Stoelting U431 Operators Manual
Model U431
SERVICE MANUAL
Manual No. 513572 Rev.5
This manual provides basic information about the machine. Instructions and suggestions are
given covering its operation and care.
The illustrations and specifi 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
specifi c safety information, the following safety defi ni-
tions 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
Sect. 1 INTRODUCTION .................................................................................... 1
1.1 Description.............................................................................................. 1
1.2 Specifications.......................................................................................... 1
Sect. 2 INST ALLATION INSTRUCTIONS .......................................................... 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 (Serial #0 thru 17977).............................................................. 5
2.6 Mix Pump (Serial #17978 and up)............................................................ 8
Sect. 3 INITIAL SET -UP AND OPERATION....................................................... 11
3.1 Safety Precautions .................................................................................. 11
3.2 Operating Controls and Indicators............................................................ 11
3.3 Important Information Regarding Cleaning and Sanitizing......................... 13
3.4 Disassembly of Freezer Parts.................................................................. 14
3.5 Cleaning Disassembled Parts ................................................................. 15
3.6 Sanitize Freezer Parts ............................................................................. 15
3.7 Cleaning the Freezer ............................................................................... 16
3.8 Assembling Freezer ................................................................................ 16
3.9 Sanitizing ................................................................................................ 18
3.10 Initial Freeze Down and Operation ........................................................... 18
3.11 Mix Information ........................................................................................ 19
3.12 Operation of Mix Pump ............................................................................ 20
3.13 Mix Pump Cleaning ................................................................................. 20
3.14 Disassembly and Inspection of Removable Parts..................................... 20
Sect. 4 MAINTENANCE INSTRUCTIONS......................................................... 23
4.1 Freezer Adjustment.................................................................................. 23
4.2 Product T emperature Adjustment ............................................................. 23
4.3 Overrun Adjustment..................................................................................23
4.4 Mix Pump Hose Reposition ..................................................................... 24
4.5 Mix Pump Hose Replacement.................................................................. 24
4.6 Cab T emperature Adjustment................................................................... 24
4.7 Drive Belt T ension Adjustment.................................................................. 25
4.8 Condenser Cleaning (Air-Cooled Freezers)............................................. 25
4.9 Preventative Maintenance........................................................................ 25
4.10 Extended S torage.................................................................................... 26
4.11 Freezer Reference Photos....................................................................... 27
TABLE OF CONTENTS
Sect. 5 REFRIGERA TION SYSTEM .................................................................. 31
5.1 Refrigeration System ............................................................................... 31
5.2 Compressor ............................................................................................ 31
5.3 Condenser .............................................................................................. 32
5.4 Evaporator .............................................................................................. 32
5.5 Cab Unit .................................................................................................. 34
Sect. 6 ELECTRICAL CONTROL SYSTEM ...................................................... 35
6.1 Control System ........................................................................................ 35
6.2 Current Sensor ........................................................................................ 36
6.3 Contactors............................................................................................... 36
6.4 Drive Motor.............................................................................................. 36
Sect. 7 MAJOR COMPONENT REMOVAL AND INSTALLATION..................... 37
7.1 Preparation for Component Removal....................................................... 37
7.2 Cooling Fan Motor Removal .................................................................... 37
7.3 Drive Motor Removal ............................................................................... 37
7.4 Gear Box Removal .................................................................................. 37
7.5 Compressor Removal.............................................................................. 38
7.6 Compressor Installation ........................................................................... 38
7.7 Gearbox Installation ................................................................................. 3 9
7.8 Drive Motor Installation............................................................................. 39
7.9 Condenser Fan Motor Installation (Air-Cooled)......................................... 39
7.10 Final Assembly of Freezer ....................................................................... 40
Sect. 8 TROUBLESHOOTING ........................................................................... 41
8.1 Troubleshooting - Freezer ........................................................................ 41
8.2 Refrigeration Drawings ............................................................................ 42
8.3 Troubleshooting - Mix Pump..................................................................... 44
8.4 Troubleshooting the Challenger T emperature Control and Sensor............. 46
Sect. 9 REPLACEMENT PARTS INFORMATION ............................................. 53
9.1 Replacement Parts Information ................................................................ 53
General Order Advice.............................................................................. 75
ILLUSTRATIONS
Figure 1 Model U431 Freezer..............................................................1
Figure 2 Specifications........................................................................1
Figure 3 Decal Label Locations ...........................................................3
Figure 4 Water/Electrical Connections .................................................4
Figure 5 Auger Rotation.......................................................................4
Figure 6 Mix Hose Installation...............................................................5
Figure 7 Mix Pump...............................................................................6
Figure 8 4 Way Tee .............................................................................7
Figure 9 Mix Inlet Tube & Probe Assy. Clip...........................................7
Figure 10 Hose Holder...........................................................................7
Figure 11 Mix Hose Installation...............................................................8
Figure 12 Mix Pump...............................................................................9
Figure 13 3 Way Tee .............................................................................10
Figure 14 Mix Inlet Tube & Probe Assy. Clip...........................................10
Figure 15 Hose Holder...........................................................................10
Figure 16 Operating Controls.................................................................11
Figure 17 Auger Flight Wear & Front Auger Support Bushing Wear .......14
Figure 18 Front Door Disassembly ........................................................15
Figure 19 Auger Flight Removal.............................................................15
Figure 20 Rear Seal Removal................................................................15
Figure 31 Rear Seal Lubrication ............................................................16
Figure 22 Spring Installation...................................................................16
Figure 23 Front Door Assembly .............................................................17
Figure 24 Air Bleed Valves ....................................................................18
Figure 25 Draining Sanitizer ..................................................................18
Figure 26 Refrigerated Cabinet .............................................................19
Figure 27 Dispensing Product ...............................................................19
Figure 28 Mix Pumps.............................................................................20
Figure 29 Removable Parts ...................................................................21
Figure 30 Cleaning Air Tube ..................................................................21
Figure 31 Cleaning Feed Tube ..............................................................21
Figure 32 Mix Pump Tube Routing .........................................................21
ILLUSTRATIONS
Figure 33 Potentiometer ........................................................................23
Figure 34 Overrun Adjustment................................................................23
Figure 35 Pump Roller Assembly ...........................................................24
Figure 36 Temperature Control Cab ......................................................25
Figure 37 Belt Adjustment......................................................................25
Figure 38 Nameplate .............................................................................31
Figure 39 Terminal Cover Removal ........................................................31
Figure 40 Compressor Connections ......................................................31
Figure 41 Expansion Valve ....................................................................32
Figure 42 Expansion Valve Removal......................................................33
Figure 43 Drier ......................................................................................33
Figure 44 Water Valves .........................................................................34
Figure 45 Front Electrical Box................................................................35
Figure 46 Front Electrical Box Up Close ................................................35
Figure 47 Electrical Panel Screws .........................................................35
Figure 48 Block Off Panel ......................................................................37
Figure 49 Drive Motor & Belt Removal ...................................................37
Figure 50 Drive Motor Removal .............................................................37
Figure 51 Gear Box Removal.................................................................38
Figure 52 Compressor Connections ......................................................38
Figure 53 Compressor Connections ......................................................38
Figure 54 Drier ......................................................................................39
Figure 55 Gear Box Removal.................................................................39
Figure 56 Belt Tension...........................................................................39
Figure 57 Motor Installation ....................................................................39
SECTION 1
INTRODUCTION
1.1 DESCRIPTION
The Stoelting U431 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 U431 pressure freezer .
Figure 1. Model U431 Freezer
1.2 SPECIFICATIONS
SNOISNEMID
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LACIRTCELE
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Figure 2. Specification
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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.
T ake notice of all warning labels on the freezer (Fig.3).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
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.
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.
Figure 4. Water/Electrical Connections
E. Place the CLEAN-OFF-ON switches in the OFF
position before continuing. Figure 1 1.
2.3 FREEZER INST ALLATION
W ARNING
INSTALLATION MUST BE PERFORMED BY A
QUALIFIED ELECTRICIAN/REFRIGERATION SPECIALIST. INCORRECT INSTALLATION COULD
CAUSE PERSONAL INJURY, SEVERE DAMAGE
TO THE MACHINE AND WILL VOID THE WARRANTY.
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. 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.
C. The freezer must have a minimum of 3 inches (6
inches high ambient conditions) of space at all sides
and 10 inches at the top for proper circulation.
CAUTION
FAILURE T O PROVIDE ADEQUA TE VENTILA TION
WILL VOID WARRANTY!
D. Water-cooled freezers need an adequate water
supply . Install 1/2 inch pipe or 1/2 inch inside diameter copper water line to the freezer. Connect
water outlet to a drain using a 1/2 inch inside
diameter line. Automatic washer hoses work well for
final connections. All water connections must
comply with local codes. Figure 4.
2.4 INSTALLING PERMANENT WIRING
Permanent wiring is required by local codes, the following
procedure must be performed:
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. (Figure 4)
NOTE
Three phase freezers in areas of unbalanced electrical loads require special attention when connecting input electrical power. The unbalanced leg of
power (called wild or high) must be connected to L2
in the junction box.
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
DRIVE switch in the CLEAN position. Auger shaft
rotation is clockwise as viewed through the clear plas-
tic front door. If the rot ation 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. (Figure 5)
CAUTION
FLUSH ALL WA TER LINES BEFORE INST ALLATION. IN STORES WITH SEDIMENT IN W ATER,
ADD SUIT ABLE FILTER OR STRAINER TO WATER INLET .
Figure 5. Auger Rotation
4
2.5 MIX PUMP (Serial #0 thru 17977)
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.
3. Gently push the hose into the black cover until it
begins to feed.
Figure 6. Mix Hose Installation
4. Allow the hose to feed itself thru the pump until
6" remains on the entering side.
5. Turn pump off.
6. Connect mix pump hose to pickup hose adapter
using small hose clamp.
CAUTION
DO NOT TWIST MIX PUMP HOSE.
7. Turn pump on.
8. Allow remaining 6" of tubing to feed thru pump
until hose adapter prevents further feeding.
9. Turn pump off.
10.Connect free end of mix pump hose to "4 way
Tee" as shown in Figure 7. When all connections
are complete the "4 way Tee" must be lower than
the black pump housing. Fig. 8
5
B. Connect 1/2 inch I.D. plastic food grade
tubing to check valve and then to the mix container.
Observe check valve flow arrow. Secure with hose
clamps. Then place assembly thru hole in cover
and install retainer clip. Figure 9.
C. Connect 1/2 inch I.D. plastic food grade
tubing between the large port of air/mix tee and
refrigeratedmix transfer line. Secure with large
hose clamp or equivalent. Figure 9.
CAUTION
AIR/MIX TEE MUST REMAIN BELOW THE
BLACK COVER/CLAMP
. IF THE TEE IS ABOVE
THE PUMP MIX WILL DRAIN TO THE AIR COMPRESSOR RESUL TING IN PUMP DAMAGE.
D. Connect mix low cords. Figure 9.
/ 1177816
Figure 7. Mix Pump
6
Refrigerated
ÅÅ
Å
ÅÅ
Mix Transfer
Line
4 Way Tee
Figure 8. 4 Way Tee
ÆÆ
Æ
ÆÆ
Large Port
ÅÅ
Å
ÅÅ
Air/Mix Tee
Low Mix Cord
Cover
ÈÈ
È
ÈÈ
ÌÌ
Ì
ÌÌ
ÇÇ
Ç
ÇÇ
Hose Holder
Figure 10. Hose Holder
ÉÉ
É
ÉÉ
Retainer
Mix
Clip
Container
Figure 9. Mix Inlet Tube & Probe Assy. Clip
7
2.6 MIX PUMP (Serial #17978 and Up)
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.
3. Gently push the hose into the black cover until it
begins to feed.
6" (15cm)
Figure 11. Mix Hose Installation
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 pickup hose
adapter using small hose clamp.
CAUTION
DO NOT TWIST MIX PUMP HOSE.
7. Turn pump on.
8. Allow remaining 6" (15cm) of tubing to feed thru pump
until hose adapter prevents further feeding.
9. Turn pump off.
10.Connect free end of mix pump hose to 3-way
Tee as shown in Figure 7. When all connections
are complete the 3- way Tee must be lower than
the black pump housing. Figure 8.
8
B. Connect 1/2 inch (12,7mm) I.D. plastic food grade
tubing to mix check valve (Item 7) and then to the
mix container. Observe check valve flow arrow.
Secure with hose clamps. Then place assembly
thru hole in cover and install retainer clip. See
Figure 9.
C. Connect 1/2 inch (12,7mm) I.D. plastic food grade
tubing between the large port of air/mix tee and
refrigerated mix transfer line. Secure with large
hose clamp or equivalent. See Figure 9.
CAUTION
AIR/MIX TEE MUST REMAIN BELOW THE
BLACK COVER/CLAMP. IF THE TEE IS
ABOVE THE PUMP MIX WILL DRAIN TO THE
AIR COMPRESSOR RESULTING IN PUMP
DAMAGE.
D. Connect mix low cords. Figure 9.
Figure 12. Mix Pump
9
ÅÅ
Å
ÅÅ
Refrigerated
Mix Transfer
ÅÅ
Å
Large Port
(Air/Mix)
Figure 13. 3-way Tee
ÆÆ
Æ
ÆÆ
ÅÅ
Line
3-way Tee
ÇÇ
Ç
ÇÇ
Hose Holder
Low Mix Cord
ÌÌ
Ì
ÌÌ
Cover
ÈÈ
È
ÈÈ
ÉÉ
É
ÉÉ
Mix
Container
Figure 14. Mix Inlet Tube & Probe Assy. Clip
Retainer
Clip
Figure 15. Hose Holder
10
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.
A. Spigot Switch
When the spigot handle is opened the SPIGOT
switch will start the auger drive and refrigeration
systems. When the spigot handle is closed, the drive
B. Clean-Off-Serve Switch
The CLEAN-OFF-SERVE switch is a three position
toggle switch used to control the operation of the
refrigeration system and auger. When the switch is
placed in the CLEAN position, the refrigeration system will be off and auger will rotate for cleaning.
When the switch is placed in the OFF position, the
refrigeration system and auger will not operate.
When the switch is placed in the SERVE position,
the refrigeration system and auger will operate auto-
matically. The switch should be placed in the SERVE
position for normal operation.
C. Cabinet-Off-On Switch
The CABINET-OFF-ON switch is a two position
toggle switch. When the switch is placed in the OFF
position, the lower cabinet refrigeration system will
not run. 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.
Standby-
Serve
Low
Mix
Light
Clean-
Off-Serve
Cab
Off-On
Cab Indicator
Standby-
Serve
Low Mix
Light
Light
Freezing
Dispense Rate
Adjusters
Pump Switch
Figure 16. Operating Controls
WARNING
The CLEAN-OFF-SERVE 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.
Clean-
Off-Serve
D. Cab Indicator Light
A flashing light indicates the cab OFF-ON switch is
in the OFF position, no refrigeration. Place the OFFON switch in the ON position for cab refrigeration.
E. Pump Switch
The pump motor switch is a two position toggle
switch. When the 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. Standby/Serve Switch
The standby/serve switch is a two position toggle
switch. When the switch is placed in the Standby
position the freezer will cycle to maintain a
temperature below 41°F. When the switch is in the
Serve position the freezer will cycle to maintain a
servable product.
G. Freezing Switch
The freezing switch is a two position toggle switch.
When the switch is placed in the ON position
the freezer will be forced to run 30 seconds after the
temperature control is satisfied.
11
H. 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.
I. High Head Pressure Cut Out
If the head pressure exceeds 445 PSIG (28 bar) air
cooled andwater cooled, the high head pressure
cutout will trip. The reset button can be accessed
from the side of thefreezer.
J. Low Mix Light
The low mix light will illuminate when the liquid level
in the mix container drops below two gallons.
K. 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.
12
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.
13
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 and handling them
requires safety
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 CLEAN-OFF-SERVE toggle
switch in the OFF position before disassembling
for cleaning or servicing. Placing the CLEAN-OFFSERVE toggle switch in the SERVE 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 17. Auger Flight Wear & Front Auger
Support Bushing Wear
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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 18. 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 20. 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 19. 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 SANITIZE 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.
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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 21. 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 22. 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.
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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 23. 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.
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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 sanitary 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 90° to
1 10°F (32°C to 43°C) water. Allow sanitizer to contact 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 CLEAN-OFF-SERVE toggle switch in
the CLEAN position.
Figure 25. Draining Sanitizer
E. Check for leaks when the freezer barrel is first
pressurized with sanitizing solution.
1. Check for leaks at the plastic front door, the
O-rings may not be sealed.
Air Bleed Valves
Figure 24. 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.
2. Check the drain located at the center of the
Drip Tray for leaks coming from the rear of the
Rear Auger Seal.
3. Check inside cab unit for leaks at hose connections.
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 (See Figure 20).
H. Close the spigot and place the mix pump switch
and the CLEAN-OFF-SERVE switch in the OFF
position.
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.
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).
B. Prepare the desired amount of mix and then fill each
storage container with approximately 3 gallons or
more of mix. Place a container(s) of mix in the refrigerated cabinet. If drawing from a storage container ,
place the draw tube through the cover to the bottom
of the container . If drawing from a bag in a box, remove the cap, push out all of the air, and insert the
adaptor.
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