer Power switch must be placed in the
OFF position when disassembling for cleaning or
servicing. The freezer must be disconnected from
electrical supply before removing any access panel.
Failure to disconnect power before servicing could
result in death or serious injury.

D. Cab Off Indicator Light

A flashing light indicates the Main Freezer Power
Switch is in the OFF position, and no refrigeration is
being supplied to the cab. Place the Main Freezer
Power Switch switch in the ON position for cab
refrigeration.

E. Pump Switch

The pump motor switches are the two toggle switches
located in the upper lefthand side of the refrigerated
cab. When a switch is placed in the OFF position, the
pump will not run. When the switch is placed in the
ON position, the pump will run until the preset
pressure is reached, then cycle ON and OFF
as product is drawn to maintain that pressure.

F. Push To Freeze Switch

The PUSH TO FREEZE switch is a membrane or
"snap" switch used to start the freezing cycle.
During initial freeze down, the The Main Freezer
Power switch and Freezing Cylinder Off-On switch
are placed in the ON position. Next, the PUSH TO
FREEZE switch is pressed and held until the drive
motor and compressor turn on.

NOTE

After the auger motor starts, there is a 3 second
delay before the compressor starts.

9

G. Amber Light

During the normal operation, the amber light next to
the PUSH TO FREEZE switch will illuminate after
the freezer has been idle for the preset cycles.
Before drawing product, press the PUSH TO
FREEZE switch. A horzontal status bar on the LCD
display will begin to fill the screen as product
freezes down. Wait until at least six bars are
dirsplayed or the green light is illuminated before
dispensing.

NOTE

If the freezer shuts off and alternating green and
amber lights flash on the control panel, the freezer
is running in the "cab only " mode (both freezing
cylinders are turned off) or the freezer is in an error
condition. Note the display on the LCD screen. If
the screen displays an error, turn the Freezing
Cylinder Off/On switch to the OFF position, correct
the problem and place the Freezing Cylinder Off/
On switch to the ON position. (Refer to Trouble­shooting in Section 4).

H. Green Light

The green light is used to indicate that the product
has reached the proper consistency and is ready
to be dispensed. The light begins to flash at 98%
of consistency.

I. Clean Switch

The CLEAN switch is a membrane, or "snap"
switch. When the switch is pushed, the freezing
cylinder's refrigeration system will be OFF and the
auger will rotate for cleaning. The CLEAN mes­sage will display on the LCD screen. When the
switch is pushed again, the auger will stop and the
amber light will flash indicating the freezer is in the
CLEAN mode. To exit the CLEAN mode turn the
Freezing Cylinder Off/On switch to the OFF
position. If the freezer is left in CLEAN for more
than 30 minutes, it will go in error.

J. Drive Motor Overload

The internal drive motor overload will trip if the drive
motor is overloaded. It will reset after approximately
10-12 minutes. If the drive motor continues to trip,
refer to Troubleshooting in Section 4-.

L. Dispense Rate Adjusters

The dispense rate adjuster limits the opening of the
spigot. To adjust product dispense rate, turn the
adjusting knob clockwise for slower flow and counter­clockwise for faster flow. It takes at least five com­plete turns of the adjusting knob to make a noticable
difference in the dispense rate.

M. High Head Pressure Cut Out

If the head pressure exceeds 445 PSIG (28 bar) , the
high head pressure cutout will trip. The reset button
can be accessed from the top left corner on the right
side panel of the freezer.

N. 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 removed and closed when
the door is properly installed.

O. Menu Navigation Buttons

The Menu Navigation Buttons allow the user to display
information regarding the freezer's status of opera
tion as well as adjust product consistency.

Selection Button (SEL) The SEL button is not
functional in the normal operation mode. This
button is only used by service technicians for
freezer calibration.

Set Button (SET) Pressing this button will save
a change made to the product consistency set
ting. Refer to Section 4 for consistency adjust
ment procedures.

Left Arrow Button

the control panel will automatically illuminate the
display. The backlight will turn off several seconds
after use. To keep the display constantly light,
press and hold the left (⇐) button for five seconds.
The backlight function can be reset to normal
operation in the same manner.

Up Arrow Button (

change the value of the product consistency.
Refer to Section 4 for consistency adjustment
procedures.

(⇐) (⇐)

(⇐) Pressing any button on

(⇐) (⇐)

⇑⇑

⇑) Pressing this button will

⇑⇑

K. Mix Low Light Indicator

A MIX LOW message will appear on the LCD
display to alert the operator of a low mix condition.
The message will display when there is approxi­mately one gallon of mix left in the mix container or
when one bag of theBCS is empty . When the MIX
LOW message is displayed, refill the container or
replace the bag immediately .

10

3.3 IMPORTANT INFORMATION REGARDING
CLEANING AND SANITIZING

Soft serve and shake freezers require special
consideration when it comes to food safety and
proper cleaning and sanitizing.

The following information specifically covers issues
for cleaning and sanitizing frozen dessert freezers.
This information is meant to supplement a
comprehensive food safety program.

Soil Materials Associated with Frozen Dessert
Machines

CLEANING

· Is the removal of soil materials from a surface.

· Is a prerequisite for effective sanitizing.

NOTE

An UNCLEAN surface will harbor bacteria that can
defy sanitizing efforts.

Bacteria can develop and resist sanitizing efforts
within a layer of soil material (milkstone). Thorough

cleaning procedures that involve milkstone
removal are critical for operators of frozen
dessert machines.

MILKFAT/BUTTERFAT – As components of ice­cream/frozen custard mix, these soils will
accumulate on the interior surfaces of the machine
and its parts. Fats are difficult to remove and help
attribute to milkstone build-up.

MILKSTONE – Is a white/gray film that forms on
equipment and utensils that come in contact with
dairy products. These films will accumulate slowly
on surfaces because of ineffective cleaning, use of
hard water, or both. Milkstone is usually a porous

deposit, which will harbor microbial
contaminants and eventually defy sanitizing
efforts.

Once milkstone has formed, it is very difficult to
remove. Without using the correct product and
procedure, it is nearly impossible to remove a thick
layer of milkstone.
(NOTE: general-purpose cleaners DO NOT remove
milkstone.) This can lead to high bacteria counts

and a food safety dilemma.

IT IS BEST TO CONTROL MILKSTONE ON A
DAILY BASIS BEFORE IT CAN BECOME A
SIGNIFICANT FOOD SAFETY PROBLEM.

In addition to food safety, milkstone can cause
premature wear to machine parts which can add to
costs for replacement parts or possibly more
expensive repairs if worn machine parts are not
replaced once they have become excessively worn.

Important Differences Between Cleaning and
Sanitizing

CLEANING vs. SANITIZING

It is important to distinguish between cleaning and
sanitizing. Although these terms may sound
synonymous, they are not. BOTH are required for
adequate food safety and proper machine
maintenance.

SANITIZING

· Kills bacteria.

· Can be effective on clean surfaces only.

· DOES NOT clean or remove milkstone.

NOTE

Using a SANTITIZER on an unclean surface

will not guarantee a clean and safe frozen
dessert machine.

Proper Daily Maintenance:
The Only Way to Assure Food Safety and
Product Quality

Proper daily maintenance can involve a wide variety
of products and procedures. Overall, the products
and procedures fall into three separate categories.

(Please note that this is a brief overview intended for
informational purposes only.)

1. CLEANING – This involves draining mix from the
freezer barrel and rinsing the machine with
water. Next, a cleaner is run through the
machine. Then, the machine is disassembled
and removable parts are taken to the sink for

cleaning.

2. MILKSTONE REMOVAL – Since almost all
cleaners do not have the ability to remove
milkstone, the use of a delimer becomes
necessary. Although this procedure may not be
needed on a daily basis, it will usually follow the
cleaning procedure. It requires letting a delimer
solution soak in the machine for an extended
period of time. Individual parts are also soaked
in a deliming solution for an extended period of
time (more about delimers in Additional
Information).

3. SANITIZING – After the machine has been
cleaned and contains no milkstone, the
machine is reassembled. Then a FDA-approved
sanitizing solution is run through the machine to
kill bacteria. The machine is then ready for food
preparation.

11

As a recommended cleaner and sanitizer for your
frozen dessert machine, STERA-SHEEN has proven
to be one of the best daily maintenance products for:

· CLEANING – Thorough removal of all solids
including butterfat and milk fat.

The ideal concentration of chlorine needs to be 100
ppm (as stated by the FDA).

NOTE

Follow the directions on the container for proper
concentration.

· MILKSTONE REMOVAL – Complete removal of
milkstone.

· SANITIZING – FDA-approved no rinse sanitizer
for food contact surfaces.

Additional Information

THE USE OF DELIMERS

A delimer is a strong acid that has the ability to
dissolve milkstone. This type of chemical may
become necessary once high levels of milkstone
have developed. While these products are very
effective for removing HIGH levels of milkstone, they
are not ideal for two reasons:

1. PRODUCT SAFETY – Strong acids are
dangerous chemicals. Carefully follow safety
instructions provided with delimer products.

2. MACHINE DAMAGE – Strong acids will attack
metal and rubber causing premature wear of
parts. The use of a delimer needs to be closely
monitored to avoid damage to machine surfaces
and parts.

There are two main factors that contribute to falling
chlorine concentrations in a sanitizing solution.

1. PRODUCT USE – As the chlorine in the
solution is being used, chlorine concentrations
fall.

2. TIME – As time passes, small amounts of
chlorine “evaporate” from the solution. (That is
why you can smell it.)

Sanitizing solutions should not be allowed to fall
below 100 ppm chlorine. New solutions should be
mixed once old solutions become ineffective.

3.4 DISASSEMBL Y OF FREEZER P ARTS

WARNING

Moving machinery can grab, mangle and dis­member. Place the ON-OFF toggle switch in the
OFF position before disassembling for cleaning
or servicing. Placing the ON-OFF toggle switch
in the ON position during cleaning or servicing
may result in serious personal injury .

With proper daily use of STERA-SHEEN or it’s
equivalent, there is no need for the use of a
DELIMER.

DO NOT USE BLEACH

· BLEACH HAS ABSOLUTELY NO CLEANING
PROPERTIES.

· BLEACH IS CORROSIVE. It can and will
damage components of the machine causing
premature wear and metal corrosion.

GENERAL PURPOSE CLEANERS

General purpose cleaners do not have the ability to
remove milkstone. Milkstone will become a problem
if not remedied with additional products and
procedures.

THE USE OF CHLORINE TEST STRIPS

“Test strips” are used to determine concentrations of
active chlorine in sanitizing solutions. To use the
strips, tear off a small portion and submerge it into
the sanitizing solution. Then, compare the color
change to the color key on the side of the test strip
dispenser to determine the approximate chlorine
concentration.

Before using the freezer for the first time, complete freezer
disassembly, cleaning and sanitizing procedures will need
to be followed. Routine cleaning intervals and procedures
must comply with the local and state health codes.
Inspection for worn or broken parts should be made at
every disassembly of the freezer for cleaning or other
purposes. All worn or broken parts should be replaced to
ensure safety to both the operator and the customer and
to maintain good freezer performance and a quality prod­uct. Two normal wear areas are the auger flights and front
auger support bushing (see Figure 12).

T o disassemble the freezer , refer to the following steps:

Wear Line

ÈÈ

È

ÈÈ

Figure 12. Auger Flight Wear & Front Auger

Support Bushing Wear

12

A. Disassembly Of Front Door

1. Remove the front door by turning off the circular
knobs and then pulling the front door off the studs.

2. Remove the air bleed valve by unscrewing the knob
while holding the valve stem from behind. Remove
the compression spring and push air bleed valve
through the rear of the front door.

3. Remove the spigot through the bottom of the front
door (see Figure 13). Remove all O-rings from
spigots.and air bleed valve.

Figure 13. Front Door Disassembly

B. Disassembly Of Auger

1. Remove the front auger support by pulling it
straight out of the freezer barrel.

2. Remove the plastic bearing from the front auger
support.

Figure 15. Rear Seal Removal

3.5 CLEANING DISASSEMBLED PARTS

Disassembled freezer parts require complete cleaning,
sanitizing and air drying before assembling. Local and
state health codes will dictate the procedure required.
Some state health codes require a four sink process (pre­wash, wash, rinse, sanitize, air dry), while others 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. To clean the freezer parts, disassemble all parts.

(Refer to section 3.4 for the disassembly of freezer
parts.)

B. Place all front door and auger parts in clean 90° to

110°F (32°C to 43°C) water and wash thoroughly
(four sink procedure only).

C. Place all parts in 90° to 110°F (32°C to 43°C) , mild

detergent water and wash thoroughly.

3. Remove the auger by pulling slowly and rotating
out of the freezer barrel. As the auger is
withdrawn, remove each plastic flight and spring
from the auger . Be careful not to scratch inside of
freezer barrel when removing flights or auger.
Remove the spring from each auger flight.

Figure 14. Auger Flight Removal

4. Keep the rear of the auger tipped up once it is
clear of the freezer barrel.

5. Wipe spline lubricant off hex end of auger with a
paper towel. Remove the rear seal. Figure 15.

D. Rinse all parts with clean 90° to 110°F (32°C to

43°C) water.

F. Sanitize all freezer parts following procedures out

lined below.

3.6 SANITIZING FREEZER PARTS

A. Use a sanitizer mixed according to manufacturer's

instructions to provide a 100 parts per million strength
solution. Mix sanitizer in quantities of no less than 2
gallons of 90° to 110°F (32°C to 43°C) water. Allow
the sanitizer to contact the surfaces to be sanitized
for 5 minutes. Any sanitizer must be used only in
accordance with the manufacturer's instructions.

B. Place all parts in the sanitizing solution for 5 minutes,

then remove and let air dry completely before assem
bling in freezer.

13

3.7 CLEANING THE FREEZER

CAUTION

Risk of Product Damage

Do not use acid cleaners, strong caustic compounds
or abrasive materials to clean any part of the freezer
exterior or plastic parts.

The exterior should be kept clean at all times to
preserve the lustre of the stainless steel. A good
grade of stainless steel has been used on the
freezer to ease clean-up. To remove spilled or dried
mix, simply wash the exterior in 90° to 110°F (32°C
to 43°C) , soapy water and wipe dry.

É

ÉÉ

ÉÉ

Lubricate

with

Socket

ÊÊ

Ê

ÊÊ

ÉÉ

É

ÉÉ

ÉÉ

É

ÉÉ

Lubricate with Petrogel

Figure 16. Rear Seal Lubrciation

C. Lubricate the hex drive end of auger with a small

amount of white socket lubricant. A small container
of socket lubricant is shipped with the freezer.

Lubricant

Do not use highly abrasive materials as they will
mar the finish. A mild alkaline cleaner is recom­mended. Use a soft cloth or sponge to apply the
cleaner. For best results, wipe in the direction of the
grain of the steel.

A. Clean the rear seal surface from inside of the freezer

barrel.

B. Using this sanitizing solution and the large barrel

brush provided, sanitize the barrel by dipping the
brush in the sanitizing solution and brushing the
inside of the barrel.

C. Remove the rear drip tray by pulling from side panel.

Clean and replace drip tray.

3.8 ASSEMBLING FREEZER

To assemble the freezer parts, refer to the following steps:

NOTICE

Petro-Gel sanitary lubricant or equivalent must be
used when lubrication of freezer parts is specified.

NOTICE

The United States Department of Agriculture and
the Food and Drug Administration require that lubri­cants used on food processing equipment be certi­fied for this use. Use Lubricants only in accordance
with the manufacturer's instructions.

A. Assemble all O-rings onto parts dry, without lubri-

cation. Then apply a thin film of sanitary lubrication
to exposed surfaces of the O-rings.

B. Lubricate rear seal area on auger shaft with a thin

layer of sanitary lubricant. Install the rear seal O-ring.
Lubricate outside of rear seal O-ring with sanitary
lubricant.

C. Install stainless steel rear seal adapter into rear seal

dry (without lubricant). Lubricate inside surface of
rear seal adapter and install onto auger shaft. DO
NOT lubricate outside of rear auger seal (see Figure

16).

D. Screw the springs onto the studs in plastic flights.

Spring must be screwed into the flights com­pletely to provide proper tension (see Figure 17).

Figure 17. Spring Installation

E. Install first flights to bottom of auger, rotate, add

successive flights from bottom as the auger is pushed
slowly into the freezer barrel. Carefully engage auger
with drive socket in speed reducer by rotating auger
slowly and pushing on end of auger.

F. Apply a thin film of sanitary lubricant to the inside and

outside of the front auger support bearing, then place
on the front of the auger. Assemble the front auger
support onto the auger bearing.

NOTICE

Position the front support on auger so legs do not
interfere with the pin on the back of the front door
assembly. Front door must push auger in slightly
when it is being tightened to prevent the rear seal
from leaking.

14

G. Assemble O-rings onto the spigot dry, without

lubrication. Then apply a thin film of sanitary lubricant
to the outside of the O-rings and spigot bodies.

H. Install the spigots through the bottom of the front

door ( see Figure 18).

Figure 18. Front Door Assembly

I. Assemble the air bleed valve O-ring onto the air

bleed valves. Position the O-ring in groove close to
the wide part. Apply a thin film of sanitary lubricant to
the O-rings.

J. Insert the air bleed valves from the back of the front

door. Install compression springs onto air bleed
valves, then screw knobs on finger tight.

K. Apply a thin film of sanitary lubricant to the door seal

O-rings, and fit into the grooves on the rear of the
front door.

L. Place the front door assembly on the mounting studs

and push front door against the freezer carefully.

M. Secure front door assembly by placing the knobs on

the studs and alternately tighten opposite corners
until finger tight only. Do not overtighten. Proper
O-ring seal can be observed through the transparent
front door.

N. Move the spigot handles to the closed position.

15

3.9 SANITIZING

Sanitizing must be done after the freezer is clean and just
before the freezer is filled with mix. Sanitizing the night
before is not effective. However, you should always clean
the freezer and parts after using it.

WARNING

The United States Department of Agriculture and
the Food and Drug Administration require that
all cleaning and sanitizing solutions used with
food processing equipment be certified for this
use.

When sanitizing the freezer, refer to local sanit ary regu­lations for applicable codes and recommended sanitiz­ing products and procedures. The frequency of sanitiz­ing must comply with local health regulations. Mix sani­tizer according to manufacturer’s instructions to provide
a 100 parts per million strength solution. Mix sanitizer in
quantities of no less than 2 gallons of 90°F to 110°F (32°C
to 43°C) water. Allow sanitizer to cont act the surfaces to
be sanitized for 5 minutes. Any sanitizer must be used
only in accordance with the manufacturer’s instructions.

C. Let sanitizing solution fill the freezer barrel to air

bleed valve, then close the valve by pulling out to
lock in place.

D. Place the Freezing Cylinder Off-On toggle switch

in the ON position then press the CLEAN switch.

CLEAN

Clean Switch

Figure 20. Clean Control

E. Check for leaks when the freezing cylinder is first

pressurized with sanitizing solution.

1. Check for leaks at the front door seals.

2. Check the drain located above the center of the
Drip Tray for leaks coming from the rear of the
Rear Auger Seal.

Air Bleed Valves

Figure 19. Air Bleed Valves

CAUTION

Risk of Product Damage

Avoid prolonged contact of sanitizer with freezer parts.
Prolonged contact of sanitizer with freezer may cause
corrosion of stainless steel parts.

A. Prepare 3 gallons of sanitizing solution following

manufacturer's instructions, and pour into storage
container.

B. Place the mix pump switch in the ON position and

open air bleed valve on the front door by pushing
valve in and holding (see Figure 19).

3. Check inside the cab unit for leaks at hose con

nections.

F. Using a sanitized soft bristle brush or equivalent,

dipped in sanitizing solution, clean mix container.

G. After five minutes, open spigot to expel sanitizing

solution. Drain all solution from freezer using all three
spigots.

H. When solution has drained, press the CLEAN

switch to stop the auger and placeFreezing Cylin­der Off-On toggle switch in the OFF position. Allow
the freezer barrel to drain completely .

The freezer is now sanitized and ready for adding mix.

3.10 INITIAL FREEZE DOWN AND OPERA TION

This section covers the recommended operating proce­dures to be followed for the safe operation of the freezer.

A. Sanitize just prior to use according to instructions

outlined in this manual.

B. If using standard mix containers, prepare the de-

sired amount of mix and then fill each storage con­tainer with approximately 2.5 gallons or more of mix.
Atach mix inlet probes to container . Place mix con­tainers in the refrigerated cabinet. If drawing from
a BCS system, place bags into mix container, re­move the cap and push out all of the air. Insert adap­tor sinto the bags.

16

seconds before dispensing additional product. After a
while the operator will sense or feel when the freezer is
beginning to fall behind, and will slow down on the rate
of draw so as not to exceed the freezer's capacity .

Mix Pump

Switches

Figure 21. Refrigerated Cabinet

C. Place the mix pump switch in the ON position. The

mix pump switch is located in the upper left hand
corner, inside the refrigerated cabinet (see Figure

21). Immediately open the spigot and let approxi
mately 8 ounces of liquid mix with sanitizing solu
tion drain out of the spigot.

D. Close the spigot and open the air bleed valve on the

front door by pushing the valve in and holding. Allow
the barrel to fill until the mix level is 1/2" (2.7 cm)
below air bleed valve, then release valve and pull
closed to lock in place.

Cab Door

Switch

Do not operate the freezer when the MIX LOW light is

on or with less than 1-3/4" (4.4 cm) of mix in the
mix container. Refill the mix container immediately .

NOTE

The freezer has a standby and sleep mode. When
the freezer is not used, after a preset number of
freezing cycles, it will enter the stand by mode
( followed by sleep mode) and remain there until
someone draws a product or pushes the push­to-freeze switch. In the sleep mode, the freezer
will keep the product below 45°F (7.2°C). Sleep
modes are not to be used in place of cleaning
and sanitizing. Frequency of cleaning and sani­tizing is determined by Federal, State, and local
regulatory agencies.

Spigot Rate

Adjusters

E. Place the OFF-ON switch in the ON position, then

press and hold the PUSH TO FREEZE switch until
the freezer starts.

NOTE

After the Drive Motor starts, there will be a 3
second delay before the Compressor starts.

F . After about 6 to 10 minutes the freezer will shut off

and the green lens will illuminate. SERVE will be dis
played on the LCD screen. The product will be
ready to serve. Freeze down time may be shorter
for some frozen diet dessert mixes. High ambient
temperatures may extend freeze down time.

G. The refrigeration is automatically actuated when

the spigot is opened.For normal dispensing, move
the spigot handle fully open. This position provides
excellent control over the product and aids in
making desired shaped portions. Spigot Rate
Adjusters are located under the Header Panel, to
the immediate right of eachSpigot Handle. T urning
the Spigot Rate Adjuster clockwise will increase
the dispense rate (see Figure 22).

The freezer is designed to dispense the product at a
reasonable draw rate. If the freezer is overdrawn, the
result will be a soft product and air pops. If this should
occur , allow the freezer to run for approximately 30

Figure 22. Dispensing Product

3.11 MIX INFORMATION

Mix can vary considerably from one manufacturer to
another. Differences in the amount of butter-fat content and
quantity and quality of other ingredients have a direct
bearing on the finished frozen product. A change in freezer
performance that cannot be explained by a technical
problem may be related to the mix.

Proper product serving temperature varies from one
manufacturer's mix to another. Mixes should provide a
satisfactory product in the 17° to 20°F (-7° to -6°C) range.
Diet and low-carb mixes typically freeze to proper consis­tency at higher temperatures.

When checking the temperature, stir the thermometer in
the frozen product to read the true temperature.

Mix does not improve with age. Old mix, or mix that has been
stored at too high a temperature, can result in a finished
product that is less than satisfactory from the appearance
and taste standpoint. To retard bacteria growth in dairy
based mixes, the best storage temperature range is
between 36° to 40°F (2.2° to 4.4° C).

17

3.12 OPERATION OF MIX PUMP

The mix pump switch is located in the upper left hand
corner, inside the refrigerated cabinet. When the pump
switch is placed in the ON position, the mix pump motor
will be actuated to pump mix into the freezer cylinder.
When the set pressure is reached, the mix pump will shut
off automatically. When the switch is placed in the OFF
position, the mix pump will be inoperative.

NOTE

The mix pump motor is equipped with an internal
overload that will “trip”, disabling the pump when the
motor is overloaded. Consult the trouble shooting
section for corrective information.The internal over­load will automatically reset after cooling. If the con­dition continues, contact a qualified service person.

CAUTION

Risk of Product Damage

Mix pump hose must be repositioned every 1 -2 weeks
or 60 hours of operation. Failure to comply will result
in reduced mix pump liquid capacity , dispense stop­page, popping, and possible mix pump hose leak­age. Hose leakage may damage the pump roller as­sembly and void the factory warranty .

A. Mix Operation: The peristaltic mix pump contains

one continuous mix pump hose. When looking at the
face of the peristaltic mix pump, the left side of the
hose is the suction or pickup. The right side of the
hose is the discharge. Mix is drawn up the suction
side of the hose and transferred thru the discharge
side to the freezer (see Figure 23).

B. Air Operation: The air compressor operates whenever

the peristaltic mix pump is running. Air enters thru a
check valve on the piston downstroke. The air is
discharged thru a second check valve, on the piston
upstroke. The air and mix join at the tee and then
travel to the freezer.

C. The over-run adjustment is preset at the factory. If an

adjustment becomes necessary, refer to Section 4.

NOTICE

Any cleaning procedure must always be followed
by sanitizing before filling freezer with mix. (Refer to
section 3.3)

3.13 MIX PUMP CLEANING

The mix pump is approved for CIP (clean in place) and is
thoroughly cleaned as cleaning solutions are pumped thru
the freezer. We recommend completely disassembling
the pump and connecting tubing every 14 days for inspection
of parts to confirm the CIP has been properly performed. If
any residue is detected clean or replace those parts as
outlined below.

1. Place the OFF-ON switch in the ON position and
press the CLEAN switch. Allow the auger to agitate
for 5 to 10 minutes.

2. Remove suction tube from mix container. Draw off the
mix remaining in freezer barrel.

3. Pump 2 gallons (7.5 liters) of cold potable water thru

freezer until water at spigot is free of mix.

4. Pump 2 gallons (7.5 liters) of 90° to 110°F (32°C to

43°C) detergent solution water thru freezer. The use
of soft water is recommended, along with dishwashing
detergents such as “Joy ,” “Dawn,” or equivalent.

5. Place mix pump switch in OFF position. Open spigot

to relieve remaining pressure.

6. Press the CLEAN switch to stop the auger and place

the OFF-ON toggle switch in the OFF position.

3.14 DISASSEMBLY AND INSPECTION OF

REMOVABLE PARTS

Inspection of removable parts should be made whenever
maintenance is performed or pump requires disassembly.

Air Line

Mix

ÆÆ

Æ

ÆÆ

Discharge

ÆÆ

Æ

ÆÆ

Mix

Intake

3-way

ÆÆ

Æ

ÆÆ

Tee

ÆÆ

Æ

ÆÆ

Figure 23. Mix Pumps

Air/mix to

ÆÆ

Æ

ÆÆ

Freezing Cylinder

WARNING

Hazardous Moving Parts

Revolving pump head can grab, mangle, and cause
serious crushing injury. The Power switch must be
placed in the OFF position for cleaning and power
must be disconnected when disassembling or

servicing.

CAUTION

System Under Pressure

Never disconnect hoses from freezer or pump without
first opening spigot to relieve pressure.

18

NOTE

If the mix lines or air line is difficult to remove, soften
with a rag soaked in hot water. Hose connections
may be sprayed with Haynes Sanitary Lubricant for
ease of removal. Do not loosen or remove the mix
pump cover wingnuts. Maintain the mix pump hose
in its operational condition.

1. Loosen clamp and remove air hose from pump
compressor.

2. Loosen clamp and disconnect mix pump hose.
Remove the pickup hose, mix check valve and pickup
hose adapter (and bag adapter if applicable) as an
assembly from mix container.

3. Completely disassemble both hose assemblies and
check valve. Place hoses, tee, check valve assem­bly , and pickup hose adapter in 90° to 1 10°F (32°C to
43°C), mild detergent water and wash thoroughly . Use
soft bristle brushes to clean inside of fittings. Rinse
all parts in clean 90° to 1 10°F (32°C to 43°C) water
(see Figure 24 and 25).

4. Carefully inspect each part for wear or damage.
Replace worn or damaged parts.

Figure 25. Removable Parts for optional BCS

5. Wash feed tube and air tube with 90° to 110°F deter­gent water and brushes provided. Rinse with clean,
90° to 1 10°F water (See Figure 26 and 27).

6. Prepare two gallons (7.5 liters) of sanitizing solution
using a USDA certified grade sanitizing solution.
Sanitize all removed parts, then air dry .

7. Check Hose Service Record decal to determine if
hose

reposition or replacement is required at this

time.

8. Reassemble both hose assemblies per the diagram
located on the inside of the cab door. Reconnect
assemblies to the pump and discharge hose, using
the clamps. (Refer to Section 2.5 Mix Pump).

9. Sanitize assembled freezer as per instructions
outlined in Section 3.9.

Figure 26. Cleaning Air Tube

Figure 24. Removable Parts

Figure 27. Cleaning Feed Tube

19

THIS P AGE INTENTIONALLY BLANK

20

SECTION 4

MAINTENANCE INSTRUCTIONS

4.1 PRODUCT CONSISTENCY ADJUSTMENT

The freezer's control system monitors the consistency
(firmness) of the product (mix) in each freezing cylinder.
The program module senses the consistency of the prod­uct and shuts off the drive motor and refrigeration system
when the pre-programmed consistency is reached. The
control panels on the front of the freezer allow the operator
to adjust each freezing cylinder to create the desired
product consistency.

A. Place the Main Freezer Power and Freezing Cylinder

OFF/ON switches in the ON position.

B. Press the SET button on the Control Panel once.

Fine Adj will appear on the LCD screen.

C. Press the up arrow button

tency setting is displayed. The higher the number, the
greater the product consistency. The control may be set
from 1 to 9. Each time the up arrow
pressed, the value will increase by 1 until the value
reaches 9, then restart at 0. The 0 setting cannot be set.

D. Press the SET button once to save the setting change

and return to the current mode display.

(⇑) (⇑)

(⇑) until the desired consis-

(⇑) (⇑)

(⇑) (⇑)

(⇑) button is

(⇑) (⇑)

Fine Adj
1-9 5

4.3 OVERRUN ADJUSTMENT

The product when served is a combination of air and mix.
Overrun is a measure of the amount of air blended into the
mix.

Overrun can be expressed in terms of the amount of weight
loss for a given volume. For example, if a pint of liquid mix
weighs 18 ounces (510 grams) and a pint of frozen product
with air added weighs 12 ounces (340 grams), the overrun
is said to be 50 percent "18 oz. (510 grams) - 12 oz. (340
grams) = 6 oz. (170 grams)", (6 /12) x 100 = 50%.

The overrun can be checked by placing a one pint
container on an ice cream scale and zeroing out the scale.
Then fill a one pint container with frozen product. The
container should be filled over the top and leveled with a
straightedge. The product should not contain any air
pockets. When weighed on an ice cream scale, one pint
(473 milliliters) of product should weigh 12 to 13 ounces
(340 to 368,5 grams).
The mix pump has been preset at the factory to produce
a product with approximately 40% overrun. Because of
differences in mix formulation, temperatures and baromet­ric pressure, this figure may vary. It will be necessary for
approximately 2 gallons (7,5 liters) of mix to be pumped thru
the freezer before changes in the product are noticeable
due to adjustments in overrun.

Overrun is controlled by the length of the air compressor
piston stroke within the piston cylinder. Lengthening the
stroke within the cylinder will increase overrun. Con­versely, shortening the stroke will decrease overrun. To
perform an overrun adjustment, refer to the following
procedure:

Figure 28. Product Conststency Control

4.2 LOCKING OUT CONTROL PANEL

The IntelliTec control has a tamper proof mode to prevent
unauthorized use. When set, all buttons on the control
panel are disabled. To lock out the control panel:

A. Press and hold the PUSH TO FREEZE button for 5

seconds.

B. While still holding the PUSH TO FREEZE button, press

the CLEAN button once.

C. Release both buttons. An astrisk (*) will apear after the

word MODE on the display, indicating that the control
is in the lock out mode.

D. To unlock the control panel, repeat steps A, B and C.

A. Turn the mix pump switch to the OFF position.

Disconnect both power sources/circuit breakers.
B. Remove the lower back panel from freezer.
C.

On air compressor side of pump, locate the long/

slender piston rocking arm. The rocking arm down-

ward travel is limited by a stationery cam. On the

face of the cam there is an overrun setting indicator

plate numbered 3 thru 8 and an adjustment knob.

Figure 29.

ÊÊ

Ê

Overrun Adjustment

Figure 29. Overrun Adjustment

21

ÊÊ

D.The overrun setting is indicated by a pointed pin.
E. T o adjust overrun, loosen the allenhead screw

(located within the center of the adjustment knob)
with the 5/32" (4mm) allen wrench provided. Rotate
the adjustment knob counterclockwise to a higher
number for higher overrun, or clockwise to a lower
number for lower overrun. Each number multiplied by
10 represents the overrun percentage (ie: #4 = 40%
overrun).

F . Tighten the allen screw, then place the wrench back

in its clip. Replace the lower back panel and secure
with the four screws. Turn the mix pump power switch
to the ON position.

4.6 DRIVE BELT TENSION ADJUSTMENT

To check belt tension, refer to Figure 30 and follow the
steps below:

WARNING

Hazardous Voltage and Moving Parts

Never attempt to repair or perform any maintenance
on freezer until all main electrical power to freezer
has been disconnected. Failure to disconnect
electrical power before servicing may result in

serious injury or death.

4.4 MIX PUMP HOSE REPOSITION (every one or
two weeks.)

NOTE

Mix pump hose must be repositioned every 1 - 2
weeks. Failure to comply will result in reduced mix
pump liquid capacity , dispense stoppage, popping,
and possible mix pump hose leakage.

1. Run cleaning solution through pump.

2. Turn pump off and relieve any pressure by

opening the spigot.

3. Grasp the pick-up hose end of the mix pump

hose with one hand and turn the pump on. Pull
down on the pick-up hose end until 12 to 14"
(30-1/2 to 35-1/2cm) of tubing has reverse fed
through the pump, then turn the pump off.

4. Loosen small clamp at the pick-up hose

adapter and (Viewed from Back) disconnect
mix pump hose.

5. Cut 7-1/2" (19 cm) of f the end of the mix pump

hose.

6. Reconnect mix pump hose to adapter.

A. Remove either side and back panels.
B. Press firmly on one belt. Figure 30.
C. When the tension is properly adjusted, the belt

should deflect approximately 3/8" (about the width
of the belt).

Figure 30. Belt Adjustment

7. Continue normal operation. Mix hose will

automatically reposition itself with adapter near
black cover .

NOTE

Each hose is long enough for 3 repositions before
replacement is required. Record each event on
Hose Service Record decal.

4.5 MIX PUMP HOSE REPLACEMENT

NOTE

Mix pump hose must be replaced when tubing can­not be further repositioned (every four to eight
weeks). Failure to comply will result in hose failure
and possible pump damage. See Section 2.5 for
instructions on mix pump hose replacement.

D. If an adjustment is necessary, remove the side panel.

Turn the jack screw located on the motor bracket,
clockwise to increase belt tension or counterclock
wise to decrease belt tension.

22

Figure 31. Removing Condenser Filter

NOTE

Belt life will be increased if new drive belts are tight­ened after two or three weeks of operation.

4.7 CONDENSER CLEANING

The condenser requires periodic cleaning. To clean the
condenser, refer to the following steps:

A. Daily Checks

Check for any unusual noise or condition and repair
immediately.

B. Monthly Checks

1. Check drive belts for wear and tighten belts if
necessary. (Refer to Section 4.5.)

2. Check the condenser for dirt. (Refer to Section

4.6).

4.9 EXTENDED STORAGE

Refer to the following steps for winterizing the freezer or
for storing the freezer over any long period of shutdown
time.

A. Clean thoroughly with warm detergent all parts that

come in contact with mix. Rinse in clear water and
dry all parts. Do not sanitize.

NOTE

Do not let cleaning solution stand in freezer barrel
or mix pump during the shutdown period.

A. Lift the condenser filter off the freezer cover panel.

Visually inspect the condenser filter for dirt (see
Figure 31).

B. If the condenser filter is dirty, vacuum or brush clean,

rinse with clean water and allow to dry before replac
ing on freezer.

NOTE

If the condenser is not kept clean, loss of refrig­eration efficiency will result.

4.8 PREVENTATIVE MAINTENANCE

It is recommended that a preventative maintenance sched­ule be followed to keep the freezer clean and operating
properly. The following steps are suggested as a preven­tative maintenance guide.

WARNING

Hazardous Voltage and Moving Parts

Never attempt to repair or perform any maintenance
on freezer until all main electrical power to freezer
has been disconnected. Failure to disconnect
electrical power before servicing may result in

serious injury or death.

The United States Department of Agriculture and the Food
and Drug Administration require that lubricants used in
food zones be certified for this use. Use lubricants only in
accordance with the manufacturer's instructions.

B. Remove, disassemble, and clean the front door,

auger shaft, and mix pump. Leave disassembled
during the shutdown period.

C. Place plastic auger flights in a plastic bag with a

moist paper towel. This will prevent flights from
becoming brittle if exposed to dry air over an
extended period of time (over 30 days).

E. Place the mix pump ON-OFF switches, Left and

Right Freezing Cylinder switches and the
Main Freezer Power switch in the OFF position.

F. Disconnect from the source of electrical supply in

the building.

4.10 ERROR CODES

The following error condition codes will display on the
control panel when the freezer is experiencing a problem.
The error condition code directs you to the system location
of the malfunction.

ERROR CODE MALFUNCTION
01 Program Board
02 High Torque Error
03 Extended Run Time Error
04 Clean Error
05 Freezing Cylinder Sensor
06 (not used on F431 models)
07 Drive Motor Current
08 Cab Sensor
09 High Pressure Cutout

Any error causing condition must be corrected, then the
power turned off, and back on before the freezer will return
to normal operation.

23

4.11 TROUBLESHOOTING

ERROR CONDITION CODE 01
If the control panel displays a program board error (Error
Code 01), place the Freezing Cylinder Off-On Switch in the
Off position, wait 10 seconds, and return the switch to the
On position. If the Control Panel still displays the error
condition code, call your Authorized Stoelting Distributor
for further assistance.

ERROR CONDITION CODE 02
If the control panel displays a high torque error (Error Code

02), the controller has sensed that the product in the
freezing cylinder has reached 125% of set consistency for
10 or more seconds. This condition may be caused if the
product consistency adjustment has been set too high. To
remedy this condition, place the Freezing Cylinder Off-On
Switch in the Off position, wait until the product in the
freezing cylinder has had adequate time to thaw to a
reasonably soft consistency, and return the switch to the
On position. Follow the Product Consistency Adjustment
procedures at the begining of this section and reduce the
Fine Adjustment value by a few points. If the Control Panel
still displays the error condition code, call your Authorized
Stoelting Distributor for further assistance.

ERROR CONDITION CODE 03
Extended run time errors (Error Code 03) are often times
caused by the mix running too low in the freezer’s mix
container, or if a restriction is preventing the mix from
entering the freezing cylinder. Check the mix level on the
affected freezing cylinder. If the level mix is low, add mix.
Look for ice crystals in the liquid mix container. Ice crystals
can clog the mix inlet system, and prevent mix from entering
the freezing cylinder. If you find ice crystals in the mix,
check the temperature of the walk-in cooler where the mix
is stored and the temperature of the freezer’s cab. If the
freezer’s cab is below 34°F (1°C), call your Stoelting
Authorized Distributor for assistance in adjusting the
freezer cab temperature.
Check the condition of the neoprene hose running through
the mix pump head. If it shows signs of wear, rotate or
replace it as outlined in Section 2.5 of this manual.
Excessive compressor run time may also occur if the
condenser filter is dirty, or if the condenser is obstructed.
Check the top of the freezer, to be sure nothing has been
placed on top of the condenser.
After the cause of the problem is found and remedied,
place the Freezing Cylinder Off-On Switch in the Off
position, wait 10 seconds, and return the switch to the On
position. If the Control Panel still displays the error
condition code, call your Authorized Stoelting Distributor
for further assistance.

ERROR CONDITION CODE 04
If the freezer is left in the Clean Mode for more than 20
minutes, the control panel will display a Clean Error (Error

04). This condition does not reflect a problem with the
freezer itself. The Clean Error has been programmed into
the controller as a safeguard to protect the freezer from
potential damage caused by the freezer being accidentally
left in the clean mode. To remedy the Clean Error, place
the Freezing Cylinder Off-On Switch in the Off position,
wait 10 seconds, and return the switch to the On position.
If the Control Panel still displays the error condition code,
call your Authorized Stoelting Distributor for further assis­tance.

ERROR CONDITION CODE 05
If the control panel displays a Freezing Cylinder Sensor
error (Error Code 05), place the Freezing Cylinder Off-On
Switch in the Off position, wait 10 seconds, and return the
switch to the On position. If the Control Panel still displays
the error condition code, call your Authorized Stoelting
Distributor for further assistance.

NOTE

When the freezer encounters a Freezing Cylinder Sensor
Error, the freezer will automatically be switched to run on
pre-configured timing cycles. This mode will allow you to
continue serving product until the freezer can be serviced.

ERROR CONDITION CODE 07
If the control panel displays a Drive Motor Current error
(Error Code 07), place the Freezing Cylinder Off-On
Switch in the Off position, wait 10 seconds, and return the
switch to the On position. If the Control Panel still displays
the error condition code, call your Authorized Stoelting
Distributor for further assistance.

ERROR CONDITION CODE 08
If the control panel displays a Cab Sensor error (Error
Code 08), place the Freezing Cylinder Off-On Switch in the
Off position, wait 10 seconds, and return the switch to the
On position. If the Control Panel still displays the error
condition code, call your Authorized Stoelting Distributor
for further assistance.

24

ERROR CONDITION CODE 09
Error 09 conditions are usually caused by insufficient

cooling at the freezer's condenser. If the control panel
displays a High Pressure Cutout error (Error Code 09),
turn the freezer power off. Press the High Pressure Cutout
Reset Switch located on the upper, left hand corner of the
left side panel. There is a round, black boot covering the
reset switch. Pressing in the center of the boot will reset
the switch.

In air cooled condenser models, check the air filter to make
sure it is clean (see section 4.6). Replace the filter as
required. Check for proper air clearance around the
freezer. The freezer must have a minimum of 3" (7,5cm)
of space on all sides and 10" (25cm) at the top for proper
circulation. A minimum of 6" (15cm) clearance is required
in high ambient conditions.
On water cooled condenser models, check for proper
waterflow through the condenser coil. After the cause of
the error is determined and corrected, turn on the Main
Freezer Power Switch and place the Freezing Cylinder
switch to the on position. If the Control Panel still displays
the error condition code, call your Authorized Stoelting
Distributor for further assistance.

ALTERNATING FLASHING CONTROL PANEL LIGHTS
When the Main Freezer Power Switch is placed in the

ON position and the left Freezing Cylinder OFF/ON switch
is left in the OFF position, the green and amber control
panel lights will flash in alternating sequence. This indi­cates that the storage cabinet is being refrigerated, but
the left freezing cylinder is not receiving power. Placing
the left Freezing Cylinder OFF/ON switch in the ON posi­tion will return the freezing cylinder to the SLEEP mode.
Pressing the PUSH TO FREEZE button will begin the
freezing cycle.

25

The Troubleshooting Tables on the following three pages list the common problems that can occur to the freezer.

FREEZER

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26

MIX PUMP

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28

SECTION 5

HOW TO ORDER REPLACEMENT PARTS

5.1 HOW TO ORDER REPLACEMENT PARTS

To assure the receipt of the proper replacement parts,
supply your Stoelting Authorized Distributor with the
following information:

A. Model number of equipment.
B. Serial number of model (stamped on nameplate)

C. Part number, part name, and quantity needed.

FRONT DOOR P ARTS

5.2 PARTS LIST AND REFERENCE DRAWINGS

The following lists and drawings will aid the user when
ordering parts or servicing.

29

AUGER P ARTS

R

AUGER AND DOO

MISCELLANEOUS PARTS

Description Part No.

Haynes Spray 12 oz.(340 grams) --------------------508017
Petro-Gel Tube 4 oz. (1 13 grams)--------------------508135
Spline Lubricant 2 oz. (57 grams)--------------------508048
Brush 4"x 8"x16" (10cm x 20cm x 40,5cm) -------208135
Brush 2.5"x 4"x12" (6,5cm x 10cm x 30,5cm)---- 208146
Brush .25"x 4"x14" (,6cm x 10cm x 35,5cm) -----208380
Brush 1"x3.5"x18" (2,5cm x 9cm x 45,5cm) ------208465
Drip Tray --------------------------------------------------- 744273
Drip Tray Grid --------------------------------------------- 417006

30

MIX PUMP PARTS

O

W

F

L

I

E

R

D

I

C

T

N

O

TUBE ROUTING

(ONLY ONE SIDE SHOWN)

31

DECALS

Qty. Part Number Description

2 324200 H.P . Manual Reset
2 324798 Clean-Off-Serve
2 324797 Standby/Serve
1 324800 Cab Off-On
2 324799 Pump Off On
1 324141 Caution, Haz. Rot. Blade - Front Panel
1 324509 Cleaning - Right Side
2 324014 Auger Rotation - Evap. Enclosure Rear
4 324686 Danger - Start Auto, on Evap. Support between belts & motors support brkt.
1 723525 Winterizing, Attach to water hose near bottom
2 324106 Caution - Elec. Wiring Mat'ls must conform between water couplings, one rear

panel bottom
2 324346 Caution - Haz. Mov . Parts, on inside of mtr support brkt @ rear
3 324107 Caution - Haz. Mov . Parts, on cond. bkt. rear & (2) on evap. enclosure sides
2 324208 Attn - Ref. Lk Chk, on evap. enclosure sides
2 723552 T ag - Supply volt., inside J-Box
1 723517 Card - Inside one J-Box
2 ID T ags, Back Panel Top
1 324548 Add. Vent Back Panel Ctr Top
1 Made in U.S.A. - Back panel
2 324103 Caution - Rot. Shaft, on gearbox support bracket
2 324151 Field Connections, J-Box cover, out side
3 324125 Danger Elec.Shock, J-Box covers outside, back panel bottom
1 324242 Warm/Cold, @ T-Stat
2 324565 Night/Serve - Temp. Control Bracket
2 324158 Use copper cond. only, inside both J-boxes
2 324566 Wired According to, on elec. schematic envelope
2 130000 Elec. Schematic Envelope
1 324065 Water Inlet - Back panel above inlet coupling
1 324803 Header Panel Decal (Stoelting Logo)
1 324804 Header Panel Decal (Stoelting Swirl)
1 324806 Header Panel Decal (A & W Logo)

32

WARRANTY

SOFT SERVE / SHAKE FREEZERS

1. Scope:

Stoelting, LLC warrants to the first user (the “Buyer”) that the freezer cylinders, hoppers, compressors, drive motors,

speed reducers, auger and auger flights of Stoelting soft serve / shake freezers will be free from defects in materials
and workmanship under normal use and proper maintenance appearing within five (5) years, and that all other
components of such equipment manufactured by Stoelting will be free from defects in material and workmanship
under normal use and proper maintenance appearing within twelve (12) months after the date that such equipment is
originally installed.

2. Disclaimer of Other Warranties:

THIS W ARRANTY IS EXCLUSIVE; AND STOEL TING HEREBY DISCLAIMS ANY IMPLIED W AR­RANTY OF MERCHANTABILITY OR FITNESS FOR PA RTICULAR PURPOSE.

3. Remedies:

Stoelting’s sole obligations, and Buyer’s sole remedies, for any breach of this warranty shall be the repair or (at
Stoelting’s option) replacement of the affected component at Stoelting’s plant in Kiel, Wisconsin, or (again, at
Stoelting’ s option) refund of the purchase price of the affected equipment, and, during the first twelve (12) months of
the warranty period, deinstallation/reinstallation of the affected component from/into the equipment. Those obliga­tions/remedies are subject to the conditions that Buyer (a) signs and returns to Stoelting, upon installation, the
Checklist/Warranty Registration Card for the affected equipment, (b) gives Stoelting prompt written notice of any
claimed breach of warranty within the applicable warranty period, and (c) delivers the affected equipment to Stoelting
or its designated service location, in its original packaging/crating, also within that period. Buyer shall bear the cost
and risk of shipping to and from Stoelting’ s plant or designated service location.

4. Exclusions and Limitations:

This warranty does not extend to parts, sometimes called “wear parts”, which are generally expected to deteriorate
and to require replacement as equipment is used, including as examples but not intended to be limited to o-rings,
auger seals, auger support bushings and drive belts. All such parts are sold

AS IS.

Further, Stoelting shall not be responsible to provide any remedy under this warranty with respect to any component
that fails by reason of negligence, abnormal use, misuse or abuse, use with parts or equipment not manufactured or
supplied by Stoelting, or damage in transit.

THE REMEDIES SET FORTH IN THIS W ARRANTY SHALL BE THE SOLE LIABILITY STOEL TING
AND THE EXCLUSIVE REMEDY OF BUYER WITH RESPECT TO EQUIPMENT SUPPLIED BY
STOEL TING; AND IN NO EVENT SHALL STOEL TING BE LIABLE FOR ANY INCIDENT AL OR
CONSEQUENTIAL DAMAGES, WHETHER FOR BREACH OF W ARRANTY OR OTHER CON­TRACT BREACH, NEGLIGENCE OR OTHER T ORT, OR ON ANY STRICT LIABILITY THEORY .