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K3/B Operations Manual

1. IMPORTANT Check the beater seal for integrity Replace if worn or damaged It should be replaced rather frequently step 5 Insert the beater assembly into the cylinder Push it while turning it clockwise until it engages in its rear hub otherwise the dispensing head cannot be fastened properly mix can flow out and serious damage may occur 6 5 2 REASSEMBLY OF THE SUNDAE DISPENSING DOOR step 1 Lubricate and slide the 2 piston O ring 1153 into their seats step 2 Lubricate the piston 30 and insert it pointed end down in the dispensing head 7 making sure that the piston square notch lines up with the 4188 Co rectangular opening on the spigot front step 3 CD Position the dispensing handle 5 on the door 7 and insert the pivot pin 6 in its housing through the handle lever hole Lubricate and slide the O ring 1289 into its seat on the pivot pin Lubricate and slide into its seat the large dispensing door O ring 1188 step 4 Insert the dispensing door assembly onto the two front panel studs and fasten it with the two knobs 8 hand tight This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 45 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 5 3 REASSEMBLING OF THE SUNDAE MIX PUMP step 1 Lubricate and replace the two O rings 1117 on the connection
2. essen 35 6 2 2 DISASSEMBLING OF THE MIX PUMDP sese enne enne enne enne 37 6 2 3 DISASSEMBLING OF THE SUNDAE DISPENSING DOOR eee 38 6 2 4 DISASSEMBLING OF THE SUNDAE BEATER sese 38 6 3 WASHING AND SANITIZING OF COMPONENT PARTS eee 39 6 4 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS 41 6 4 1 REASSEMBLY OF THE SHAKE CYLINDER BEATER sse 41 6 4 2 REASSEMBLY OF THE SHAKE DISPENSING DOOR isssseeees 42 6 4 3 REASSEMBLY OF THE SHAKE MIX PUMP esses eene 43 6 4 4 REASSEMBLY OF THE MIX HOPPER AGITATOR sess 45 6 5 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS 45 6 5 1 REASSEMBLY OF THE SUNDAE BEATER esses essen enne 45 6 5 2 REASSEMBLY OF THE SUNDAE DISPENSING DOGR vrrrrrnvvrnnnrnnnrrrnnnnovvrnerrennnn 45 6 5 3 REASSEMBLING OF THE SUNDAE MIX PUMP sese 46 6 5 4 REASSEMBLING OF THE MIX TANK AGITATOR sese 47 6 6 SANITIZING THE WHOLE MACHINE iiec pert Spec nen aa ea n ede aea ina rey rete 47 6 6 1 SANITIZE THE HOPPER ond o ut EpeE repe E I oe R leas skia 47 6 6 2 SANITIZE THE PUMP AND FREEZING CYLINDER esee 47 6 6 5 DRAIN ESN 47 6 7 SYRUP SANITIZING PRIMING AND CALIBRATION SHAKE SIDE 48 6 8 MIX PRIMING vvs 48 T MONTHLY CLEANING sesssssecsseossoosssoessoessoesssosssooseosssossscsecsssosssossssessossscosssoessoss
3. 9 1 ALARMS TROUBLESHOOTING The machine is provided with a self diagnosis function which indicates any failure during operation The display blinks when an alarm is active and becomes on solid if an alarm was detected and then reset Push RESET button in order to refresh the display when the alarm has been reset Use the following table to determine whether a service call is required critical alarm If a service call is required write down the alarm message and inform the service company The machine can dispense product in case a non critical alarm is active ALARM DESCRIPTION CORRECTIVE ACTION Add Mix Mix level is lower than the medium level sensor Pour the mix in the hopper Mix Out Mix level is lower than the low level sensor Pour the mix in the hopper Safety Therm Cyl TESC Cylinder safety thermostat tripped The machine switches to Stop without completing the heat treatment cycle The mix is NOT pasteurized CALL FOR SERVICE Safety Therm Hop TESV Hopper safety thermostat tripped The machines switches to Stop without completing the heat treatment cycle The mix is NOT pasteurized CALL FOR SERVICE Overload beater PTMA Thermal relay of beater motor has tripped CALL FOR SERVICE Pressure Switch PR Pressure switch for high gas pressure has tripped Check air flow to the condenser if not blocked CALL FOR SERVICE Overload Compres PTMC Thermal relay of compressor mot
4. The first row indicates the step number and the second row indicates the description and value 2 Push or in order to increase or decrease the value 3 Push STOP to move to the next step 4 To exit the Manager Menu push button The following table illustrates all the steps of the manager menu STEP N Display Min Max Default first row second row Lo a p LLL LLL en PERENNE u01 Hor 00 23 Tobeadjusted U02 Minutes 1 00 59 Tobeadjusted U07 Language ITA ENG ENG 00 Start Distr Hour 00 Beeper 1 00 Syrup 1 pump speed Syrup 3 pump spee d Syrup 2 pump speed d Syrup 4 pump speed Time and date adjustment Language selection Start Pasteurisation time Start Production time Disable enable the audible alarm when mix level is low Syrup pumps speed to calibrate the syrup quantity 1 oz fluid ounce in 5 or 7 sec This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 16 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 2 1 2 SUNDAE FUNCTIONS STOP BUTTON By pressing this push button during operation the machine stops LED on DISPLAY Comments 10 33 21 Fri When the machine is in STOP the display shows Time and Date 10 33 21 Fri In case we have an ALARM activated the backlight of the LCD Overload Be
5. s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 7 MONTHLY CLEANING 7 4 AIR FILTER CLEANING It is necessary to clean the air filter every month as follows Step 1 Locate and remove the filter from the equipment Step 2 At the back sink prepare a warm solution of McD All Purpose Super Concentrate APSC HCS from the sink proportioner Step 3 Wash the filter thoroughly in the warm McD All Purpose Super Concentrate APSC HCS solution Step 4 After washing the mesh filter rinse thoroughly using hot water from the hose at the back sink NOTE Flush in the opposite direction to normal air flow through the filter Step 5 Shake all the water from the filter Step 6 Using a clean sanitized towel wipe any remaining moisture from the filter Step 7 Place the filter into the filter track Step 8 Push the filter in until it is seated Step 9 Cleaning the mesh filter is complete CAUTION Never use sharp metal objects to execute this operation a regular operation of the freezing system mostly depends on condenser cleanout This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 50 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 8 PREVENTATIVE MAINTENANCE 8 1 CHECK OUT LIST During daily weekly and fortnightly clea
6. step 11 Press the 9 button and let the beater run for about 10 seconds step 12 Push the STOP button step 13 Use the white hopper brush to scrub the mix hopper mix level sensor and the outside the agitator shaft Use the small brush to clean the mix inlet hole and the drive hub of the mix pump step 14 Push the ey button and let the liquid flow completely out step 15 Then push the STOP button to close the piston step 16 Rinse the machine Rinse with clear water push the Z button and let the water flow completely out Press the STOP button to close the piston step 17 Sanitize the machine Fill the hopper with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gal 9 1 2 liters of water 100 PPM step 18 Press the button and let the beater run for 10 seconds then push STOP Use the white hopper brush to scrub the mix hopper mix level sensor and the outside the agitator shaft Use the small brush to clean the mix inlet hole and the drive hub of the mix pump step 19 Leave the solution of McD Sanitizer for a minimum of 1 minute step 20 Push the er button and let the sanitizer flow completely out step 21 Push the STOP button This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 31 of 56 s a ice users amyh my documents steve holcomb k 3_g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 1 3 D
7. Carpigiani K 3 Equipment Manual 2 4 OPERATION 2 4 1 DISPENSING MILK SHAKE e Once the milk shake has completed the freezing cycle and the LED is on solid place a cup on the cup holder and press one of the coloured cup buttons brown red yellow or blue in order to dispense milk shake e The machine automatically dispenses the milk shake in the cup placed on the cup holder up to the level set by the sensor e The dispensing may be stopped at anytime by pressing any of the coloured cup buttons JER WARNING SN OT dis important to keep the sensor clean and to use a fresh clean cup of the recommended type N 1 The cup seal must always face away from the sensor 2 4 2 DISPENSING SUNDAE In order to dispense sundae place a cup or a cone under the spout and slowly pull down the dispensing handle As soon as the sundae comes out twist the cup or the cone to form a cone shaped serving When the portion has reached the desired size close the dispensing handle and quickly pull the cone or the cup down in order to sharpen the tip 2 5 PROGRAMMED CLEANING CYCLE The machine is equipped with an automatic system that calls for washing of the parts in contact with the product at least every 14 days In PROD the second row of the display indicates the days remaining to the next cleaning Sundae Ready Wash in 14days 2 6 POWER FAILURE In the event of a black out with the machine in e AGITATION e
8. Page 47 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 7 SYRUP SANITIZING PRIMING AND CALIBRATION SHAKE SIDE Make sure your hands are clean and sanitized before performing the following procedures Sanitizing the syrup lines a Fill an empty pail with McD sanitizer prepared in water 122 140 F 50 60 C 1 packet in 2 1 2 gallons 9 1 2 liters of water 100 PPM and mix the powder b Place the pick up tubes inside Push STOP button then the corresponding coloured cup button two times to run the syrup pump at maximum speed and let the sanitizing solution flow for 1 minute Press STOP button to stop the syrup pump c Repeat for all syrup lines Drain the sanitizer from the syrup lines a Remove the pick up tubes from the pail and put them on a clean towel in the cabinet Place an empty pail under the draw spout and push STOP button then push twice on each coloured cup button to run the syrup pumps and drain the residues of sanitizer b Push STOP button to stop the pump Priming the syrup lines with syrup a Place each pick up tube in its syrup jug or connect the syrup connector to the syrup bag Place empty bucket under the spout c Press coloured cup button two times until the syrup is dispensed discard this sample d Press STOP button to stop the syrup pump e Repeat for all syrup flavors f Using a clean sanitized towe
9. Version 1 July 06 Carpigiani K 3 Equipment Manual 5 3 CHECK TOPPING PUMP TEMPERATURE AND VOLUME NOTE This procedure should be performed on a morning after the pumps were disassembled and cleaned Step 1 Dispense one serving of topping into a sundae cup Discard this sample Step 2 Dispense second serving into a sundae cup Step 3 Insert the digital thermometer into the topping Let the digital thermometer stabilize for 20 seconds NOTE Topping temperature should be between 115 and 125 46 and 52 and must be this temperature before the pump calibration can begin Water bath temperature should be between 135 and 145 F 57 and 63 Step 4 If the temperature is too cold or too warm call service to adjust Step 5 Hold the small chamber of the calibrating cup under the dispensing nozzle Step 6 Push the dispensing lever down for one full stroke The topping should be directed to the bottom of the calibrating cup Do not allow the topping to fall on the sides of the cup NOTE The amount of dispensed topping should be one fluid ounce 29 6 ml Step 7 If the amount of dispensed topping is not correct consult the troubleshooting section of your equipment manual Step 8 Repeat for the other topping pump This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 28 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigi
10. 2 gal 9 1 2 liters of water 100 PPM Step 9 Push on the quick coupling connector ref 1a to disconnect the syrup pickup tube from the pump tube Step 10 Push on the quick coupling connector ref 1b to disconnect the syrup feed tube from the pump tube Step 11 Open the pump by pushing down on the hinged cover ref 2 Step 12 Grasp the pump tube ref 385 from one end pull it up and pull out the second end remove the pump tube 385 Pump tube Installation Step 1 Lubricate the o rings on the syrup line fittings Step 2 Place the pump tube into the pump body Step 3 Pull up the pump cover to close it Step 4 Connect the syrup feed tube into the pump tube fitting This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 52 of 56 s a ice users amyh my documents steve holcomb k 3_g doc Version 1 July 06 Carpigiani K 3 Equipment Manual Step 5 Connect the syrup pickup tube into the pump tube fitting Step 6 Replace the syrup jugs Step 7 Prime the syrup lines Dispense one serving of syrup into a cup and discard this sample Step 8 Calibrate the syrup system according to the instructions in the equipment manual This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 53 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 9
11. BUTTONS Every coloured cup button corresponds to a milk shake flavour In PRODUCTION the product is dispensed according to the flavor selected If while dispensing milk shake you push any coloured cup button the milk shake will immediately stop without reaching its automatic level such a function can be used to dispense small portions to try out In STOP by pushing the button a the piston opens and remains opened by pushing again it closes In STOP The coloured cup button are used for syrup calibration zo Le SYRUP QUANTITY CHECK and SYRUP SYSTEM CLEANING While the machine is in STOP Push one time a coloured cup button The respective peristaltic pump will run for 5 or 7 sec Check the quantity of the syrup using the calibration cup This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 15 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual If the quantity of syrup is not satisfactory then modify the calibration as explained in the manager menu By pushing a second time while the syrup pump is ON the pump will run at MAX speed in order to flush and clean the syrup tubes MANAGER MENU 1 To access the Manager Menu push simultaneously both keys and then release immediately On the display you will read the first step of the Manager Menu Step U01 Hour 10
12. Carpigiani K 3 Equipment Manual 2 3 MANAGER MENU 5 To access the Manager Menu push simultaneously both keys and then release immediately On the display you will read the first step of the Manager Menu Step U01 Hour 10 The first row indicates the step number and the second row indicates the description and value 6 Push or in order to increase or decrease the value 7 Push STOP to move to the next step 8 To exit the Manager Menu push AGITATION key The following table illustrates all the steps of the manager menu eee U01 Hor 00 23 Tobeadjusted U02 Minutes 1 00 59 Tobe adjusted Day of Week To be adjusted STEP N Display Min Max Default first row second row ee ee dd am Uo7 Language ITA ENG ENG U08 jStatPastoHou 00 23 no 02 U09 JStarDistrHour 00 23 no 08 U10 Bepr 00 0t 01 Time and date adjustment Language selection Start Pasteurisation time Start Production time Disable enable the audible alarm when mix level is low THE MACHINE IS READY FOR START UP ONLY AFTER IT HAS BEEN PERFECTLY CLEANED AND SANITIZED FOR HYGIENIC AND SAFETY REASONS HANDS SHOULD NEVER BE PLACED INSIDE THE MIX TANK DURING THE MACHINE OPERATION This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 20 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06
13. HEAT TREATMENT HEATING or PAUSE stage the machine will resume operating in the same function where it was when the power went off If the machine was in one of the following functions e STORAGE e PRODUCTION e HEAT TREATMENT COOLING stage upon the return of power the temperature at the time of failure and the duration of the black out will be automatically checked and the machine will resume operating in the same function or it will start a new HEAT TREATMENT cycle in accordance with the applicable safety standards CAUTION If a blackout exceeds four hours itis always necessary to avoid health hazards in the dispensed product to disassemble to wash to rinse and to sanitize the parts as indicated in Section 4 of this manual This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 21 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 3 DAILY CLOSING PROCEDURES 3 1 MILK SHAKE SIDE Make sure your hands are clean and sanitized before performing the following procedures 3 1 1 DISASSEMBLING AND CLEANING THE COMPONENTS Remove cup holder drip tray and drip trough to wash rinse sanitize at the sink and replace them on the machine 3 1 2 SANITIZING THE DOOR AREA a Fill an empty pail with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gallons 9 1 2 liters of water 100 PPM
14. Manual step 11 Clean the machine Fill the hopper with 2 1 2 gallons 9 1 2 liters of warm APSC solution step 12 Clean the hopper walls the level sensor and outside of the agitator shaft using the supplied brushes step 13 Pull the dispensing handle and let the liquid flow out completely step 14 Rinse the machine Rinse with clear water pull the spigot handle and let the water flow out step 15 Sanitize the machine Fill the hopper with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gal 9 1 2 liters of water 100 PPM step 16 Press button and let the beater run for 10 seconds Use the white hopper brush to scrub the mix hopper mix level sensor and the outside of the agitator shaft Use the small brush to clean the mix inlet hole and the drive hub of the mix pump step 17 Push the STOP button Let the McD Sanitizer solution stand for a minimum of 1 minute step 18 Pull the dispensing handle and let the water flow completely out This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 36 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 2 2 DISASSEMBLING OF THE MIX PUMP step 1 Remove driveshaft 96 and seal 243 step 2 Keeping the feeding tube 271 upward turn it counterclockwise and pull it out step 3 Pull the spring 206 and the back f
15. Storage Led lights ON as soon as the Pasteurisation cycle ends The machine preserves the mix at 2 C 35 F in the hopper and in the cylinder this button is used to decrease the value in the manager menu this button is also used to RESET the ALARM MESSAGES on the display MIX LEVEL SIGNAL In each hopper we have 2 level sensors MEDIUM level and LOW level When the MIX LEVEL LED flashes it means that the mix level in the hopper is lower than the medium mix level sensor When the MIX LEVEL LED is on it means that the mix level in the hopper is lower than the minimum mix level sensor The display indicates ADD MIX or MIX OUT Maximum filling level indicator Mix level sensor EE When the LCD back light is blinking that means an alarm has tripped When it becomes solid the alarm which has previously tripped has automatically reset and the indication on the display must be reset by pressing RESET button 6 2 2 EVENTS In order to read the events the machine should be in STOP then push until READ EVENTS is displayed 02 00 00 06 APR START PASTEUR The first event will appear on the display Push or in order to scroll UP or DOWN the events list Push to exit the events reading and go to STOP This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 19 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06
16. condition the mix must be pasteurized run a pasteurization cycle until PASTO END appears to unlock the machine Push STOP then PROD This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Page 54 of 56 Carpigiani K 3 Equipment Manual TECHNICAL SERVICE ON THE MACHINE INTERVENTI DURANTE LA VITA DELLA MACCHINA MACCHINA MACHINE MATRICOLA MATRICLE CLIENTE CLIENT CARPIGIANI MACHINE MASCHINE SERIAL N FABRIK NR CLIENT KUNDE K 3 INTERVEN TECNICO INCONVENIENTE RIMEDIO REMEDY comunicato INSPECT TECHNICIAN PROBLEM SOLUTION at OPERATI TECHNICIEN PANNE BESEITIGUNG refered to ARBEIT TECHNIKER ST RUNG e Mitteilung Installazione Installation Installation Inbetriebsetzung Chiamata del Request call Demande du Meldung wom Chiamata del Request cali Demande du Meldung vom Chiamata del Request call Demande du Meldung vom Chiamata del Request call Demande du Meldung vom Chiamata del Request call Demande du Meldung vom 1 Spedire o consegnare a Servizio Clienti BO via Emilia 45 40011 Anzola Emilia 1 Please fill in this report and send it or deliver to Servizio Clienti BO via Emilia 45 40011 Anzola Emilia 1 S V P remplisser ce formulaire et envoyer au Servizio Cli
17. e f the heat treatment cycle was not successfully completed the machine will be locked out Check the reason by reading the alarm messages and press in order to reset the message on the display Press STOP then PROD button to run a manual heat treatment cycle If the heat treatment cycle is successfully completed the lock out resets automatically and the machine is ready to go in production No product can be dispensed during the heat cycle approximately three hours 4 1 MILK SHAKE SIDE Make sure your hands are clean and sanitized before performing the following procedures 4 1 1 SANITIZE THE DOOR AREA a Fill an empty pail with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gallons 9 1 2 liters of water 100 PPM and mix the powder b Dip the door spout brush in the pail of sanitizer and brush clean several times the dispensing spout area and the spinner plate c Spray the spigot area and spigot spout with sanitizer d Wipe exterior of machine with clean sanitized towel 4 1 2 REMOVING THE SANITIZING SOLUTION FROM SYRUP LINES a Remove the pick up tubes from the pail containing the sanitizing solution and put them on a clean towel in the cabinet b The machine is in STORAGE function push STOP c Push the corresponding coloured cup button two times to run the syrup pumps at maximum speed in order to empty the tube from the remaining sanitizing solution d Press STOP button to stop the syrup pum
18. machine with a small amount of McD sanitizer solution in a pail c Dip the door spout brush in the pail of sanitizer and brush clean the dispensing spout d Spray the spigot area and spigot spout with sanitizer e Wipe exterior of machine with clean sanitized towel 3 2 2 PREPARE THE MACHINE FOR THE OVERNIGHT HEAT TREATMENT CYCLE a Open the hopper cover to verify the mix level b Fill the hopper with McD sundae mix to the Max level The ADD MIX message on the display should be off c Keep the machine in PROD mode WARNING If the mix in the hopper is below the medium level ADD MIX message on the display the heat treatment cycle will not start NOTE To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows Push for 3 seconds button the respective led will flash indicating that the keyboard is blocked At this stage you can clean the keyboard without any risk To reactivate the keyboard push for 3 seconds button the led will get off This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 23 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 4 DAILY OPENING PROCEDURES e Check that heat treatment cycle has been successfully completed and the display indicates the message PASTO END followed by the time and day of completion
19. piston housing O rings 1240 located inside the dispensing door d the spout cap plate O ring 1253 e Remove the duck bill valves and the 8 o rings 1246 of the syrup valve block 6 1 5 DISASSEMBLING OF THE SHAKE CYLINDER BEATER step 1 Remove the shake beater 21 from the cylinder pulling it towards you CAUTION Be careful not to hit the cylinder walls with the shaft of the beater when pulling it out step 2 Slide the beater seal 28 out of the beater shaft CAUTION Make sure that the beater seal is in its place and be careful not to lose it and to reassemble it after washing step 3 Remove the idler 24A from the beater frame 21A step 4 Remove the beater blade pin 726 pulling it upward and remove the blade 430 step 5 Remove the pin O ring 1271 Beveled blade Je 2 NU Rubber stoppers Description Beater Counter beater Stuffing box beater seal Beater blade Beater blade pin O ring 28A This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 34 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 2 DISASSEMBLING AND CLEANING THE SUNDAE SIDE 6 2 1 DRAINING AND CLEANING THE SUNDAE SIDE Drain the machine step 1 Place an empty pail under the SUNDAE spout step 2 Press the STOP button step 3 Pull the dispensing lever and drain the ice cream
20. reached the desired consistency the display shows READY Do Not Serve Overload Beater In case of ALARM this will be displayed on the second row N Hopper 146 Cylinder V 136 While in Prod mode we can go to the next page of the display by pushing PROD key Temperatures are indicated o Set 090 Hot 085 Pushing PROD again we move to the next page showing actual consistence and the SET to be reached Cones today Pushing PROD again we move to the next page showing 4 1543 the daily cone counter Total Cones Pushing PROD again we move to the next page showing 123456789 the TOTAL cones counter o TEV 10 TGV 22 TEC 13 TE1 12 Pushing PROD again we move to the next page showing the temperature in the hopper in the cylinder ae e 3 8 o l TET 60 Pushing PROD again we move to the next page showing the actual Topping temperature Pushing PROD again we move to the next page that is the first page This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 13 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual AGITATION BUTTON By pressing this button from STOP the led turns on and the display indicates KEY DISPLAY Comments TEV 13 TEC 13 Pushing one time this button the beater motor and t
21. remain at room temperature for long periods of time 5e Hopper storage must maintain a temperature of 40 F 4 4 C Storage temperatures above 45 F will allow bacteria to multiply to dangerous levels in less than one hour 5f Once the mix is placed in the hopper the hopper covers must be used to maintain the correct temperature and minimize mix contamination This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 8 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 1 INTRODUCTION 1 1 GENERAL INFORMATION 1 1 1 MANUFACTURER S IDENTIFICATION DATA The machine has a data plate carrying manufacturer data machine type and serial number assigned when it is manufactured LEGEND A Serial number B Machine type C Voltage MAX BREAKER FUSE SIZE D Fuss Breaker Size MINIMUM CIRCUIT AMPACITY m E Gas type and weight D F Frequency 1 2 INFORMATION ABOUT THE MACHINE 1 2 1 GENERAL DATA Electronic self heat treatment floor machine for the production and immediate distribution of milkshake ice cream having the following main features Refrigerated upper tanks Cylinder feeding pumps to control product overrun Automatic system to dispense the milkshake with a 4 flavors syrup selection Two containers for hot toppings with heating temperature control Two containers for room temperature to
22. small parts be washed in a pan or other container so they will not be lost step 3 Sanitize the pump components immerging them in a container with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gal 9 1 2 liters of water 100 PPM and mix the powder and waiting for 1 minute step 4 Allow the pump parts to air dry after sanitizing e REASSEMBLY step 1 Lubricate and position the knob O ring in its groove on the knob Set the knob aside step 2 Assemble the washer the spring the head insert and the head tube on the piston and stem assembly step 3 Slip the gaging collars if they are used onto the head tube then place the locking collar on the head tube 1 5 16 O RING VALVE BODY CYLINDER ASSEMBLY VALVE a BODY CYLINDER ASSEMBLY NOTCH CENTER LOCKING GROOVE LOCKING GROOVE CYLINDER ASSEMBLY DISCHARGE TUBE ASSEMBLY FLATS 1 LOCKING GROOVE n VALVE BODY step 4 Hold onto the head tube and push the piston and stem assembly into the head tube compressing the spring When the threaded end of the stem projects through the head tube thread the knob onto the piston and stem assembly step 5 Set the assembled plunger assembly aside step 6 Lubricate the O ring with approved lubricant and install the O ring in its groove on the discharge tube assembly bushing Temporarily set the discharge tube assembly aside step 7 Lubricate the O rin
23. the syrup pump at maximum speed and let the water flow for 1 minute Press STOP button to stop the syrup pump d Repeat for all syrup lines Rinsing the syrup lines a Filla pail with tap water and place the pick up tubes inside Push the corresponding coloured cup button two time and let the water flow for 1 minute Press STOP button to stop the syrup pump b Repeat for all syrup lines This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 29 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 12 DRAINING AND CLEANING THE MILK SHAKE SIDE WARNING Every time the f j shows WASH TODAY alarm you have to push once the button in order to reset the alarm message Drain the Milk Shake step 1 Put an empty pail under dispensing spout step 2 Push the STOP button step 3 Push the ey button then push OM to allow the milk shake to flow out until it becomes liquid step 4 Push the STOP button to close the piston stop the beater motor and the mix pump step 5 Remove the pressure tube In the hopper disconnect the pressure tube from the pump turn it sideways and remove it by pulling it up from its seat Remove the mix pump Grasp the pump and turn it in a clockwise direction of 45 then pull it out towards you Make sure that the pump drive shaft and seal are taken out with the pum
24. Combination shake sundae dispenser K 3 Equipment Operating Manual This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Manufactured by Carpigiani Group Via Emilia 45 Anzola Emilia Bologna 40011 ITALY Telephone 800 648 4389 Facsimile 336 661 9895 First Printing March 06 Printed in Italy Version 1 July 06 Replaces Carpigiani K 3 Equipment Manual Table of Contents WARRANTV asics cc cca eich st cs 5 CONVENTIONAL SYMBOLS ssseessessoeseesoescoesoessesoossossoeseossossseesossosssessoesoossoesoesoossossoesoossossosee 6 TROUBLESHOOTING BACTERIA CONTAMINATION 4 eere ee ee eese een neta aen 7 L INTRODUCTION m 9 1 1 GENERAL INFORMA EID iesu On REED on Ros ro a a EE LEEA EE E ia 9 1 1 1 MANUFACTURER S IDENTIFICATION DATA eei ert FU ptt reae rds 9 1 2 INFORMATION ABOUT THE MACHINE eren enne enne nenne 9 1 2 1 GENERAL DATA sicissiccoinssnssnnrraiarcensniersansneagoiessssneubinedselaiebessbbsnbassotaanes seueswnincbneedsountene 9 L22 INTENDED USE i scaxesncsenesnvccsnaienvesniess oe ieavneuensaaitesisenvncatesonisoaneten EE EA ENOR E 9 1 2 3 NOISE ee 9 1 2 4 TECHNICAL FEAL URED HN 10 1 2 5 MACHINE ASSEMBLY IDENTIFICATION ccccccssesssesscccsscccsssscessscesssccseescessecseenss 10 1 2 6 AUTOMATIC HEAT
25. ISASSEMBLING OF THE SHAKE MIX PUMP step 1 Remove the pump drive shaft and seal from the pump step 2 By holding the feeding tube 271A upwards turn it counter clockwise and pull it out 96 Description 202A 2 Hand screws Check valve slit Pressure pipe Driving gear Driven gear Pump body Pump shaft Shake chamber tube Pump housing Spring Connection tube Feeding tube Seal mix pump shaft Pressure relief valve O ring O ring O ring 271A O ring O ring O ring 1117 1117 31 9 step 3 Using the O ring extractor remove the O ring 1412 Remove the spring 206A and the back flow valve 245 step 4 Unscrew the 2 knobs 8B and separate the cover 202A from the pump body 39A step 5 Using the or ring extractor remove the large O ring 1178 Tapping the pump body against the palm of your hand remove the pump gears 38 and 384A step 6 Pull the connection tube 207 from the pressure pipe Remove the O rings 1131 and 1117 and the duck bill valve 31 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 32 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 1 4 DISASSEMBLING OF THE SHAKE DISPENSING DOOR CAUTION Before disassembling the dispensing head make sure that the hopper and the cylinder are completely draine
26. IZE THE DOOR AREA apene tnt Suns ead shpoag P dai erat deve UR VOR da 24 SIJTALDIRITHEJMSCHTNE edda 24 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 2 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 4 2 SUNDAE SIDE vr 25 4 2 1 PREPARING THE HOT TOPPING saisis ek ub tdi seint db 25 4 22 S START THE MACHINE proni R L E ER R A Ue eMe deanna E DEDE 25 5 WEEKLY CLEANING veske 26 5 1 WASHING AND SANITIZING OF THE TOPPING CONTAINERS 26 5 1 1 CLEANING IHE TOPPING ANS arenaene edunt aa uide 26 5 1 2 CLEANING THE TOPPING HOPPER 2 ciisevectisausscsiiseanettiaas brecsaspandivesa cetanesavneieanitedeonse 26 5 2 DISASSEMBLING WASHING AND SANITIZING OF THE HOT TOPPING PUMPS PN 26 5 3 CHECK TOPPING PUMP TEMPERATURE AND VOLUME 28 6 EVERY 14 DAYS CLEAN NG mA 29 6 1 DISASSEMBLING AND CLEANING THE MILK SHAKE SIDE 29 6 1 1 CLEANING THE SHAKE SYRUP SYSTEM eov iSo eanet 29 6 1 2 DRAINING AND CLEANING THE MILK SHAKE SIDE sse 30 6 1 3 DISASSEMBLING OF THE SHAKE MIX PUMP sse 32 6 1 4 DISASSEMBLING OF THE SHAKE DISPENSING DOOR sssee 33 6 1 5 DISASSEMBLING OF THE SHAKE CYLINDER BEATER sse 34 6 2 DISASSEMBLING AND CLEANING THE SUNDAE SIDE see 35 6 2 1 DRAINING AND CLEANING THE SUNDAE SIDE
27. TREATMENT CYCLE sess 11 1 2 7 TEMPERATURE GN 11 1 2 8 TANK LIDS HOLDER ves sctincecsssedgenns ogherxsdessinanetghade stay eap ey a Bod arene eivandauncednaien 11 2 INSTRUCTIONS FOR USE ioosicittns sacan tenu ka eda Eapy UE equa socero un a R0 ER EEBU CDX Eng Rn ski L enn Dua a cts 12 2 1 ong 9 P 12 2 1 1 MILK SHAKE FUNCTIONS SE 13 2 1 2 SUNDAE FUNCTIONS opeen RE EEE O EE OEE 17 2 2 FEN Speed 19 2 3 MANAGER RR 20 2 4 OPERATION MT Eai 21 2 4 1 DISPENSING MILK SHAK E GN 21 2 4 2 DISPENSING SUNDAE hacerme nna aa AEE E R 21 2 5 PROGRAMMED CLEANING CYCLE srein a a aa 21 2 6 POWER FAILURE jp 21 3 DAILY CLOSING PROCEDURES e ssesssoessocesoossssesssesesoossoosssosssosssoesssoessosssosssssssssese 22 3 1 MILK SHAKE SIDE 25d tee pute eura theceatvecetraradeusiietucidedistictateseecasduaddcuiuaacus 22 3 1 1 DISASSEMBLING AND CLEANING THE COMPONENTS see 22 MAST TANG TIE DOR AREA TRU 22 3 1 3 SYRUP LINE CLEANING SANITIZING auis sordide adire XD ath EP ausiai 22 3 1 4 PREPARING THE MACHINE FOR THE OVERNIGHT HEAT TREATMENT CYCLE 22 3 2 SUNDAE SIDE T EUR 23 3 2 1 SANITIZE THE DOT AI A m 23 3 2 2 PREPARE THE MACHINE FOR THE OVERNIGHT HEAT TREATMENT CYCLE 23 4 DAILY OPENING PROCEDURES wisiscccssssccssscossnscssvesvenssscessteenssessaasenenscenanaccuancceexcssenes 24 4 1 MILK SHAKE SIDE 2 25 5 petenti eea eE aeaa E aa E Eaa anaapa Easa 24 4 1 1 SANIT
28. Wash the disassembled parts with the APSC solution and scrub them thoroughly with the brushes provided with the machine As you proceed rinse with hot water Make sure all lubricant and mix film is removed from parts step 3 Fill another sink with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gal 9 1 2 liters of water 100 PPM step 4 Place the parts in the sanitizing solution Leave them there for a minimum of 1 minute step 5 Place the milk shake components on the milk shake tray to air dry step 6 Place the sundae components on the sundae tray to air dry step 7 Return to the machine with a small amount of McD Sanitizer step 8 Dip a brush into the sanitizer and thoroughly brush both freezing cylinders step 9 Dip a brush into the sanitizer and thoroughly brush clean the mix inlet hole and the pump drive hub openings in the rear of both mix hoppers Step 10 Spray the back of cylinder with sanitizer This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 39 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual step 11 Dip a brush into the sanitizer solution thoroughly brush clean the syrup injectors located on the front panel just under the milk shake cylinder Repeat steps 8 9 and 10 several times 4 Air Dry 3 Sanitize y 2 Rinse IMPORTANT We reco
29. again we move to the next page that is the first page This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 17 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual TOPPING HEATER In PROD function the two hot topping containers are heated automatically to reach the desired temperature In case the water level in the bainmarie is too low the display will indicate an alarm in order to refill with water AGITATION BUTTON By pressing this button from STOP the led turns on The beater and the mix pump motor get ON until you press STOP or after 3 minutes The display indicates KEY DISPLAY comments TEV 13 TEC 13 Pushing one time this button the beater motor and the mix pump motor will turn ON _ Beater Motor OFF STOP whereas the mix pump remains ON g TEV 13 TEC 13 Pushing a second time this button the beater motor will N LOCK BUTTON To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows O Push for 3 seconds button the respective led will flash indicating that the keyboard is blocked At this stage you can clean the keyboard without any risk To reactivate the keyboard push for 3 seconds button the led will get off G HEAT TREATMENT FUNCTION INCREASE FUNCTION The heat treat
30. age 51 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 Ju ly 06 Carpigiani K 3 Equipment Manual 8 2 SIX MONTHS CHECK UP AND MAINTENANCE e Replace the syrup pump tube every 6 months e Replace rubber parts O ring beater seal rubber pipes pressure relief valves e Check proper scraping action of the beater blade e Checkthe correct operation of syrup pumps dispensed syrup quantity 8 2 1 PERISTALTIC PUMP TUBE REPLACEMENT INSTRUCTION Pump tube Removal Step 1 Remove the syrup feed tubes from the syrup containers Wipe the outside of the feed tubes with a clean sanitized towel Step 2 Remove the syrup jugs Step 3 Place the syrup feed tubes in a pail of McD All Purpose Super Concentrate APSC HCS 1 packet in 2 1 2 gal 9 1 2 liters of water 100 PPM To avoid contamination cover syrup containers with a plastic wrap Step 4 Press STOP button LED On Step 5 Press twice the coloured cup button to start the flow of McD All Purpose Super Concentrate APSC HCS through the syrup line Step 6 Allow the McD All Purpose Super Concentrate APSC HCS to flow until all of the syrup is flushed from the line Step 7 Once the line is free of syrup remove the syrup feed tube from the McD d All Purpose Super Concentrate APSC HCS and run the pump until the TE syrup line is free from liquid Ref 1a Step 8 Repeat steps 3 through 8 using McD Sanitizer HCS 1 packet in 2 1
31. al is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 48 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual Prime Hopper e Retrieve 1 bag of McD shake or sundae mix from the walk in refrigerator e With the both sides of the machine in STOP mode place an empty pail under the draw spouts e Pull the handle for SUNDAE sides or press the ey button for the SHAKE side e With the draw handle SUNDAE side or piston SHAKE side open pour one bag of mix into the hoppers allowing it to drain into the freezing cylinders e When only full strength mix not mix and sanitizer is flowing from the draw spouts close the draw handle for SUNDAE side or press the ey button for the SHAKE side Connect the mix pressure pipe e When the mix stops bubbling from the bottom of the hopper take the mix pressure pipe from the sanitizing solution and insert it in its position in the bottom of the hopper Make sure your hands are clean and sanitized Press the 9 button and let run the beater for only five seconds just to check the pumps work well the push STOP e Turn the pressure pipe clockwise towards the pump and connect the tube to the pump e Press PROD button to start the Automatic freezing operation e Replace the hopper cover This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 49 of 56
32. al protection switch on all poles of the line adequately sized to the absorption power shown on machine data plate and with contact opening of 3 mm at least This switch is used to cut off the power supply Any replacement of the power cable must be carried out only by a specialized and authorized technician e Never put your hand into the machine during production and cleaning operations Before carrying out any maintenance operation make sure that the machine is in STOP position and main switch has been cut out e tis forbidden to wash the machine by means of a stream of water under pressure e Disconnect electrical power before removing any side or rear panel e CARPIGIANI is not responsible for any accident that might happen during operation cleaning and or servicing of its units if this warning has not been fully complied with This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 6 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual Troubleshooting Bacteria Contamination Product samples should be taken periodically by a qualified expert in order to asses the bacteria count in the product The bacteria count in the samples should be below the Standard Plate Count SPC COON enna figures given below Should the bacteria counts exceed the figures listed above then there is a source of bac
33. and mix the powder b Return to the machine with a small amount of McD sanitizer solution in a pail c Dip the door spout brush in the pail of sanitizer and brush clean several times the dispensing spout area and the spinner plate d Spray the spigot area and spigot spout with sanitizer e Using a clean sanitized towel wipe the freezer door front panel the area around the freezer door and any other areas that demonstrate a build up of either moisture or food splashed 3 1 3 SYRUP LINE CLEANING SANITIZING Wiping pick up tubes a Remove the syrup pick up tubes from the syrup jugs or disconnect the syrup connectors from the bags b Wipe the outside of the pick up tubes syrup connectors with a clean sanitized towel c Remove the syrup jugs syrup bags from the cabinet Sanitizing the syrup lines a Fill an empty pail with McD sanitizer prepared in water 122 140 F 50 60 C 1 packet in 2 1 2 gallons 9 1 2 liters of water 100 PPM and mix the powder b Place the pick up tubes inside Push STOP button then the corresponding coloured cup button two times to run the syrup pump at maximum speed and let the sanitizing solution flow for 1 minute Press STOP button to stop the syrup pump c Repeat for all syrup lines d Keep the pick up tubes in the pail containing the sanitizing solution e The machine is in STOP function push PROD button ATTENTION Make sure that you don t keep the machine in STOP in fact th
34. ani K 3 Equipment Manual 6 EVERY 14 DAYS CLEANING After exactly 14 DAYS from the last brush cleaning the machine must be thoroughly washed and restarted It automatically locks out and must be disassembled washed sanitized and reassembled before operations can resume Every time product is dispensed the display indicates the number of days to the next brush cleaning The following is the list of operations to be performed on the 14 day in addition to the regular daily and weekly cleaning procedure NOTICE MAKE SURE YOUR HANDS ARE CLEAN AND SANITIZED 6 1 DISASSEMBLING AND CLEANING THE MILK SHAKE SIDE NOTICE ALL PARTS REMOVED FROM THE MACHINE SHOULD BE PLACED INTO A CONTAINER AND TRASPORTED TO THE SINK FOR CLEANING RINSING AND SANITIZING 6 1 1 CLEANING THE SHAKE SYRUP SYSTEM Wiping pick up tubes a Remove the syrup pick up tubes from the syrup jugs or disconnect the syrup connector from the syrup bag b Wipe the outside of the pick up tubes with a clean sanitized towel Remove the syrup jugs syrup bags from the syrup compartment Cleaning the syrup lines a Remove the cup holder and place an empty pail under the door spout b Fill a pail with the McD All Purpose Super Concentrate APSC and hot water 122 140 F 50 60 C or refill a pail of hot McD APSC from the KayStar dispenser at the back sink c Place the pick up tubes inside Press STOP then push the corresponding coloured cup button two times to run
35. ar Driving gear Pump hosing rear Pump drive shaft Pump hosing front Spring Connection tube Seal mix pump drive shaft Pressure relief valve Feeding tube O ring O ring U O ring O ring 1117 31 C This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Page 46 of 56 Carpigiani K 3 Equipment Manual 6 5 4 REASSEMBLING OF THE MIX TANK AGITATOR step 1 Relocate the agitator back in its seat pay attention to engage it onto its shaft correctly 6 6 SANITIZING THE WHOLE MACHINE The machine must be sanitized before mix is poured in carry out the following operations for both shake side and sundae side of the machine NOTE After the machine s brush cleaning and more precisely from the moment you close the front door lid of the machine it is necessary to run the machine in production by pushing PROD button within 60 minutes After the 60 minutes the machine does not accept the PROD button any more and it sets to heat treatment function automatically In other words you should make the Sanitization of the whole machine and the Mix Priming within 60 minutes then push PROD button 6 6 1 SANITIZE THE HOPPER e Fill the hopper to the maximum level with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gal 9 1 2 litres of water 100 PPM and al
36. ater display will flash and the display indicates the kind of ALARM PRODUCTION BUTTON Press PROD button to start the production mode LED on The motor and compressor are automatically controlled by HARD O TRONIC system By pressing this button from STOP the display indicates KEY DISPLAY comments Do Not Serve Wash in 14 days When the sundae is not ready the display shows DO NOT SERVE Sundae Ready Wash in 14 days When the sundae has reached the desired consistency the display shows READY Do Not Serve Overload Beater In case of ALARM this will be displayed on the second row N Hopper 4146 Cylinder W 136 While in Prod mode we can go to the next page of the display by pushing PROD key Temperatures are indicated o Set 090 Hot 085 Pushing PROD again we move to the next page showing actual consistence and the SET to be reached Cones today Pushing PROD again we move to the next page showing 4 1543 the daily cone counter Total Cones Pushing PROD again we move to the next page showing 123456789 the TOTAL cones counter o TEV 10 TGV 22 TEC 13 TE1 12 Pushing PROD again we move to the next page showing the temperature in the hopper in the cylinder 09000 TET 60 Pushing PROD again we move to the next page showing the actual Topping temperature Pushing PROD
37. beater shaft and properly lubricated during operation otherwise mix will leak in the drip tray step 5 Insert the beater assembly into the cylinder push it to the end and rotate it slightly until its shaft enters the rear hub the self adjusting blade should be inside the rim of the cylinder This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 41 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 4 2 REASSEMBLY OF THE SHAKE DISPENSING DOOR step 1 Lubricate and replace the 4 syrup outlet o rings 1109 on the front panel of machine step 2 Lubricate the O rings and replace them in their respective position i e a Replace the 8 o rings 1246 on the syrup distribution block 377 b Replace the 4 duck bill valves 31A on the syrup distribution block 377 c Replace the syrup distribution block 377 in its position on the front panel of the machine d Replace the 2 piston housing O ring 1240 in the dispensing door e Replace the O ring 1130 on the piston f Replace the O ring 1195 on the dispensing door g Replace the O ring 1142 on the spinner plate step 3 Holding the dispensing door 7A upward lubricate and replace the piston 30A in its position in the front door step 4 Fit the dispensing door 7A in the four front panel studs and fasten it with the four knobs 8A hand tighten
38. d 2 Description B 30A Dispensing door Hand screws Piston iaz Syrup duck bill valves a Spinner Spout cap Syrup valves support 1246 O ring o og 5 O ring OL sa O ring sann O ring m O ring Y dn 1109 step 1 With the machine in STOP mode push button to open the piston step 2 Open the protection cover ref C step 3 Slide up with the fingers the connection ref A and turn clockwise the bracket ref B Step 4 Remove the cup holder Step 5 Twist spout cap 370 clockwise then pull it down in order to remove it the warning IMSB OPEN flashs on the display step 6 Slide the spinner out 369 CAUTION Be careful not to drop the spinner it may be seriously damaged step 7 Unscrew the four door retaining knobs 8A and remove the dispensing door from the four studs by pulling it towards you Fig 4 step 8 Remove the valve block 377 sliding it down step 9 Remove the 4 o rings 1109 from syrup outlet on the front of the machine step 10 Gn Holding the dispensing door 74 straight up 4 remove the piston by pulling it upward Fig 5 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 33 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual step 11 Using the O ring extractor remove a the piston O ring 1130 b the door O ring 1195 c the 2
39. discharge tube assembly by rotating it counterclockwise until the flats on the discharge tube bushing clears the valve body locking grooves then carefully mE pull the discharge tube assembly from the valve body E step 3 eas Separate the O ring from the discharge tube bushing by squeezing on the O ring ASSEMBLY A ens TUBE and sliding it in the bushing groove until the O ring can be rolled out from the j M groove l step 4 Remove the cylinder assembly from the valve body by applying down pressure on the cylinder assembly while rotating it counterclockwise direction until the tabs of the DAING v cylinder assembly clear the locking grooves on the valve body A step 5 DISCHARGE TUBE Remove the O ring from the valve body ME step 6 Place all parts in a clean container ge c e WASHING NOTE DO NOT use tools that can scratch polished surfaces Do use clean and sanitized brushes This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 26 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual step 1 Wash all pump components in the McD All Purpose Super Concentrate APSC and hot water 122 140 F 50 60 C or with hot McD APSC from the KayStar dispenser at the back sink step 2 Rinse them with clear water Use the supplied brushes to clean the discharge tube assembly and the valve body It is recommended that the
40. e machine will show on the display the message WHY IN STOP in order to remind you to push PROD button as soon as you finish the syrup cleaning procedure 3 1 4 PREPARING THE MACHINE FOR THE OVERNIGHT HEAT TREATMENT CYCLE a Open the hopper cover to verify the mix level b Fill the hopper with McD shake mix to the Max level The ADD MIX message on the display should be off c Keep the machine in PROD mode WARNING If the mix in the hopper is below the medium level ADD MIX MESSAGE ON DISPLAY the heat treatment cycle will not start NOTE To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows Push for 3 seconds button the respective led will flash indicating that the keyboard is blocked At this S stage you can clean the keyboard without any risk To reactivate the keyboard push for 3 seconds button the led will get off This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 22 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 3 2 SUNDAE SIDE Make sure your hands are clean and sanitized before performing the following procedures 3 2 1 SANITIZE THE DOOR AREA a Fill an empty pail with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gallons 9 1 2 liters of water 100 PPM and mix the powder b Return to the
41. enci BO via Emilia 45 40011 Anzola Emilia 1 Bitte einsenden oder aush ndingen an kunderndienstabt Servizio Clienti BO via Emilia 45 40011 Anzola Emilia 2 Fare firmare al Manager o proprietario 2 Signature of the Manager or franchisee 2 Signature du Manager ou proprietaire 2 Unterschrift vom Manager oder Inhaber This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 55 of 56 slaWicelusersiamyhlmy documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 56 of 56 slaWicelusersiamyhlmy documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual
42. eration described may do harm if not carried out in the observance of safety rules NOTE ne It points out significant information for the staff involved WARNING alike The staff involved is warned that the in observance of information may cause a loss of data and damages to the machine PROTECTIONS This symbol placed by description side means that the operator must use personal protections against an implicit risk of accident SAFETY When using industrial equipment and plants one must be aware of the fact that drive mechanisms rotary motion high voltage components as well as parts subject to high temperatures may cause serious damages to persons and things Who is in charge of plant safety must be on the look out that an uncorrect use or handling is avoided Safety devices must neither be removed nor tampered Only original spare parts are to be used especially as far as those components with safety functions are concerned ex protection microswitches thermostats To achieve the above the following is necessary At working place an instruction manual relevant to the machine should be available Such documentation must be carefully read and regulations must consequently be followed Only adequately skilled personnel will have to be assigned to electrical equipment WARNING The machine must be installed only by a specialized and authorized technician when installing the machine insert a differential magnetotherm
43. g with food grade lubricant and install the O ring in its groove in the valve body step 8 Align the tabs on the cylinder flange with the notches in the valve body Tilt the cylinder assembly slightly and slide the widest section of the flange under the center locking groove of the valve body Rotate the cylinder assembly clockwise while applying down pressure on the cylinder assembly until the flange tabs fully engage the locking grooves of the valve body step 9 Position the discharge tube assembly on the valve body aligning the flats on the discharge tube assembly bushing with the locking tabs on the valve body Push down on the discharge tube assembly until it is seated Rotate the discharge tube assembly clockwise to lock it in place step 10 Slide the lid onto the discharge tube assembly and the cylinder assembly and secure the lid with the discharge tube nut step 11 Apply food grade lubricant to the discharge fitting O ring and install the O ring on the discharge tube fitting Install the fitting in the discharge tube by pushing the fitting into the discharge tube and rotating it in a clockwise direction step 12 Apply a small amount of food grade lubricant to the seal flare install the plunger assembly in the pump body assembly and tighten the locking collar This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc s a ice users amyh my documents steve holcomb k 3 g doc Page 27 of 56
44. h my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual SOURCE OF CONTAMINATION PREVENTION 4 Incorrect cleaning and sanitation procedures 4a Sink must be perfectly clean and contain enough solution to cover the biggest component Brush clean and sanitize the freezer on a regular basis 4b Use the correct brushes lubricants and single service towels 4c Store and use chemicals as directed by the instructions on their labels 4d Use a few good employees to follow the cleaning procedure correctly and consistently Allow the employee uninterrupted time to complete the cleaning procedure 4e Allow the sanitizing solution to stand in the hopper and freezing cylinder for five minutes 4f Wash and sanitize the lubricant tube after each use Always replace the cap on the tube 4g Machine components and brushes should be air dried overnight Never store them in the storage cooler 4h Always follow daily cleaning procedures Regularly wipe down the outside of the machine and dispensing spouts with a sanitized towel 5 Improperly stored mix 5a Use mix stock with oldest date first Observe expiration dates 5b Place the mix directly in the cooler Do not stack mix outside or under direct sunlight before placing it in the cooler 5c Always leave one inch between the mix and other products in the cooler to allow air to circulate 5d Mix must not
45. he insulated cylinder evaporator hopper assembly 5 years from date of first installation Replaced parts are covered for 1 year from date of their installation Freight and duty on parts replaced under warranty are covered Labor Warranty The labor required to correct component malfunctions or to replace defective parts is provided free of charge for 1 year from date of installation Special Conditions Local rates and conditions for out of warranty service will be negotiated between the authorized local service agency and local McDonald s organizations This label filled by the installer indicating the warranty periods is placed on the upper part of the right side panel WARRANTY EXPIRATION DATES START UP DATE Day Month Year ITEM PARTS WARRANTY LABOR WARRANTY Hopper assembly Compressor Beater motor All other components Parts that are normally subject to wear are excluded from warranty coverage This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 5 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual Conventional Symbols ATTENTION ELECTRIC SHOCK DANGER The staff involved is warned that the in observance of safety rules in carrying out the operation described may cause an electric shock ATTENTION GENERAL DANGER The staff involved is warned that the op
46. he mix pump motor will turn ON TEV 13 TEC 13 Pushing a second time this button the beater motor will Beater Motor OFF SOP whereas the mix pump remains ON N oF LOCK BUTTON To clean the keyboard panel with a clean towel it is recommended to block the keys of the keyboard as follows Push for 3 seconds button the respective led will flash indicating that the keyboard is blocked At this stage you can clean the keyboard without any risk To reactivate the keyboard push for 3 seconds button the led will get off HEAT TREATMENT FUNCTION INCREASE FUNCTION The heat treatment function can be activated only if the mix in the hopper is above the Medium Level ADD MIX message on display must be off AUTOMATIC HEAT TREATMENT CYCLE while the machine is in production SHAKE LED on and the mix is above the medium level the heat treatment cycle starts automatically at a certain time as programmed in the Manager Menu normally at 2 00 AM During the display indicates HEAT TREATMENT CYCLE the mix in the hopper and in the cylinder is heated up to 65 C kept at 65 C for 30 minutes and finally cooled down to 2 C At the end of the cycle the display shows PASTO END followed by date and hour of termination The machine passes automatically to STORAGE function To serve shake press STOP then the PROD button Note Once the heat treatment cycle has started it can not be interrupted The comp
47. he powder b Return to the machine with a small amount of McD sanitizer solution in a pail c Dip the door spout brush in the pail of sanitizer and brush clean the dispensing spout d Spray the spigot area and spigot spout with sanitizer e Wipe exterior of machine with clean sanitized towel 4 2 2 PREPARING THE HOT TOPPING a Remove the topping containers and check the water level Refill hot topping bainmarie with water to reach the level indicated A level sensor is placed inside the hopper when the water level is low an alarm appears on the display until the proper level is restored b Refill sundae toppings in the bin as needed c Replace the topping covers and pumps in the heated topping well d As soon as the machine is in PROD and the water level is satisfied the topping heaters will be automatically on 4 2 3 START THE MACHINE The machine is in STORAGE function Push STOP then push PROD buttons in order to start the machine Within few minutes the Sundae is ready to serve This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 25 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual WEEKLY CLEANING On a weekly basis certain machine parts must be disassembled washed sanitized and re assembled The following is the list of operations to be performed weekly in addition to the regular daily cleani
48. iding it off the two front panel studs step 2 Remove the pivot O ring 1289 step 3 Pull the dispensing handle 5 so the piston 30 raises in its housing and pull the pivot pin 6 out releasing the dispensing handle 5 step 4 Using the dispensing handle lever pull the piston 30 out completely step 5 Using the o ring extractor remove a the 2 piston O rings 1153 b the large dispensing door O ring 1188 28 6 2 4 DISASSEMBLING OF THE SUNDAE BEATER step 1 Pull the beater 21 out of the cylinder step 2 Slide the beater seal 28 out of the beater shaft step 3 430 Pull out and remove the end pusher 25P and the idler 24 step 4 Remove the 3 beater blades 430 CAUTION The beater seal is very important It must be checked regularly for wear and tear It must always be on the beater shaft and properly lubricated during operation otherwise mix will leak in the drip tray This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 38 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 3 WASHING AND SANITIZING OF COMPONENT PARTS step 1 Fill a clean sink with the McD All Purpose Super Concentrate APSC and hot water 122 140 F 50 60 C or with hot McD APSC from the KayStar dispenser at the back sink step 2
49. ing them in alternate sequence step 5 Lubricate the spinner shaft and insert the spinner 369 into its housing step 6 Mount the spinner plate 370 step 7 Move up the spigot piston slide up the connection ref A and close the bracket ref B on the piston step 8 Close the protection cover ref C Ensure cover is closed properly otherwise the machine will not operate step 9 With the machine in STOP mode push the Er button to close the piston Description 30A Dispensing door Hand screws Piston Syrup duck bill valves 1198 Spinner Spout cap 1240 CC 1130 Syrup valves support O ring O ring O ring O ring Ses O ring 2218 O ring Lane O ring 1246 0000 31A 377 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 42 of 56 slalliceluserstamyhimy documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 4 2 1 Shake side warning When using only 3 syrups 4 X Rif 2 Rif 1 In case you are using only 3 syrup flavours you should close the hole of the front lid using the tap ref 1 delivered with the accessories This step can fit only in the hole indicated by X in the fig To block it firmly use the key ref 2 By doing so the forth syrup flavour that corresponds to the blue cup button becomes disabled The tap and its o ring should be disassembled cleaned and sanitized duri
50. kg 13 5 oz 400 ml Liters Liters portions portions 208 230 3 60 48 32 K3 82 38 380 88 40 160 m i DE a 1 5 8711395 380 415 3 50 48 18 1 2 5 MACHINE ASSEMBLY IDENTIFICATION LEGEND Syrup tanks cabinet Hopper cover Hot toppings Room temperature toppings Dispensing head shake side Dispensing head soft side Aircondenser This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Page 10 of 56 Carpigiani K 3 Equipment Manual 1 2 6 AUTOMATIC HEAT TREATMENT CYCLE The machine has been pre set at the factory to start automatically a heat cycle every night at 2 am the automatic heat treatment time can be re set at a different time by a trained technician 1 2 7 TEMPERATURE CONTROL When the machine is set to STOP the tank temperature is controlled if it is higher or equal to 59 F 15 C the execution of a heat treatment program is forced So by pressing the PROD button heat treatment program will automatically start NOTE After the machine s brush cleaning it is necessary to push the PROD button within 60 minutes after the front lid closing During the 60 minutes the test at 59 F 15 C is masked and Production is accepted After the 60 minutes the machine does not accept the PROD button any more and it sets to heat treatment function 1 2 8 TANK LIDS HOLDER When
51. l wipe the door cabinet WARNING To avoid potential bacteria growth in the syrup system during operations all the syrup lines must always be filled with syrup Calibrate syrups as follows e press STOP button LED will light e place calibration cup under the spout e press coloured cup button to start the syrup pump and dispense syrup for 5 seconds milk shake or 7 seconds TTS The pump will automatically stop During the syrup dispensing the display indicates the syrup number and the speed of the pump e check syrup quantity it should be 1 fluid ounce 30 ml 1 8 ounce e As soon as the piston closes and the syrup pump stops the display keeps indicating the pump speed an the buttons flash for 3 seconds during this period push or in order to increase or decrease the speed of the pump This adjustment becomes effective from the next time you push the syrup buttons Repeat the calibration for each flavor 6 8 MIX PRIMING Reminder After the machine s brush cleaning and more precisely from the moment you close the front door lid of the machine it is necessary to run the machine in production by pushing PROD button within 60 minutes After the 60 minutes the machine does not accept the PROD button any more and it sets to heat treatment function automatically In other words you should make the Sanitization of the whole machine and the Mix Priming within 60 minutes then push PROD button This manu
52. lete heat treatment cycle will take less than 4 hours to be completed During the heating and Pause cycles the mix in the machine is very hot Do not attempt to draw mix or disassemble the machine This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 14 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual STORAGE DECREASE FUNCTION RESET ALARM MESSAGES The Storage led lights ON as soon as the Pasteurisation cycle ends The machine preserves the mix at 2 C 35 F in the hopper and in the cylinder this button is used to decrease the value in the manager menu this button is also used to RESET the ALARM MESSAGES on the display MIX LEVEL SIGNAL In each hopper we have 2 level sensors MEDIUM level and LOW level When the MIX LEVEL LED flashes it means that the mix level in the hopper is lower than the medium mix level sensor When the MIX LEVEL LED is on it means that the mix level in the hopper is lower than the minimum mix level sensor The display indicates ADD MIX or MIX OUT Maximum filling level indicator Mix level sensor Esq When the LCD back light is blinking that means an alarm has tripped When it becomes solid the alarm which has previously tripped has automatically reset and the indication on the display must be reset by pressing RESET button MILK SHAKE DISPENSING
53. low to drain into the cylinder e Using the brush clean the mix level probes the entire surface of the mix hopper the surface of the mix pump and the outside of the hopper agitator 6 6 2 SANITIZE THE PUMP AND FREEZING CYLINDER e Press the push button and let the beater run for about 10 seconds Press the push button STOP The cylinder and the pump are now filled with the sanitizing solution e Return to the machine with a small amount of McD sanitizer solution in a pail e Dip the door spout brush in the pail of sanitizer and brush clean the dispensing spout Repeat the operation 2 times e Wipe the exterior of machine with clean sanitized towel Repeat the operation 2 times e Wait for at least 5 minutes before proceeding with the next instructions 6 6 3 DRAIN THE SANITIZER e Place an empty pail under the draw spout and pull the handle for SUNDAE side e Or press the button for the SHAKE side e Allow all of the sanitizer to drain e If the sanitizing solution does not flow out completely keep the spigot open and press the button keep the beater running for 5 seconds so that the last solution residues flow out then push STOP CAUTION Do not keep the beater running for more than the time strictly needed to complete washing and sanitization Without the lubrication of mix butterfat the beater blades wear out quickly This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc
54. low valve 245 out Using the o ring extractor remove the O ring 1412 step 4 Unscrew the 2 knobs 8B and separate the cover 202 from the pump body 39 step 5 Using the o ring extractor remove the large O ring 1178 Tapping the pump body against the palm of your hand remove the pump gears 38 38A step 6 Pull the connection tube 207 from the pressure pipe Remove the O rings 1131 and 1117 and the duck bill valve 31 96 1117 Description Hand screws 1117 Check valve slit Pressure pipe Driven gear N 0 Driving gear Pump hosing rear Pump drive shaft Pump hosing front Spring Connection tube Seal mix pump drive shaft 32 Pressure relief valve Feeding tube O ring O ring O ring C5 31 8B This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 37 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 2 3 DISASSEMBLING OF THE SUNDAE DISPENSING DOOR CAUTION Before disassembling the dispensing head make sure that the hopper and the cylinder are completely drained Description Dispensing handle Handle pin Soft serve door Handscrews Dispensing piston Piston lever ac 1188 O ring O ring O ring step 1 With the machine in STOP mode remove the two retaining knobs 8 and pull the de assembly towards you sl
55. ment function can be activated only if the mix in the hopper is above the Medium Level ADD MIX message on display must be off AUTOMATIC HEAT TREATMENT CYCLE while the machine is in production SHAKE LED on and the mix is above the medium level the heat treatment cycle starts automatically at a certain time as programmed in the Manager Menu normally at 2 00 AM During the display indicates HEAT TREATMENT CYCLE the mix in the hopper and in the cylinder is heated up to 65 C kept at 65 C for 30 minutes and finally cooled down to 2 C At the end of the cycle the display shows PASTO END followed by date and hour of termination The machine passes automatically to STORAGE function To serve shake press STOP then the PROD button This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 18 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual Note Once the heat treatment cycle has started it can not be interrupted The complete heat treatment cycle will take less than 4 hours to be completed During the heating and Pause cycles the mix in the machine is very hot Do not attempt to draw mix or disassemble the machine WARNING Do not draw sundae or disassemble the machine during the heat treatment because the product is very hot and under pressure STORAGE DECREASE FUNCTION RESET ALARM MESSAGES The
56. mmend not to wash the Sundae and Milk Shake components all together This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 40 of 56 Version 1 July 06 s a ice users amyh my documents steve holcomb k 3 g doc Carpigiani K 3 Equipment Manual 6 4 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS 6 4 1 REASSEMBLY OF THE SHAKE CYLINDER BEATER step 1 Lubricate the blade pin O ring 1271 and slide it onto the pin 726 726 Beveled 1271 Rubber stoppers Description Beater Counter beater Beater seal Beater blade Beater blade pin O ring CAUTION Check the rubber stoppers for integrity Replace if worn or damaged step 2 Place the blade 430A in its housing on the beater 21A aligning the pin hole with the hole on the beater Secure the blade 430A onto the beater 21A inserting the beater blade pin 726 into the blade and the beater hole The head of the rubber stoppers should rest on the beater frame step 3 Replace the idler 24A in the beater frame 21A first inserting the front shaft into the slot of the beater front housing and then inserting the idler shaft into the rear housing Push it towards the back otherwise the idler may fall out step 4 Lubricate the sides of the beater seal 28A and slide it onto the beater shaft CAUTION The beater seal is very important It must be checked regularly for wear and tear It must always be on the
57. ng procedure Make sure your hands are clean and sanitized before performing the following procedures 5 1 WASHING AND SANITIZING OF THE TOPPING CONTAINERS 5 1 1 CLEANING THE TOPPING BINS a Remove the topping pumps and bins from the machine and take them to back sink b Discard the toppings weekly to break the bacterial cycle c Wash the bins thoroughly with the McD All Purpose Super Concentrate APSC and hot water 122 140 F 50 60 C or with of hot McD APSC from the KayStar dispenser at the back sink eliminating any product residue d Place the bins into the McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gal 9 1 2 liters of water 100 PPM for 1 minute e Make sure that the bins are empty and leave them out to air dry 5 1 2 CLEANING THE TOPPING HOPPER a Place an empty container under the drain tap inside the syrup cabinet b Open the tap and drain the water completely from the topping hopper caution water is hot c Close the tap 5 2 DISASSEMBLING WASHING AND SANITIZING OF THE HOT TOPPING PUMPS Clean the hot topping pumps Place the lower end of the pump into a container of clean warm water and operate the pump until the water being discharged is clear e DISASSEMBLY COLLAR step 1 ASSEMBLY Loosen the locking collar until the plunger assembly can be removed from the pump cylinder NOTE The plunger spring is slightly compressed so use care when removing the knob step 2 Remove the
58. ng the periodical cleaning 6 4 3 REASSEMBLY OF THE SHAKE MIX PUMP step 1 Lubricate and replace the O ring 1117 on the connection tube 207 step 2 Lubricate and replace the O ring 1131 and the duck bill valve 31 on the pressure pipe 32A step 3 Insert the connection tube assembly in the pressure pipe 32A step 4 Place the pressure pipe in a sanitizing solution step 5 Insert the pump gears 38 38A into the pump body 39A step 6 Lubricate and replace the pump body O ring 1178 step 7 Lubricate and replace the drive shaft seal 243 into the pump body 42394 step 8 Lubricate and replace the O ring 1412 on the feeding tube 222714 step 9 Hold the pump cover 202A upside down and insert the back flow valve 245 and spring 206A in their pump cover housing This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 43 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual step 10 Insert the feeding tube 271A in the pump cover push and turn it clockwise step 11 Lubricate the drive shaft 96 Position drive shaft into the rear of mix hopper pushing it towards the back and rotating it slightly until it enters the drive hub Hold the pump body assembly with the blocking pin hook on the right keep your thumbs over the pump gears so that they remain in place push and turn
59. ning operations check carefully the integrity of parts subject to wear if they appear worn torn or not totally functional replace them The manufacturer offers programmed maintenance plans that include the periodical replacement of parts subject to wear CHECK SUGGESTED ACTION SHAKE SIDE PUMP e Integrity of O ring and overflow valves e If they show cuts replace them e Dry smoothness of gears in their seats e f they do not turn well or turn too freely replace them or have them checked by a technician DISPENSING DOOR e Check integrity of O ring check smoothness of e Replace if they show damage piston TANK MIXER e Check if it rotates freely e Reassemble CYLINDER BEATER e Check if beater and counter beater show e Replace if broken or cracked dents e Integrity of beater seal 28 e Replace if damaged SUNDAE SIDE PUMP e Integrity of O ring and overflow valves e If they show cuts replace them e Dry smoothness of gears in their seats e If they do not turn well or turn too freely replace them or have them checked by a technician DISPENSING LID e Check integrity of O ring check smoothness of Replace if they show damage piston CYLINDER BEATER e check it beater and idler show dents e Replace it if broken or cracked e integrity of beater seal 28 e Replace if damaged This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc P
60. or has tripped CALL FOR SERVICE Al Hopper probe TEV Hopper temperature sensor is out of order CALL FOR SERVICE Al Cylind Probe TEC Cylinder temperature sensor is out of order CALL FOR SERVICE Al IceHop Probe TGV Hopper evaporator sensor is out of order CALL FOR SERVICE Spigot Opened IMS Faceplate is open or disassembled Install the faceplate Al Evapor Probe TE Temperature probe on cylinder out of order CALL FOR SERVICE Power on A black out has occurred Ice Cylinder ICE Bad heat exchange in the cylinder check mix pump efficiency check the scraper blades Timeout Prd Cooling problem the product is not getting hard while cooling if this alarm appears frequently CALL FOR SERVICE Belt Alarm The hopper agitator is not turning check that the mixer is positioned correctly otherwise CALL FOR SERVICE Wash In n days It indicates the days remaining for next cleaning when wash today appears the machine must be disassembled cleaned and sanitized Press RESET button to reset the message on the display Do Not Serve Product under process please wait and don t serve yet No Topping Water The Water in the topping bin is lower than the sensor level Add water in the topping bin Al Topping Probe Temperature probe for topping heating is out of order CALL FOR SERVICE Pasto needed The machine is in soft lock
61. p Remove the mix agitator Remove the agitator from the hopper by pulling it upwards step 6 Pump body Push the ar button in order to open the piston and drain the rest of the liquid mix step 7 Use the a button to open and close the piston when necessary while still in STOP Drain the hopper completely To close the piston press the STOP button step 8 Feeding Rinse the machine Pour 2 5 gallons 9 5 liters of cool clean water into the mix hopper Use the white hopper brush to scrub the mix hopper mix level sensor and the outside the agitator shaft Use the small brush to clean the mix inlet hole and the drive hub of the mix pump This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 30 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual step 9 Drain rinse water from hopper and cylinder Place an empty pail under the milk shake spout Push the button to open the spigot piston and let the water drain out Press the button and let the beater run for about 10 seconds Press the STOP button to stop the beater the piston closes automatically Push the button to open the spigot piston and let the water flow completely out Repeat steps 8 and 9 until the rinse water being dispensed is clear step 10 Clean the machine Fill the tank with 2 1 2 gallons 9 1 2 liters of warm water APSC solution
62. p e Repeat for all syrup lines 4 1 3 PRIMING THE SYRUP LINES WITH SYRUP a Place each pick up tube in its syrup jug or connect the syrup connector to the syrup bag b Place empty bucket under the spout c Press coloured cup button two times until the syrup is dispensed discard this sample d Press STOP button to stop the syrup pump e Repeat for all syrup flavors f Using a clean sanitized towel wipe the door cabinet 4 1 4 START THE MACHINE The machine is in STOP function Push PROD button in order to start the machine The LED will flash and the shake freezing process is carried out for 15 minutes During this time you CANNOT dispense Milk Shake When PROD LED stays solid Milk Shake is ready to serve WARNING Do not keep a syrup line empty In case you are using only 3 syrup flavours you should close the hole of the front lid using the tap delivered with the accessories as indicated in sect 6 4 2 1 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 24 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 4 2 SUNDAE SIDE Make sure your hands are clean and sanitized before performing the following procedures 4 2 1 SANITIZE THE DOOR AREA a Fill an empty pail with McD Sanitizer prepared in water 70 90 F 21 32 C 1 packet in 2 1 2 gallons 9 1 2 liters of water 100 PPM and mix t
63. ppings Automatic heat treatment system to heat treatment the product inside the mix tank and inside the cylinder during pause periods for instance during night time e Electronic consistency control system hard o matic 1 2 2 INTENDED USE The K 3 machine must only be used for the production of ice cream and milkshake within the functional limits listed below e Voltage 10 e Min ambient temperature 50 F 10 C e Max ambient temperature 109 F 43 C e Max relative ambient humidity 85 This machine has been designed for its use in closed places not subject to explosion proof standards consequently it shall be used in places complying with normal atmosphere 1 2 3 NOISE The continuous level of acoustic radiation pressure which has been weighed and called A on working place turns to be lower than 70 dB A both by aircooled and water cooled units This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 9 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 1 2 4 TECHNICAL FEATURES LL Die T S a a E T Installed Full Hourly Production Hopper capacity Flavors Electrical supply power load Net Model SUNDAE SHAKE SUNDAE TTS fae Gallons Galons SUNDAE SHAKE Volt V Phase Cycle Hz kw Amps Ib kg 3 5 oz 100 gr Ib
64. r the exclusive use of licensees and employees of McDonald s Systems Inc Page 12 of 56 s a ice users amyh my documents steve holcomb k 3_g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 2 1 1 MILK SHAKE FUNCTIONS o STOP BUTTON By pressing this button during operation the machine stops LED on DISPLAY Comments 10 33 21 Fri When the machine is in STOP the display shows Time and Date 10 33 21 Fri In case we have an ALARM activated the backlight of the Overload Beater LCD display will flash and the display indicates the kind of ALARM PRODUCTION BUTTON Preparation startup On pushing this button its LED will blink 15 minutes while the machine is freezing the product For that time dispensing is not allowed Production LED is always on The product is ready to be dispensed and it is kept at the desired consistency by the Hard o Tronic system If the machine has been in the production mode and then placed in Stop the 15 minutes start up procedure will be automatically bypassed if the time in Stop does not exceed 60 minutes otherwise the start up procedure will be repeated By pressing this button from STOP the display indicates KEY DISPLAY comments Do Not Serve Wash in 14 days When the ice cream or Milk Shake is not ready the display shows DO NOT SERVE Sundae Ready Wash in 14 days When the ice cream or Milk Shake has
65. sossss 50 7 1 AIR FILTER CLEANING siirre a E E E Rl ot gud 50 8 PREVENTATIVE MAINTENANCE esseeeseoessoesssesssecssocssooesooessoesssesesoossoosssoessesesoosssossss 51 8 1 TR CUT IS Ticc nO DUE I Pcr uu n ItuR Di etin i icu A SE ND C MU E 5 8 2 SIX MONTHS CHECK UP AND MAINTENANCE eere 52 6 2 1 PERISTALTIC PUMP TUBE REPLACEMENT INSTRUCTION c0cccccccceeseeeees 52 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 3 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 9 1 IP donc A 54 This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 4 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual Warranty The warranty doesn t cover parts and labor to correct or repair malfunctions or machine failures caused by operator error machine abuse unauthorized service intervention or external causes Parts Warranty e Warranty on all component parts except for parts subject to normal wear such as o rings belts rubber valves pump gears etc 1 years from date of first installation e Warranty on the beater motors 2 years from date of first installation e Warranty on the compressor 3 years from date of first installation e Warranty on t
66. step 4 Press the button step 5 When the product coming out becomes liquid push the STOP button and leave the spout open step 6 Remove the pressure tube In the hopper disconnect pressure pipe from the mix pump turn it sideways remove it pulling it up from its seat and let the product flow completely out Remove the mix pump Grasp the pump and turn it in a clockwise direction of 45 then pull it out towards you Make sure that the pump drive shaft and seal are taken out with the pump Remove the mix agitator Remove the agitator by pulling it upwards step 7 Rinse the machine Close the spout handle pour 2 5 gallons 9 5 liters of cool clean water into the mix hopper Use the white hopper brush to scrub the mix hopper mix level sensor and the outside the agitator shaft Use the small brush to clean the mix inlet hole and the drive hub of the mix pump Drain rinse water from hopper and cylinder Place an empty pail under spout Open the spigot piston and let the water drain out step 8 Rinse with warm water until the solution runs clear step 9 Press the button and let the beater run for 10 seconds step 10 Turn the machine off by pushing the STOP button and let the water flow out This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 35 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment
67. terial contamination The source of contamination must be identified and corrected High bacteria counts are indicate that a product is not safe for consumption You must inform the machine operator on how to prevent bacterial contamination of the product Note Soft serve yogurt will generally have high bacteria counts this is normal and helps define the product However COLIFORM bacteria contamination is NOT ACCEPTABLE in any food product The information given below will help prevent coliform bacteria contamination problems The following is a list of possible bacteria contamination sources along with methods of prevention SOURCE OF CONTAMINATION PREVENTION 1a Wash hands and forearms thoroughly 1 Operator contact 1b Wear rubber gloves if cuts or skin conditions exist 1c Wash hands periodically throughout the day 2a Provide the proper brushes 2 Mix residue deposits milkstone 2b Thoroughly brush clean all parts and components to build up prevent the formation of milkstone a porous substance which will house bacteria and contaminate fresh mix 3a Lubricate all rubber parts contacting the mix with a food grade lubricant 3 Worn or damaged parts 3b Inspect o rings for damage Only replace with factory approved parts 3c Regularly check drip troughs for excessive leakage This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 7 of 56 s a ice users amy
68. the pump clockwise until the drive shaft mates with the driving gear Now turn the pump counter clockwise until it locks onto the blocking pin step 12 Assemble the pump cover 202A with the feeding tube downwards onto the pump body and turn the two knobs 8B tightly 96 Hand screws Check valve slit Pressure pipe Driving gear Driven gear Pump body Pump shaft Shake chamber tube Pump housing Spring Connection tube 1117 Feeding tube Seal mix pump shaft Pressure relief valve O ring O ring O ring O ring O ring O ring s This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 44 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 6 44 REASSEMBLY OF THE MIX HOPPER AGITATOR step 1 Relocate the agitator back in its seat pay attention to engage it onto its shaft correctly 6 5 REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS 28 6 5 1 REASSEMBLY OF THE SUNDAE BEATER step 1 Insert the 3 beater blades 430 onto the beater frame step 2 Insert the end pusher 25P onto the beater frame step 3 Insert the end of the idler shaft 24 in the rear housing of the beater through the end pusher Push the idler into position step 4 Lubricate the sides of the beater seal 28 and slide it onto the beater shaft
69. tube 207 step 2 Lubricate and replace the O ring 1131 and the duck bill valve 31 on the pressure pipe 32 step 3 Insert the connection tube assembly in the pressure pipe 32 step 4 Place the pressure pipe in a sanitizing solution step 5 Insert the pump gears 38 38A into the pump body 39 step 6 Lubricate and replace the pump body O ring 1178 step 7 Lubricate and replace the drive shaft seal 243 into the pump body 39 step 8 Lubricate and replace the O ring 1412 on the feeding tube 271 step 9 Hold the pump cover 202 upside down and insert the back flow valve 245 and spring 206 in their pump cover housing step 10 Insert the feeding tube 271 in the pump cover push and turn it clockwise step 11 Lubricate the drive shaft 96 96 Position drive shaft into the rear of mix hopper pushing it towards the back and rotating it slightly until it enters the drive hub Hold the pump body assembly with the blocking pin hook on the right keep your thumbs over the pump gears so that they remain in place push and turn the pump clockwise until the drive shaft mates with the driving gear Now turn the pump counter clockwise until it locks onto the blocking pin step 12 Assemble the pump cover 4202 with the feeding tube downwards onto the pump body and turn the two knobs 8B tightly Description Hand screws Check valve slit Pressure pipe Driven ge
70. you need to refill the mix tank lift the lid and turn it upside down Insert the handle of the lid in the slot of the holder placed on the other lid You need not to remove the holder LID HOLDER This manual is for the exclusive use of licensees and employees of McDonald s Systems Inc Page 11 of 56 s a ice users amyh my documents steve holcomb k 3 g doc Version 1 July 06 Carpigiani K 3 Equipment Manual 2 INSTRUCTIONS FOR USE 21 CONTROLS The K 3 is equipped with two front push button panels one for the controls related to the SHAKE side and one for the controls related to the SUNDAE side WHITE BASE DISPENSING BUTTON for SMOOTHY OPEN PISTON TO EMPTY THE MACHINE CLEANING LCD back lights flashing for MILK SHAKE DISPENSING BUTTONS Warning light for LOW mix level read info on display e av OLOJO 0G0O00 Pasteurization Led Storage Led lights on from start Pasto till Pasto End lights on from Pasto End increase button for manager menu decrease button for manager menu Alarm and warning reset MAIN FUNCTIONS Agitation Button Lock button Stop Production IMPORTANT Push buttons are activated keeping the finger not the nail pressed on it for at least 1 2 second safety feature WARNING TO REDUCE WEARING OF THE BEATER BLADE POS 430 USE AGITATION FUNCTION JUST FOR THE TIME STRICTLY NECESSARY This manual is fo

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