Shake & Sundae Carpigiani Every 2 Weeks Maintenance

This form is for the bi-monthly maintenance of the Shake and Sunday Carpigiani. It's very specific that after exactly 14 days upon the last cleaning, the machine must be thoroughly washed and restarted. It has a list of operations that need to be performed on the 14th day in addition to the regular daily and weekly cleaning procedure.

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04/26/2021

Shake & Sundae Carpigiani Every 2 Weeks Maintenance

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 14TH DAY IN ADDITION TO THE REGULAR DAILY AND WEEKLY CLEANING PROCEDURE.

NOTICE: MAKE SURE YOUR HANDS ARE CLEAN AND SANITIZED.

DISASSEMBLING AND CLEANING THE MILK SHAKE SIDE

NOTICE: ALL PARTS REMOVED FROM THE MACHINE SHOULD BE PLACED INTO A CONTAINER, AND TRANSPORTED TO THE SINK FOR CLEANING, RINSING AND SANITIZING.

CLEANING THE SHAKE SYRUP SYSTEM

Wiping pick up tubes:

Remove the syrup pick up tubes from the syrup jugs or disconnect the syrup connector from the syrup bag.

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:

Remove the cup holder and place an empty pail under the door spout.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).

Place the pick up tubes inside. Press STOP then push the corresponding “coloured cup” button two times to run the syrup pump at maximum speed and let the water flow for 1 minute. Press STOP button to stop the syrup pump.

Repeat for all syrup lines.

Rinsing the syrup lines:

Fill a 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.

Repeat for all syrup lines.

DRAINING AND CLEANING THE MILK SHAKE SIDE

WARNING : Every time the display shows “WASH TODAY” alarm, you have to push once the button in order to reset the alarm message.

Drain the Milk Shake

Put an empty pail under dispensing spout.

Push the “STOP” button.

Push the button then push button to allow the milk shake to flow out until it becomes liquid

Push the “STOP” button to close the piston, stop the beater motor and the mix pump

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 pump.

Remove the mix agitator: Remove the agitator from the hopper by pulling it upwards.

Push the button in order to open the piston and drain the rest of the liquid mix.

Use the 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.

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.

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.

Clean the machine Fill the tank with 2-1/2 gallons (9-1/2 litres) of warm water APSC solution.

Press the button and let the beater run for about 10 seconds.

Push the “STOP” button.

Use the appropriate 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 button and let the liquid flow completely out.

Then push the “STOP” button to close the piston.

Rinse the machine Rinse with clear water, push the button and let the water flow completely out. Press the “STOP” button to close the piston.

Sanitizing 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].

Press the button and let the beater run for 10 seconds then push STOP. Use the appropriate 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.

Leave the solution of McD Sanitizer for a minimum of 1 minute.

Push the “ ” button and let the sanitizer flow completely out

Push the “STOP” button

DISASSEMBLING OF THE SHAKE MIX PUMP

Remove the pump drive shaft and seal from the pump.

By holding the feeding tube (#271A) upwards turn it counter-clockwise and pull it out.

Using the O-ring extractor, remove the O-ring (#1412). Remove the spring (#206A) and the back flow valve (#245).

Unscrew the 2 knobs (#8B) and separate the cover (#202A) from the pump body (#39A).

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 38A).

Pull out the connection tube (#207) from the pressure pipe(#32A).. Remove the O-rings (#1131 and 1117) and the duck bill valve (#31).

DISASSEMBLING OF THE SUNDAE DISPENSING DOOR

CAUTION: Before disassembling the dispensing head, make sure that the hopper and the cylinder are completely drained.

With the machine in STOP mode, remove two retaining knobs (#8) and pull the door assembly towards you sliding it off the two front panel studs.

Remove the pivot O-ring (#1289)

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).

Using the dispensing handle lever, pull the piston (#30) out completely .

Using the o-ring extractor, remove:

the 2 piston O-rings (#1153)

the large dispensing door O-ring (#1188).

DISASSEMBLING OF THE SUNDAE BEATER

Pull the beater (#21) out of the cylinder.

Slide the beater seal (#28) out of the beater shaft.

Pull out and remove the end pusher (#25P) and the idler (#24).

Remove the 3 beater blades (#430). Carpigiani suggests to replace the blades each 6 months (please see the tune-up kit card).

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.

WASHING AND SANITIZING OF COMPONENT PARTS

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).

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.

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 litres) of water = 100 PPM].

Place the parts in the sanitizing solution. Leave them there for at least 1 minute.

Place the components on the milk shake tray to air-dry.

Place the sundae components on the sundae tray to air-dry.

Return to the machine with a small amount of McD Sanitizer.

Dip a brush into the sanitizer and thoroughly brush both freezing cylinders.

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.

Spray the back of cylinder with sanitizer.

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.

IMPORTANT!! We recommend not to wash the sundae and shake components together.

REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS

REASSEMBLY OF THE SHAKE CYLINDER BEATER

Lubricate the blade pin O-ring (#1271) and slide it onto the pin (#726).

CAUTION! Check the rubber stoppers onto the blade for integrity. Replace if worn or damaged. Carpigiani suggests to replace the blade once a year (please see the tune-up kit card).

WARNING Like all moving parts, the complete beater is also subject to wear and tear. For this reason, we recommend checking the amount of wear to parts in direct contact with one an-other (beater/beater idler and beater/cylinder walls) on a regular basis

In particular, make sure that the wear on the bushing on the beater idler is no more than 2 mm, as indicated by the marking on the bushing itself. If there is more than 2 mm wear, it is necessary to replace the beater idler.

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.

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.

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 beater shaft and properly lubricated, during operation, otherwise mix will leak in the drip tray.

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.

REASSEMBLY OF THE SHAKE DISPENSING DOOR

Lubricate and replace the 4 syrup outlet o-rings (#1109) on the front panel of machine.

Lubricate the O-rings and replace them in their respective position i.e.:

Replace the 8 o-rings (#1246) on the syrup distribution block (#377),

Replace the 4 duck bill valves (#31A) on the syrup distribution block (#377),

Replace the syrup distribution block (#377) in its position on the front panel of the machine,

Replace the 2 piston housing O-ring (#1240) in the dispensing door,

Replace the O-ring (#1130) on the piston,

Replace the O-ring (#1195) on the dispensing door,

Replace the O-ring (#1142) on the spinner plate

Holding the dispensing door (#7A) upward, lubricate and replace the piston (#30A) in its position in the front door.

Fit the dispensing door (#7A) in the four front panel studs and fasten it with the four knobs (#8A) hand-tightening them in alternate sequence.

Lubricate the spinner shaft and insert the spinner (#369) into its housing.

Mount the spinner plate (#370).

Move up the spigot piston, slide up the cylinder (ref. A) and close the bracket (ref. B) on the piston.

Close the protection cover (ref. C). Ensure cover is closed properly otherwise the machine will not operate.

With the machine in STOP mode push the button to close the piston.

Shake side warning – When using only 3 syrups.

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 during the periodical cleaning.

REASSEMBLY OF THE SHAKE MIX PUMP

Lubricate and replace the O ring (#1117) on the connection tube (#207).

Lubricate and replace the O-ring (#1131) and the duck bill valve (#31) on the pressure pipe (#32A).

Insert the connection tube assembly in the pressure pipe (#32A).

Place the pressure pipe in a sanitizing solution.

Insert the pump gears (#38-#38A) into the pump body (#39A).

Lubricate and replace the pump body O-ring (#1178).

Lubricate and replace the drive shaft seal (#243) into the pump body (#39A).

Lubricate and replace the O-ring (#1412) on the feeding tube (#271A).

Hold the pump cover (#202A) upside down and insert the back flow valve (#245) and spring (#206A) in their pump cover housing.

Insert the feeding tube (#271A) in the pump cover: push and turn it clockwise.

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 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.

Assemble the pump cover (#202A) with the feeding tube downwards onto the pump body and turn the two knobs (#8B) tightly

REASSEMBLY OF THE MIX HOPPER AGITATOR

Relocate the agitator back in its seat, pay attention to engage it onto its shaft correctly

REASSEMBLY OF WASHED AND SANITIZED COMPONENT PARTS

REASSEMBLY OF THE SUNDAE BEATER

Insert the 3 beater blades (#430) onto the beater frame. Carpigiani suggests to replace the blades each 6 months (please see the tune-up kit card).

Insert the end pusher (#25P) onto the beater frame.

Insert the end of the idler shaft (#24) in the rear housing of the beater, through the end pusher. Push the idler into position.

Lubricate the sides of the beater seal (#28) and slide it onto the beater shaft.

IMPORTANT : Check the beater seal for integrity. Replace if worn or damaged. It should be replaced rather frequently.

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.

REASSEMBLY OF THE SUNDAE DISPENSING DOOR

Lubricate and slide the 2 piston O-ring (#1153) into their seats.

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 rectangular opening on the spigot front.

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).

Insert the dispensing door assembly onto the two front panel studs and fasten it with the two knobs (#8) hand tight.

REASSEMBLING OF THE SUNDAE MIX PUMP

Lubricate and replace the two O-rings (#1117) on the connection tube (#207).

Lubricate and replace the O-ring (#1131) and the duck bill valve (#31) on the pressure pipe (#32).

Insert the connection tube assembly in the pressure pipe (#32).

Place the pressure pipe in a sanitizing solution.

Insert the pump gears (#38-#38A) into the pump body (#39).

Lubricate and replace the pump body O-ring (#1178).

Lubricate and replace the drive shaft seal (#243) into the pump body (#39).

Lubricate and replace the O-ring (#1412) on the feeding tube (#271).

Hold the pump cover (#202) upside down and insert the back flow valve (#245) and spring (#206) in their pump cover housing.

Insert the feeding tube (#271) in the pump cover: push and turn it clockwise.

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 the pump clockwise until the drive shaft mates with the driving gear. Now turn the pump counter clockwis

Assemble the pump cover (#202) with the feeding tube downwards onto the pump body and turn the two knobs (#8B) tightly.

REASSEMBLING OF THE MIX TANK AGITATOR

Relocate the agitator back in its seat: pay attention to engage it onto its shaft correctly.

SANITIZING OF THE ENTIRE 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 pasteurisation function automatically. In other words, you should make the “Sanitization of the whole machine“ and the “Mix Priming“ within 60 minutes, then push PR

SANITIZE THE HOPPER

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 allow it to drain into the cylinder.

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

SANITIZE THE PUMP AND FREEZING CYLINDER

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.

Return to the machine with a small amount of McD sanitizer solution in a pail.

Dip the door spout brush in the pail of sanitizer and brush clean the dispensing spout. Repeat the operation 2 times.

Wipe the exterior of machine with clean sanitized towel. Repeat the operation 2 times.

Wait for at least 5 minutes before proceeding with the next instructions.

DRAIN THE SANITIZER

Place an empty pail under the draw spout and pull the handle (for SUNDAE side).

Or press the “ ” button (for the SHAKE side).

Allow all of the sanitizer to drain.

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.

SYRUP SANITIZING, PRIMING AND CALIBRATION (SHAKE SIDE)

Make sure your hands are clean and sanitized before performing the following procedures.

Sanitizing the syrup lines:

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).

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.

Repeat for all syrup lines.

Drain the sanitizer from the syrup lines

Remove the syrup pick up pipes from the pail and put them on a clean towel . Place an empty pail under the draw spout and push STOP button, then press twice each “coloured cup” button to run the syrup pumps and drain the residues of sanitizer.

Push STOP button to stop the pump.

Priming the syrup lines with syrup:

Place each syrup pick up pipe in its syrup jug or connect the syrup connector to the syrup bag.

Place empty bucket under the spout.

Press the “coloured cup” button twice until the syrup is dispensed, and then discard this portion of syrup.

Press STOP button to stop the syrup pump.

Repeat for all syrup flavors.

Using a clean, sanitized towel, 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:

Press “STOP” button, LED will light.

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.

Check syrup quantity; it should be 1 fluid ounce (30 ml), 1/8 ounce.

As soon as the piston closes and the syrup pump stops, the display blinks and shows the pump’s speed.

The buttons flash for 3 seconds; acting upon those buttons we may increase or decrease the pump’s speed. This adjustment becomes effective from the next time you push the syrup buttons

REPEAT THE CALIBRATION FOR EACH FLAVOUR.

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 pasteurisation function automatically. In other words, you should make the “Sanitization of the whole machine“ and the “Mix Priming“ within 60 minutes, then push PR

Prime Hopper:

Retrieve 1 bag of McD shake or sundae mix from the walk-in refrigerator.

With the both sides of the machine in STOP mode, place an empty pail under the draw spouts.

Pull the handle (for SUNDAE sides) or press the button (for the SHAKE side).

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.

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 button (for the SHAKE side).

Connect the mix pressure pipe:

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 button and let run the beater for only five seconds just to check the pumps work well, the push STOP.

Turn the pressure pipe clockwise towards the pump and connect the tube to the pump.

Press PROD. button to start the Automatic freezing operation.

Replace the hopper cover.

Source: Carpigiani (www.manualslib.com)