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COMMERCIAL FOOD WASTE DISPOSERS SERVICE MANUAL 1 HP 3/4 HP 1 1/4 HP 1/2 HP 1 1/2 HP 5 HP 3 HP 2 HP 10 HP 560P455P01 REV A TABLE OF CONTENTS 1. INSTALLATION INSTRUCTIONS 1/2 HP, 3/4 HP, 1 HP, 11/4 HP, and 11/2 HP Models 1-4 2 HP, 3 HP, 5 HP, and 10 HP Models 5-8 2. SINK MOUNTED MODELS DISASSEMBLY PROCEDURE 3. TRIPOD MOUNTED MODELS DISASSEMBLY PROCEDURE AND GENERAL DATA 9 Upper Housing Disassembly 10 Grind Ring Disassembly 10 Turntable Disassembly 11 Turntable and Grind Ring Information 12 Seal Disassembly and Replacement 13 Motor Removal from Tripod 14 Small and Mid-sized Models Bearing Removal 14 Disassembly Procedure for Stator and Rotor 15 Disassembly of the Upper Motor 15 Motor Data for Models 16 Stator and Cooling Fan Removal 17 Rotor and Bearing Removal 17 End Shield Removal 18 Stator and Overload Protector Information 18 Overload Protector Terminals 19 Electrical Description and Terminals 19 Testing and Capacitor on Models 1/2 HP through 2 HP 20 Impeller Replacement 20 Cutter Blade Replacement for Models 1/2 HP through 1 HP 21 Boot Seal Replacement for Models 1/2 HP through 1 HP 21 Disassembly of Tripod Legs 22 4. WIRING DIAGRAM FOR ONE PHASE MOTORS 23 5. WIRING DIAGRAM FOR THREE PHASE WYE MOTORS 24 6. COMMERCIAL DISPOSER TROUBLESHOOTING CHART 25 COMMERCIAL DISPOSER MODELS 1/2 HP, 3/4 HP, 1 HP, 11/4 HP, 11/2 HP INSTALLATION INSTRUCTIONS BEFORE INSTALLING, READ ENTIRE INSTRUCTIONS CAREFULLY. RISK OF INJURY TO PERSONS FROM HAZARDOUS MOVING PARTS. SERIOUS INJURY POSSIBLE IF NOT PROPERLY INSTALLED WITH A HOPPER OR A CONE SPECIFIED IN THE INSTRUCTION MANUAL. FIG. 1 FIG. 2 B MODEL 6T A SINK HOLE C DIA. No. 9T SPRAY RINSE No. 6T SPRAY RINSE HOLE APPROX. 30” FIG. 3 9” MIN. 6” MIN. A B C 2215 15” CONE 2211 18” CONE 10 1/ 4” 31/ 2” 131/ 2” 113/ 4” 31/ 2” 161/ 2” 131/ 4” 31/ 2” 191/ 2” MODEL 9T DISH TABLE APPROX. 14” 6-5/8” A B C 2” TO 4” A 6” 2216 12” CONE CONE SINK 2216 12” CONE 2215 15” CONE 2211 18” CONE 12 7/ 8” 61/ 8” 131/ 2” 12 7/ 8” 45/ 8” 161/ 2” 12 7/ 8” 31/ 8” 191/ 2” IF YOU ARE REPLACING AN OLD DISPOSER GO TO MOUNTING DISPOSER INSTALLATION OF CONE SINK INTO DISH OR WORKTABLE 1. (See Figures 1 and 2.) Locate hole center as shown on Figure 2. Cut a “C” (Figure 2) diameter hole in dish or work table, a minimum of 2” from the inside front edge (operator’s side). Hole can be cut with a “nibbler” after a knockout hole 1-1/2” diameter has been punched. 2. Lift cone to underside of table with cone flange overlapping all around (Figures 1 and 3). 3. Check alignment of cone spray fittings to be sure they are in the proper position. For 15” and 18” cones, position such that holes are located to right and left side of operator. (See Figure 7 for location.) 4. Tack weld, spot weld, bolt, or rivet flange of cone sink to underside of dish or work table. If bolted or riveted, smooth top surface and washsolder around bolt or rivet heads and sand smooth. 5. Bead weld or solder and wash-solder all around where the table joins flange of cone sink for a clean, watertight, sanitary installation. 6. The cone sink has been designed with the step, as shown in Figure 3. In the welding or soldering operation required to assemble the cone sink to the dish or work table, every attempt should be made to keep the recessed, flat portion of the cone free of the welded or solder material. This will minimize the clean-up time required and provide a smooth, flat surface for any cover. SPRAY-RINSE INSTALLATION 1. Locate center (Figures 1 and 2). 2. Drill 7/16” diameter hole through center. FIG. 4 FIG. 5 3. Assemble 7/8” punch and tighten bolt head, as shown in Fig. 4, until the die pierces the stainless steel, leaving a clean opening of 7/8”. BODY VALVE BASE 4. Place body valve and base in position, assemble washer and locknut as shown in Figure 5. 5. Attach vol-temp assembly to the projecting nipple, as shown in Figure 7. WASHER LOCKNUT 7/8” PUNCH MOUNTING DISPOSER For models to be installed in sink with 3-1/2” outlet, see separate sheet enclosed for mounting instructions. FIG. 6 CONE SINK CO NUT N 1. Clamp ring taped to top side of Hush Cushion® should be placed on underside of top flange of Hush Cushion®. Line up holes in clamp ring with holes in Hush Cushion® and insert six screws also contained in plastic bag. Insert through clamp ring and Hush Cushion® from the underside. CLAMP RING 2. Line up holes in loose steel clamp ring on cone sink with screws in Hush Cushion® and raise disposer into position with screws matching holes in clamp ring in approximate position with plumbing drain outlet. HUSH CUSHION CLAMP RING MOUNT SCREW 3. To manually raise the disposer into position, lift the unit by grasping the disposer with one hand from the bottom of the motor, and with the other hand around the Hush Cushion®, guide the unit into position, as shown in Figure 6. 1 MOUNTING DISPOSER – Continued (Refer to Figure 6) 4. Attach a nut by two or three threads to screw and then attach another nut to screw on the opposite side of disposer. Finger-tighten two screws to hold unit in place. Attach remaining four nuts to screws and finger-tighten evenly. 5. Check alignment with plumbing. Adjustment in alignment to plumbing can be made by rotating the unit carefully before tightening the nuts. To assist in rotating unit, raise the unit from the bottom of the motor to relieve weight. 6. With the unit in its proper position, proceed to tighten six nuts evenly. PLUMBING INSTALLATION IMPORTANT! Before installing the disposer, the connecting waste line must be cleaned out to the connecting sewer main. MAKE ALL PLUMBING AND ELECTRICAL CONNECTIONS ACCORDING TO LOCAL CODES. Recessed thread fittings must be used throughout and all pipe ends should be carefully reamed. FIG. 7 CONE ASSEMBLY (Typical Installation) #9 SPRAY RINSE (OPTIONAL) NOTE: A globe valve, if used for metering flow, must be installed between solenoid valve and disposer. See metering valve Fig. 7. Any valve ahead of the solenoid valve must be opened and cause no restrictions. Looking from top. VOL-TEMP ASSEMBLY (included with 9T) 1" MIN. ABOVE TABLE RIM CHECK CODE CLOCKWISE ROTATION 1/2" SYPHON BREAKER IMPORTANT! Do not test or run disposer without minimum water flow (see Plumbing Installation) as this will damage the seal and void the warranty. 1/2" GLOBE VALVE (for metering flow) 1/2" SOLENOID VALVE SPRAY CONE FITTINGS 1/2" MINIMUM WATER FLOW RATE 5 GALLONS PER MINUTE WHILE IN USE 1/2" HOT WATER SUPPLY NOTE: BASE UNIT INCLUDES DISPOSER, MOUNTINGS, AND DRAIN OUTLET. OTHER ITEMS SHOWN IN GRAY IN FIGURE 7 ARE AVAILABLE IN EQUIPMENT GROUPS ORDERED SEPARATELY. 3/4" GLOBE VALVE DISHTABLE OR DRAIN BOARD RIM TO FLOOR STANDARD 34" 1-1/2" WASTE LINE SWITCH 3/4" COLD WATER SUPPLY 1. For spray-rinse with vol-temp, run a 1/2” hot water line to point indicated in Figure 7. Connect to spray-rinse globe valve, hot water side. At no time should hot water be connected directly to disposer or cone sink. 2. Run a 1/2” cold water connection to point indicated in Figure 7. 3. Install solenoid valve in line, in upright (coil side up) position as shown in Figure 7, with arrow on side pointing in direction of water flow. 4. Install syphon breaker as in Figure 7. CHECK LOCAL CODE. 5. Make connection to water inlet fitting of cone sink. See Figure 7. 6. Make 1/2” cold water connection to spray-rinse globe valve, cold water side. This must be separate cold water line. Do not tee off of line to cone unless a 3/4” line is furnished to assembly location. See Figure 7. 7. Assemble swirl spray(s) as shown in Figure 9. The assembly method for the swirl spray(s) is the same for all models. Other combinations of convertible and fixed swirl spray(s) are optional. The outlet hole of the fixed swirl spray should be horizontal to promote vortex action in the cone. NOTE: The convertible spray should be easily adjustable by the operator to function as a swirl spray or as a dish-washing flume. Avoid excessive tightening of nut or locknut. 8. Connect 1/2” pipe to swirl spray as shown in Figure 7. 9. The disposer is equipped with a drain outlet designed for a slip-joint connection to a conventional 11/2” trap (not furnished). Connect the trap with a branch waste line running directly into the sewage connection (Figure 7). Do not connect into a grease trap. A minimum slope of 1/4” per foot of run of waste line is recommended. Limit 11/2” drain line to a 15-foot run, free of turns. A minimum number of elbows, tees, etc., reduce the possibility of plumbing stoppages. If unusual sewer conditions exist (too many bends, main too long, low water pressure resulting in low flow rate*, or if a high percentage of food waste is leafy and/or paper), the use of a time delay relay and water injector into sewer is suggested. Under such conditions, additionally, a larger size cold water line, larger solenoid valves and larger syphon breakers should be used to overcome potential stoppages. (Parts and data available from factory.) *Minimum cold water flow rate used with Models 1/2 HP through 11/2 HP: 5 gallons per minute or enough to push waste through pipeline into the sewer. TIP: Water volume adjustment: The top of the swirling water should occasionally crest to the body of the swirl water inlet. 10. To use the optional supplementary water connection, see Figure 8. 2 FIG. 8 OPTIONAL SUPPLEMENTARY WATER CONNECTION FIG. 10 INSTALLATION DIMENSIONS AND DRAINLINE CONNECTIONS SYPHON BREAKER MUST be above Table Floor Level. Check local code for confirmation. 1” I.D. FLEXIBLE HOSE 6” 2 5/32” 1/2” GLOBE VALVE 3” 1/2” SOLENOID VALVE 3 9/16” 81/2” JUNCTION BOX SLOPE = PER FOOT 1/4” A CLAMP 815/16” 1/2” ELBOW 1/2” COLD WATER SUPPLY FIG. 9 TOGGLE SWITCH A SWIRL SPRAY(S) ASSEMBLY 7 3/4” FLOOR LINE 1/2-1 3/4-1 3/4-3 1-1 1-3 { = = = = = 18 7/16 18 15 /16 18 7/16 18 15 /16 18 7/16 1 1 1 1 1/4-1 1/4-3 1/2-1 1/2-3 = = = = 1911 /16 18 15 /16 1911 /16 18 15 /16 AERATOR SPRAY FIG. 11 SINK MOUNTED MODELS (SM) SPRAY GASKETS LOCK NUT TUBING CONICAL WASHER 31/2” STEEL WASHER NUT 11/8” 21/2” BRASS WASHERS 81/2” 39/16” CONICAL – BRASS WASHERS SLOPE = PER FOOT 1/4” A TUBING SPRAY HEAD GASKET LOCK NUT NUT SPRAY HEAD STEEL WASHER 815/16” 7 3/4” FLOOR LINE A { 1/2 HP-1SM = 17 11 /16 3/4 HP-1SM = 18 3/16 3/4 HP-3SM = 1711 /16 ELECTRICAL CONNECTIONS All electrical connections must be made in accordance with local wiring codes Flexible BX cable should be used in making electrical connections to motor to avoid transmission of noise. Be careful not to pinch wires when replacing terminal box. IMPORTANT! THE DISPOSER MUST BE CAREFULLY AND PERMANENTLY GROUNDED. GROUND SCREW IS PROVIDED. Overload Protection: Reset button overload provided on all standard models. IMPORTANT NOTE: Disposer motor phase, single or three phase, must be the same as power source and line phase. Disposer wiring connection voltage must be the same as the voltage of power source. ALL SINGLE PHASE MOTORS 3-Pole, 20 Amp., heavy duty switch encased in waterproof receptacle. Two poles of switch control motor and third pole controls solenoid, isolating the two circuits to prevent solenoid kickback when switch is turned off. Refer to Figures 12 and 13 for recommended wiring installation. SINGLE PHASE 1/2 HP Factory Wired for 110-120-V A.C. unless otherwise specified. To connect for 220-240-V A.C. refer to information on inside face of terminal box cover. SINGLE PHASE 3/4 HP, 1HP, 11/4 HP, and 11/2 HP Factory Wired for 220-240 volts. To reconnect for 110-120 volts refer to information on inside face of terminal box cover. NOTE: After installation, be sure turntable rotates clockwise. CAUTION: When making field changes for voltage, be certain to change all other related electrical circuits such as solenoid valves, relays, etc. ALL THREE PHASE MOTORS 3-Pole, 20 Amp., heavy duty switch encased in waterproof receptacle. Tap off any two leads for the solenoid valve. Refer to Fig. 14 and 15 for typical wiring installation. THREE PHASE 3/4 HP, 1HP, 11/4 HP, and 11/2 HP All three phase motors are factory wired for 208-240-V A.C. AFTER INSTALLATION BE SURE TURNTABLE ROTATES CLOCKWISE. If not, interchange any two of the three wires. To reconnect for 460 volts, refer to information shown on inside face of terminal box cover. 3 FIG. 12 SINGLE PHASE FIG. 13 WIRING FOR SINGLE PHASE UNITS WITH MANUAL SWITCH SOLENOID VALVE CLOCKWISE WHITE WIRE ROTATION HOT WIRE POWER “IN” ON MANUAL SWITCH POWER SUPPLY FUSE PER LOCAL CODE L1 L-1 JUNCTION BOX SWITCH BOX AND COVER F F /O L2 L-2 VOLTS 1/2 HP– 1-1/2 HP 110-120 220-240 TURNTABLE ROTATION AS VIEWED FROM THE TOP CLOCKWISE ROTATION T1 T-1 MODEL PART NO. 2420 NOTES: T2 T-2 MOTOR JUNCTION BOX 1. Motor wired at Factory for 220-240 volts except for 1/2 HP. For 110-120 volts, connect motor wires as shown inside of motor junction box cover. SOLENOID RATED VOLTAGE TO MATCH LINE VOLTAGE FIG. 14 THREE PHASE FIG. 15 WIRING FOR THREE PHASE UNITS WITH MANUAL SWITCH SOLENOID CLOCKWISE VALVE 3 PHASE ROTATION POWER LINE L1 L-1 L2 L-2 POWER SUPPLY FUSE PER LOCAL CODE L3 L-3 CLOCKWISE ROTATION JUNCTION BOX T1 T-1 T2 T-2 T3 T-3 MANUAL SWITCH 208-240 460 2420 NOTES: MOTOR JUNCTION BOX SOLENOID RATED VOLTAGE TO MATCH LINE VOLTAGE FIG. 16 WIRING FOR THREE PHASE UNITS WITH MAGNETIC SWITCH ALL VOLTAGES – DO NOT USE L3 OR T3 FOR SINGLE PHASE APPLICATION SWITCH START - STOP (MOUNT NEAR UNIT) THESE TERMINALS MAY BE LABELED T4 OR L4 START 3 2 T-3 L-3 T-2 L-2 T-1 L-1 COIL RATED VOLTAGE TO MATCH LINE VOLTAGE TURNTABLE ROTATION AS VIEWED FROM THE TOP 2. Interchange T1 and T3 to reverse rotation. MAGNETIC SWITCH MODEL 3/4 HP – 1-1/2 HP VOLTS PART NO. 208-240 2416 460 2417 NOTES: CLOCKWISE ROTATION 1. Motor wired at Factory for 208-240 volts. For 460 volts, connect motor wires as shown inside of motor junction box cover. SWITCH BOX ON FRONT OF UNIT 2. Interchange T1 and T3 to reverse rotation. MOTOR: CONSULT CHART FOR CORRECT MAGNETIC SWITCH 3. No heaters used with magnetic switch. POWER SUPPLY - FUSE PER LOCAL CODE. FIG. 17 WIRING FOR SINGLE PHASE UNITS WITH MAGNETIC SWITCH SWITCH START - STOP (MOUNT NEAR UNIT) THESE TERMINALS MAY BE LABELED T4 OR L4 START 3 COIL RATED VOLTAGE TO MATCH LINE VOLTAGE 2 STOP SWITCH BOX ON FRONT OF UNIT SOLENOID-RATED VOLTAGE TO MATCH LINE VOLTAGE 1/2 HP– 1-1/2HP PART NO. 1. Motor wired at Factory for 208-240 volts. For 460 volts, connect motor wires as shown inside of motor junction box cover. FF /O ON SOLENOID-RATED VOLTAGE TO MATCH LINE VOLTAGE VOLTS TURNTABLE ROTATION AS VIEWED FROM THE TOP 3 POLE SWITCH STOP MODEL T-2 L-2 T-1 L-1 MOTOR: CONSULT CHART FOR CORRECT MAGNETIC SWITCH TURNTABLE ROTATION AS VIEWED FROM THE TOP MAGNETIC SWITCH MODEL VOLTS PART NO. 1/2 HP – 1 1/2 HP 110-120 2414 220-240 2415 NOTES: CLOCKWISE ROTATION POWER SUPPLY - FUSE PER LOCAL CODE. 1. Motor wired at Factory for 220-240 volts except for 1/2 HP. For 110-120 volts, connect motor wires as shown inside of motor junction box cover. 2. No heaters used with magnetic switch TESTING – IMPORTANT! Do not test or run disposer dry as this will damage the seal and void the warranty. 1. Test assembly for leaks: a. where cone sink joins table b. where disposer joins cone c. all piping connections d. “Swirl Spray” fittings 2. After plumbing and electrical connections are made, turn on disposer to be sure all parts are in working order and that the disposer turntable rotates clockwise when viewed from above. Open valve in vacuum breaker line, and using valves in plumbing assembly (Fig.7), adjust so that water swirls around just below the rim of the cone sink. Leave valves in these positions. These combinations provide a flow of approximately 8 gallons of water per minute. 3. Replace cover, retest for leaks and turn unit off. 4. Unit is now ready for operation. 4 INSTALLATION INSTRUCTIONS COMMERCIAL DISPOSER MODELS 2 HP, 3 HP, 5HP AND 10HP BEFORE INSTALLING, READ ENTIRE INSTRUCTIONS CAREFULLY. RISK OF INJURY TO PERSONS FROM HAZARDOUS MOVING PARTS. SERIOUS INJURY POSSIBLE IF NOT PROPERLY INSTALLED WITH A HOPPER OR A CONE SPECIFIED IN THE INSTRUCTION MANUAL. FIG. 1 FIG. 2 B MODEL 6T A SINK HOLE C DIA. No. 9T SPRAY RINSE No. 6T APPROX. 30” FIG. 3 9” MIN. 6” MIN. APPROX. 14” A B C SPRAY RINSE HOLE 2215 15” CONE 2211 18” CONE 10 1/ 4” 31/ 2” 131/ 2” 113/ 4” 31/ 2” 161/ 2” 131/ 4” 31/ 2” 191/ 2” MODEL 9T DISH TABLE FLAT PORTION OF CONE SINK 6-5/8” A B C 2” TO 4” A 6” 2216 12” CONE CONE SINK 2216 12” CONE 2215 15” CONE 2211 18” CONE 12 7/ 8” 61/ 8” 131/ 2” 12 7/ 8” 45/ 8” 161/ 2” 12 7/ 8” 31/ 8” 191/ 2” IF YOU ARE REPLACING AN OLD DISPOSER GO TO POSITIONING AND INSTALLATION OF COMMERCIAL DISPOSER INSTALLATION OF CONE SINK INTO DISH OR WORKTABLE 1. (See Figures 1 and 2.) Locate hole center as shown on Figure 2. Cut a “C” (Figure 2) diameter hole in dish or work table, a minimum of 2” from the inside front edge (operator’s side). Hole can be cut with a “nibbler” after a knockout hole 11/2” diameter has been punched. 2. Lift cone to underside of table with cone flange overlapping all around (Figures 1 and 3). 3. Check alignment of cone spray fittings to be sure they are in the proper position. For 15” and 18” cones, position such that holes are located to right and left side of operator. (See Figure 7 for location.) 4. Tack weld, spot weld, bolt, or rivet flange of cone sink to underside of dish or work table. If bolted or riveted, smooth top surface and washsolder around bolt or rivet heads and sand smooth. 5. Bead weld or solder and wash-solder all around where the table joins flange of cone sink for a clean, watertight, sanitary installation. 6. The cone sink has been designed with the step, as shown in Figure 3. In the welding or soldering operation required to assemble the cone sink to the dish or work table, every attempt should be made to keep the recessed, flat portion of the cone free of the weld or solder material. This will minimize the clean-up time required and provide a smooth, flat surface for any cover. 7. Minimum installation criteria: • Minimum clearance between left and right side of waste disposer and side wall: 18 inches. • Minimum clearance to back wall: 10 inches. • No front panel/door between waste disposer installation cavity under a sink/dish table and room. SPRAY-RINSE INSTALLATION FIG. 4 1. Locate center (Figures 1 and 2). 2. Drill 7/16” diameter hole through center. 3. Assemble 7/8” punch and tighten bolt head, as illustrated, until the die pierces the stainless steel, leaving a clean opening of 7/8”. 4. Place body valve and base in position, assemble washer and locknut as shown in Figure 5. 5. Attach vol-temp assembly to the projecting nipple. FIG. 5 BODY VALVE BASE WASHER 7/8” PUNCH POSITIONING AND INSTALLATION OF COMMERCIAL DISPOSER 1. Subassemble plumbing for swirl sprays as shown in detail in Figure 6, and as shown assembled on final unit in Figure 7. 2. Slide Hush Cushion® up over edge of flange on cone sink. The inner edge of this Hush Cushion® is chamfered to facilitate this operation. 3. Slide one clamp ring over Hush Cushion®, place between two upper beads and tighten, this firmly attaches the Hush Cushion® to the cone sinks. NOTE: On the six inch opening only to make certain that the Hush Cushion® is not mounted upside down, look down into the cone sink from above the work table and check that the wording is readable on the center plug on the Hush Cushion®. This reads, “Remove before using”. FIG. 6 SPRAY RINSE GLOBE VALVE 1/2” 1/2” “T” 1/2” TUBE FITTING 1/2” COPPER TUBING LOCKNUT 1/2” COPPER TUBING 1/2” CLOSE 1/2” TUBE NIPPLE FITTING NIPPLE 1/2” X 6” 1/2” “T” 1/2” CLOSE NIPPLE 1/2” X 4” NIPPLE 5 FIG. 7 #9T SPRAY RINSE (Dotted Outline Illustates 9T Rinse) NOTE: MAGNETIC SWITCH AND REMOTE PUSH BUTTON STATION A globe valve used for metering flow to prevent solenoid hammering must be installed between solenoid valve and disposer. See Fig. 7. Any valve ahead of the solenoid valve must be opened and cause no restrictions. APPROX. 40" SYPHON BREAKER (Check Local Code) IMPORTANT! Do not test or run disposer without minimum water flow (see Plumbing Installation) as this will damage the seal and void the warranty. 1" MIN. ABOVE TABLE RIM ELBOW TUBE FITTING 1/2" GLOBE VALVE FOR METERING* HUSH CUSHION¤ NOTE: CLAMP RING TUBE Disposer assembly includes disposer, outlet, nipple, Hush Cushion®, clamps and supporting legs. Other items must be purchased separately. Items shown in gray in Figure 7 are available in equipment groups ordered separately. POWER SUPPLY 1/2" GLOVE VALVE MANUAL SWITCH SOLENOID VALVE 1/2" GLOBE VALVE WASTE LINE SEE FIG. 11 GATE VALVE GATE VALVE 1/2" HOT WATER AERATOR SPRAY FIG. 8 3/4" COLD WATER HOT WATER FIG. 9 CONVERTIBLE SPRAY SPRAY GASKETS LOCK NUT TUBING CONICAL WASHER STEEL WASHER NUT The convertible spray should be located opposite the direction of travel of dishes in scrapping operation. BRASS WASHERS CONICAL – BRASS WASHERS TUBING SPRAY HEAD GASKET LOCK NUT NUT SPRAY HEAD STEEL WASHER 4. Slide second clamp ring loosely over Hush Cushion® and up to previously tightened clamp ring. Do not tighten. 5. Unscrew legs until there is a space of approximately 1/4” between the top of the upper housing and the Hush Cushion®. Raise disposer until the upper housing slides into the Hush Cushion®. Slide the loose clamp ring between the two lower beads on the Hush Cushion® and tighten. 6. Assemble swirl spray or swirl sprays as shown in Figure 8. The method of assembly of the swirl sprays is typical. Other combinations of convertible and fixed swirl sprays are available. The outlet hole of fixed spray head should be horizontal to promote swirling action in cone sink. (convertible spray see Figure 9.) 7. Connect copper tube or tubes to swirl sprays and bend in gradual curve to connect to fittings in valves. See Figure 7. 8. Thread special nipple into drain outlet, slide hush connector over pipe and assemble and tighten clamp ring in two grooves. NOTE: ALL PLUMBING AND ELECTRICAL CONNECTIONS SHOULD BE MADE ACCORDING TO LOCAL CODES. INSTALLATION DIMENSIONS AND DRAINLINE CONNECTIONS FIG. 10 J 2HP-1 L K A* H D Sink Flange C Water Inlet A* G* B Slope = 1/4” Per Foot G minus B * FIG. 11 5HP-38 10HP-3 32 3 / 8 - 35 1/ 8 32 3 / 8 - 35 1/ 8 32 3 / 8 - 35 1/ 8 32 7/ 8 - 35 3/ 8 32 61/ 64 - 35 29/ 64 32 61/ 64 - 35 29/ 64 215/ 16 209/16 2215/ 32 221/ 2 2237/ 64 2337/ 64 C 6 5/ 8 6 5/ 8 6 5/ 8 6 5/ 8 6 5/ 8 6 5/ 8 D 6 6 6 6 8 8 E 161/ 4 161/ 4 1715/ 16 1719/ 64 17 3/ 8 17 3/ 8 16 161/ 8 165/ 8 16 23/ 32 16 23/ 32 G* Drain DIMENSIONS 3HP-3 5HP-3 B F F E 2HP-3 16 25 3 / 4 - 281/ 2 25 3 / 4 - 28 1/ 2 25 3 / 4 - 281/ 2 261/ 4 - 28 3/ 4 26 21/ 64 - 28 53/ 64 26 21/ 64 - 28 53/ 64 H 51/ 8 51/ 8 6 7/ 8 87/16 87/16 87/16 J 5 3/ 4 5 3/ 4 8 7/ 8 8 8 8 K 2 5/ 8 2 5/ 8 33/ 8 4 3/ 4 4 3/ 4 4 3/ 4 L 67/ 16 6 7/ 16 713/ 16 1013/ 16 1013/ 16 1013/ 16 Legs are adjustable beyond the minimum shown in the screw adjustment. 2” clearance must be maintained beneath unit for proper ventilation. 6 TRAP DISPOSER WALL If space between disposer and wall is insufficient to allow for installation of trap, waste line may have to be at an angle to the wall as shown. PLUMBING INSTALLATION NOTE: Refer to FIgure 10 for installation dimensions and drainline connections. 1. Plumb unit using valves and fittings as shown typically in Figure 7. NOTE: Syphon breaker, available as option item, is approved in most areas. Check local code to be sure it conforms in your area. 2. When overhead spray rinse is used, split the incoming 3/4” cold water into two 1/2” lines and connect one to the 1/2” “T” at the bottom of the unit and the other to the globe valve on the cold water side of the spray rinse. Connect one 1/2” hot water line to the globe valve on the hot water side of the spray rinse. 3. On models 3 HP, 5 HP, and 10 HP connect 3” drain to the hush connector. Drain line must have a minimum of bends. The unit is equipped with a drain outlet designed for a connection to a conventional 3” trap. For model 2 HP drain line and trap will be 2”. IMPORTANT! Before installing the disposer, the connecting waste line must be cleaned out all the way to the connecting sewer main. DO NOT CONNECT INTO GREASY TRAP. The trap may be connected to a 3” branch waste line running directly into the stack. For model 2 HP, branch waste line can be 2”. A minimum slope of 1/4” per foot of run of waste line is recommended. Limit the horizontal drain line to a 15 foot run free of turns; then, using a long 45° “Y”, connect to a 3” or 4” horizontal line or stack. Recessed thread fittings must be used throughout and all pipe ends should be carefully reamed. A minimum number of elbows, tees, etc., reduce the possibility of plumbing stoppages. Water is injected to underside of table chamber through a control that allows approximately 4 gallons per minute flow. Do not restrict or alter this control as it is necessary to properly clean the inside of the unit. IMPORTANT: If unusual sewer conditions exist (too many bends or too long to main), if the water pressure is low for application resulting in low water flow rate, or if high percentage of leafy and/or paper material is included in food waste, serious consideration should be given to the use of a time delay and water injector into the sewer to overcome stoppages. Under such conditions a larger size cold water line should be used along with larger solenoid valves and syphon breakers. (Parts and data available from factory.) *Minimum Water Flow RATE Used with Model: 2 HP and 3 HP – 10 gallons per minute. 5 HP and 10 HP – 14 gallons per minute. TESTING IMPORTANT! Do not test or run disposer without minimum water flow (see Plumbing Installation) as this will damage the seal and void the warranty. 1. Test assembly for leaks: a. Where cone sink joins table b. Where disposer joins cone sink c. At all piping connections d. Where swirl spray fittings connect 2. After plumbing and electrical connections are made, turn on disposer to be sure all parts are in working order and that the disposer turntable rotates clockwise when viewed from above. Open valve in vacuum breaker line and, using globe valves in plumbing assembly (Refer to Figure 6), adjust so that water swirls around just below the rim of the cone sink. Leave valves open in these positions. NOTE: When the convertible swirl spray is used to remove food waste from dishes, adjust the flow to provide a convenient combination of anti-splash and high flow volume characteristics (top of flume approximately 3” above cone sink). These combinations provide a flow of approximately 8 gallons of water per minute. 3. Replace cover, retest for leaks and turn unit off. 4. Unit is now ready for operation. OPERATING INSTRUCTIONS IMPORTANT! Do not test or run disposer without minimum water flow (see Plumbing Installation) as this will damage the seal and void the warranty. 1. Push “start” button. Be sure unit is running and water is flowing before any waste is fed into the disposer. Do not pack food waste into unit. Do not dump garbage can loads directly into unit. Feed waste in gradually. 2. DO NOT ALLOW GLASS, METAL OR CROCKERY TO ENTER. IF THIS OCCURS, STOP THE UNIT AND REMOVE SUCH MATERIAL. 3. IF THE MOTOR STOPS, push stop button. Remove any waste material which caused stoppage. Check the turntable to see that it will turn freely. Wait three minutes, push red reset button firmly (LOCATED ON JUNCTION BOX OF MOTOR). Then push “start” button. 4. If the motor hums and the turntable does not rotate freely, there is usually a jamming obstruction, such as metal. STOP UNIT. With a suitable bar or stick, pry against one of the impellers and rotate the turntable in a counterclockwise direction. When the turntable is free, REMOVE THE BAR AND THE OBSTRUCTION MATERIAL BEFORE RESTARTING UNIT. CAUTION – LOSS OF ONE PHASE IN THREE PHASE UNITS (if one fuse blows while running) WILL CAUSE MOTOR TO LABOR AND HEAT. PROLONGED OPERATION WILL DAMAGE THE MOTOR. 5. If the motor remains silent after resetting the overload protector (as instructed in item 3 above) and the turntable rotates freely, check the electric fuses and complete electrical circuit. 6. ALWAYS ALLOW THE DISPOSER AND THE WATER TO RUN FOR THREE MINUTES AFTER EACH OPERATION to keep the unit clean and to flush all food waste out of the drain lines. THIS IS IMPORTANT! CAUTION: ALWAYS TURN THE DISPOSER OFF AND LET IT COME TO A STANDSTILL BEFORE PUTTING YOUR HAND INTO THE HOPPER OR NEAR THE GRINDING CHAMBER. DO NOT LOOK FOR CAUSE UNTIL STARTING CONTROL IS TURNED OFF. ELECTRICAL INSTALLATION 1. Use waterproof conduit and make all electrical connections according to local codes. 2. Wire three phase units using manual switches as shown in wiring diagram, Figure 12. 7 FIG. 12 WIRING FOR THREE PHASE UNITS WITH MANUAL SWITCH MANUAL SWITCH MODEL 2 HP L1 L-1 L2 L-2 POWER SUPPLY FUSE PER LOCAL CODE L3 L-3 3 HP SEE CHART FOR APPROPRIATE SWITCH T1 T-1 T2 T-2 T3 T-3 CLOCKWISE ROTATION TURNTABLE ROTATION AS VIEWED FROM THE TOP 5 HP VOLTS PART NO. 208-240 2420 460 2420 208-240 2421 460 2421 208-240 2421 460 2421 NOTES: 1. Motor wired at Factory for 208-240 volts. For 460 volts, connect motor wires as shown inside of motor junction box cover. MOTOR JUNCTION BOX SOLENOID RATED VOLTAGE TO MATCH LINE VOLTAGE 2. Interchange T1 and T3 to reverse rotation. 3. Magnetic and manual starters, supplied do not require heaters to complete the circuit. Disposers have built-in overload protection. FIG. 13 WIRING FOR THREE PHASE UNITS WITH MAGNETIC SWITCH MAGNETIC SWITCH SWITCH START - STOP (MOUNT NEAR UNIT) MODEL THESE TERMINALS MAY BE LABELED T4 OR L4 2 HP START STOP 3 2 T-3 L-3 T-2 L-2 T-1 L-1 COIL RATED VOLTAGE TO MATCH LINE VOLTAGE 5 HP SWITCH BOX ON FRONT OF UNIT SOLENOID-RATED VOLTAGE TO MATCH LINE VOLTAGE 3 HP 10 HP MOTOR: CONSULT CHART FOR CORRECT MAGNETIC SWITCH POWER SUPPLY FUSE PER LOCAL CODE. VOLTS PART NO. 208-240 2416 460 2417 208-240 2416 460 2417 208-240 2416 460 2417 208-240 2416 460 2417 NOTES: CLOCKWISE ROTATION 1. Motor wired at Factory for 208-240 volts. For 460 volts, connect motor wires as shown inside of motor junction box cover. TURNTABLE ROTATION AS VIEWED FROM THE TOP 2. Interchange T1 and T3 to reverse rotation. 3. Magnetic and manual starters, supplied do not require heaters to complete the circuit. Disposers have built-in overload protection. FIG. 14 WIRING FOR SINGLE PHASE UNITS WITH MANUAL SWITCH MANUAL SWITCH MODEL POWER SUPPLY FUSE PER LOCAL CODE L1 L-1 L2 L-2 T1 T-1 T2 T-2 2 HP CLOCKWISE ROTATION MOTOR JUNCTION BOX SOLENOID RATED VOLTAGE TO MATCH LINE VOLTAGE 8 TURNTABLE ROTATION AS VIEWED FROM THE TOP VOLTS 110-120 220-240 PART NO. 2420 NOTES: 1. Motor wired at Factory for 220-240 volts. For 110-120 volts, connect motor wires as shown inside of motor junction box cover. 2. Magnetic and manual starters, supplied do not require heaters to complete the circuit. Disposers have built-in overload protection. SINK MOUNTED MODELS DISASSEMBLY PROCEDURE COMMERCIAL DISPOSER MODELS 1/2 HP, 3/4 HP, 1 HP, 11/4 HP, 11/2 HP 1. Remove unit from sink or cone. 2. Remove 6 screws which hold upper housing to motor housing (Fig.1) There are nuts and lock washers under the motor housing. 3. Lift off upper housing to expose grind ring and turntable. The grind ring can be lifted out. Remove the grind ring. FIG. 1 4. Remove the turntable screw. This has a Left Hand Thread. Jam the turntable with a screw driver to prevent its turning while removing screw. (See Fig. 2) HOLD TURNTABLE FIG. 2 5. The turntable screws onto the rotor by a left hand thread. If only the seal or turntable require replacement, the rotor can be held by a large screwdriver in the slot in the top of the shaft. With the rotor held from turning, tap the impellers with a mallet to start the turntable. REMEMBER THAT THIS IS A LEFT HANDED THREAD. (See Fig. 3) 6. The seal is now exposed and can be replaced. Follow instructions which come with the replacement seal or see Page 13 of this manual. 7. If the bearing or stator require replacement, proceed to remove the stator as described on page 17. FIG. 3 9 COMMERCIAL DISPOSER MODELS 2 HP, 3 HP, 5 HP, 10 HP TRIPOD MOUNTED MODELS DISASSEMBLY PROCEDURE UPPER HOUSING DISASSEMBLY PROCEDURE Remove the eight Allen Head screws which hold the upper housing to the motor housing. Use a 5/16” Allen Head wrench as shown. It may be necessary to tap the upper housing around the outer edge to loosen it from the motor housing surface. Use a wooden mallet. For a complete separation, insert a screwdriver between both housings and pry up. GRIND RING DISASSEMBLY PROCEDURE NOTE: Gasket on top of grind ring MUST be replaced once the upper housing is removed. Lift off upper housing to expose the grind ring and turntable. The grind ring can easily be lifted out unless the silastic sealant is binding it. In this case, scrape off the sealant from the grind ring outer edge, and tap the ring very lightly with a mallet to loosen it. After the grind ring has been removed, the motor housing gasket can be peeled off and discarded to be replaced by a new gasket. 10 TURNTABLE DISASSEMBLY PROCEDURE COMMERCIAL DISPOSER MODELS 2 HP, 3 HP, 5 HP, 10 HP To remove the turntable, first remove the center bolt. The 2 HP model has a left handed bolt. Turn the bolt clockwise to loosen it. For 3 HP, 5 HP, and 10 HP models, turn the bolt counter-clockwise to remove it.To prevent the turntable from rotating with the wrench turns, insert a large screwdriver under the outer edge of the turntable as shown in the top right diagram. This will allow you to tap the wrench with a mallet to loosen the screw if necessary. Fig. A shows the correct screw and washer configuration. Next, insert another large screwdriver on the opposite side of the turntable outer edge as shown. Push downward using both screwdrivers as levers to hoist the table up and off of the shaft. BOLT WASHER FIG. A 11 TURNTABLE AND GRIND RING INFORMATION All of our commercial disposers have stainless steel turntables which have been dynamically balanced for smooth operation. These turntables rotate at a speed of 1,725 R.P.M., which means that they revolve this many times each minute. Centrifugal force hurls food waste outward to be crushed by the teeth of the grind ring. In addition, the turntables have impellers which swivel and can retract if they are jammed so that they return to the grinding position during revolution. Both impellers are fortified with diamond-hard carbide inserts which provide longer life usage on the heavy duty units. Also, a stainless steel under cutter blade is located beneath the grind ring which snips fibrous or stringy waste into smaller particles making them less likely to clog the drain lines. GRIND RING TEETH TURNTABLE ROTATION WARNING All of our disposers are designed so that the turntables revolve in a clockwise direction. Reversed line leads will cause a backwards turn in a counterclockwise direction which will damage the unit. The arrow which is molded into the turntable indicates the proper turn direction. To change the turn, refer to the correct wiring diagram and reverse the line leads. See bottom of Page 3. 12 ARROW INDICATING TURNING DIRECTION OF TURNTABLE STAINLESS STEEL UNDER CUTTER BLADE SWIVEL IMPELLERS AND DIAMOND HARD INSERTS SEAL DISASSEMBLY AND REPLACEMENT PROCEDURE SEAL DESCRIPTION The seal consists of two assemblies. The upper half is the counter face assembly, which rotates with the turntable. It consists of a lapped ring (to mate with the lower half) and a rubber sealing gasket (to seal between the table hub and counter face). The lower half is a seal assembly, which remains stationary. It consists of a carbon ring A to mate with the counter face and is spring loaded to maintain sealing contact with the counter face. This spring has a rubber boot B to prevent leakage around and beneath the spring. NOTE: Care must be taken not to damage the mating surfaces of the counter face and seal assemblies. Any damage to these surfaces will cause operational noise and water leakage. CHECK “1” AREA Before removing the seal from the motor housing hub area, you must first scrape the existing Permatex sealant from the outer diameter of the seal rim. After this is done, you may use a large screwdriver to pry the seal up and out. CAUTION: Do not remove the seal unless there is evidence of an actual seal failure. SEALING GASKET SEALING GASKET COUNTER FACE COUNTERFACE UPPER HALF UPPER HALF AA SEAL SEAL ASSEMBLY ASSEMBLY LOWER HALF BB LOWER HALF ALSO CHECK “2” AREA Seal and Motor Housing locations plus Permatex Sealing area. “1” and “2” Critical Sealing areas shown. After the seal is removed, be sure to clean the complete motor seal seat surface area. Next, apply Permatex to the outer rim of the new seal assembly. Then, press the seal assembly into place, applying even pressure to the outer rim of the seal. Fig. B shows how you can make use of a devised cup-like tool that will allow you to tap down the outer rim only of the seal assembly. The cross section drawing shows proper insertion of the seal pressure gauge tool which is included in the Seal Kit. FIG. B MOTOR SHAFT Seal Kit Part Numbers 2 HP #01-22-688 3 HP #01-22-689 5 and 10 HP #01-22-756 SEAL ASSEMBLY SEAL PRESSURE GAUGE MOTOR HOUSING SEAL ASSEMBLY CROSS SECTION VIEW 13 MOTOR REMOVAL FROM THE TRIPOD Before attempting to remove the motor from the tripod, make sure that these top mating parts have been disassembled: Upper Housing, Grind Ring with gasket, Turntable, Seal assembly, with shim washers and snap ring. See previous pages. If the unit can be turned over upside-down, all that is necessary is to remove the four Allen Head screws with a 1/4” Allen Head wrench as shown at right. If the tripod is left standing as shown, a support under the motor will be needed to keep it from dropping after the screws are removed. In the pictures below, a heavy wooden board was used as a prop under the motor to support it. SMALL AND MID-SIZED MODELS BEARING REMOVAL The 1/2 HP through the 2 HP models have an upper bearing that is secured in the motor housing with a Truarc snap ring retainer. This bearing can be easily removed by turning the housing over and removing the snap ring retainer, then pushing or pulling the bearing up out of the housing. After the bearing has been replaced the snap ring REMOVING OR REPLACING PROCEDURE USING TOOL 2 HP MODEL 14 retainer can be replaced. The bearing is prelubricated with a special grease by the bearing manufacturer. NOTE: If the unit is running with noise or displays leaking problems, be sure to inspect this bearing. These conditions can hamper the normal functioning of this bearing and cause internal damage. TUARC RING RETAINER 1/2 HP THROUGH 11/2 HP MODELS DISASSEMBLY PROCEDURE STATOR AND ROTOR All of the present commercial disposer motors have built-in manual reset overload protectors located in a conduit box on the outside of the motor. This motor assembly is not integral, and any of the parts can be replaced. See the motor chart on page 16. DISASSEMBLY OF THE UPPER MOTOR SEALING GASKET COUNTERFACE UPPER HALF A B SEAL ASSEMBLY LOWER HALF The upper end shield and the bottom end shield are connected by four motorthru bolts which must first be removed with a 7/16” socket wrench. It is also necessary to remove the three screws which hold the bearing retainer onto the rotor shaft under the top end shield. SHIM INFORMATION Each of the shims below have been designed to control the compression between seal surfaces “A” and “B” and the turntable. If this is not controlled correctly, the seal will become damaged. SHIM AS REQUIRED .015 Shim = Part number 0064023 .010 Shim = Part number 0064024 .005 Shim = Part number 0064025 Remove the snap ring by using a screwdriver and prying outward until the ring snaps out of the shaft slot. The upper end shield can now be removed. (Continued on the next page.) 15 MOTOR DATA FOR MODELS 16 DISPOSER HP VOLTS AMPS PHASE HERTZ RPM 1/2 110-120/220-240 9.2/4.6 1 60 1725 1/2 100-120/200-240 7.4/3.8 1 50 1425 3/4 110-120/220-240 10.6/5.3 1 60 1725 3/4 100-120/200-240 9.8/5.5 1 50 1425 3/4 208, 220-240/440-480 2.8/1.4 3 60 1725 3/4 200-240/380-460 3.8/1.9 3 50 1425 1 110-120/220-240 12.0/6.0 1 60 1725 1 100-120/200-240 10.7/6.0 1 50 1425 1 208, 220-240/440-480 3.2/1.6 3 60 1725 1 200-240/380-460 4.6/2.3 3 50 1425 11/4 110-120/220-240 12.8/6.4 1 60 1725 11/4 100-120/200-240 14.0/7.8 1 50 1425 11/4 208, 220-240/440-480 3.9-4.0/2.0 3 60 1725 11/4 200-240/380-460 4.0/2.0 3 50 1425 11/2 110-120/220-240 14.4/7.2 1 60 1725 11/2 100-120/200-240 15.6/7.8 1 50 1425 11/2 208, 220-240/440-480 4.3-4.4/2.2 3 60 1725 11/2 200-240/380-460 4.4/2.2 3 50 1425 2 110-120/220-240 17.0/8.5 1 60 1725 2 100-120/200-240 16.0/8.0 1 50 1425 2 208, 220-240/440-480 5.6/2.8 3 60 1725 2 200-240/380-460 6.6/3.3 3 50 1425 3 208-220/240 7.0/3.5 3 60 1740 3 380-460 5.4 3 50 1425 5 208-220/440 16.0/8.0 3 60 1740 5 200-240/380-460 17.2/8.6 3 50 1425 10 208-220/440 19.4/9.7 3 60 1740 10 200-240/380-460 20.6/10.3 3 50 1425 STATOR AND COOLING FAN REMOVAL To remove the stator and fan, it is necessary to turn the motor up-side down to expose the fan guard. The guard is fastened with four screws on the outer edge which can be easily removed. All of these units are built with a cooling fan which rotates with the motor on the shaft. Loosen nut ans bolt. Now the fan can be removed by using a pair of screwdrivers as levers to slide the fan off of the shaft. ROTOR AND BEARING REMOVAL After the upper and lower shields have been removed, the rotor can easily be pulled out of the stator coil area. ROTOR RETAINER CAUTION: During this procedure, avoid any contact of the rotor with the stator coil windings as damage may occur. STATOR COIL WINDINGS The entire rotor assembly or either the top or bottom bearings can now be replaced. TOP BEARING BOTTOM BEARING TOP BEARING 17 END SHIELD REMOVAL After the rotor and fan are removed from the unit, the end shield can be disassembled from the stator. Use a mallet and tap gently to work the end shield away from the stator. Inside of the end shield is a retaining spring which is easily removed. STATOR BODY END SHIELD RETAINING SPRING STATOR AND OVERLOAD PROTECTOR ELECTRICAL DESCRIPTIONS JUNCTION BOX The overload protector which is mounted on the Junction Box can easily be replaced. An outer label mounted on the outside of the stator will give detailed electric data of the disposer. To remove the cover of the box, undo four screws. On the reverse side of the cover is a line wiring label. This diagram should match the phase sequence of your disposer. STATOR SECOND LABEL SHOWS LINE WIRING AND MATCHES PHASE SEQUENCE OF DISPOSER REVERSE SIDE OF COVER 18 THERMAL OVERLOAD OVERLOAD PROTECTOR To remove the overload protector, undo the two holding screws. Numbers appearing near the six terminals show wire hookups per diagram on Page 22. See enlarged drawing below. MOUNTING SCREWS STATOR COIL RED RESET BUTTON 6 3 5 OVERLOAD PROTECTOR LOCATION OVERLOAD PROTECTOR 1 2 4 TERMINAL IDENTIFICATION NUMBERS ELECTRICAL DESCRIPTION Each motor has been tested for phase sequence and line volts. For example, this motor is wired for 208-220 Volts - three phase and can be connected to operate on 220 or 440 Volts. There are three pairs of winding, and these are parallel across one of the phases. When connected for 460 Volts, each pair is connected in series. LEAD NUMBERS 16 AND 6 LEAD NUMBERS 15 AND 5 LEAD NUMBERS 14 AND 4 LEADS TO LINE 208/220 VOLTS EXAMPLE OF WINDING LEADS (See external diagram, pages 23 and 24) 19 TESTING THE MOTOR CAPACITOR FOR MODELS 1/2 THROUGH 2 To test the motor capacitor, it is necessary to disconnect and remove the capacitor from the motor. With a test light, check the current through the capacitor as shown at right. If there is no current, replace the capacitor. Next, check for a short circuit from each terminal post to the aluminum capacitor casing. If there is a short, replace the capacitor. The actual capacity of the capacitor can only be checked with a capacitor bridge. CAPACITOR TERMINALS 25 WATT LAMP RESISTOR CAPACITOR 115V/60 CYCLE, A.C. CURRENT DIAGRAM FOR MAKING OPEN CIRCUIT TEST, GROUND TEST, AND SHORT CIRCUIT TEST NOTE: The above continuity and short circuit tests must be made with a 115 Volt, 60 cycle alternating current. REPLACEMENT OF IMPELLERS ON TURNTABLES The installation of new impellers is recommended only when the turntable is equipped with heavy, forward impeller stops as shown. In cases of excessive wear, the replacement of all impellers is recommended to assure proper turntable balance. Care must be taken to see that the crimp washer, is fully seated into the groove on the impeller shaft. The inset illustration to the right shows vice-grips which have been modified for this purpose. SHAFT GROVE FORWARD IMPELLER STOP THRUST WASHER (BEVEL UP) CRIMP WASHER SPACER CRIMP WASHER 20 CUTTER BLADE REPLACEMENT FOR SMALL 1/2 HP THROUGH 1 HP The cutter blade has been designed as a snipping device to reduce fibrous or stringy food waste into small particles, thereby lessening the chance of a clog in the drain line. Following are the replacement instructions. TO INSTALL CUTTER BLADE KIT NO. 00-80-067: 1. Remove the table assembly from the unit. (See Page 11). 2. Remove the old rivet and cutter blade. 3. Assemble spacer, cutter blade, and rivet to the table assembly in the order illustrated at right. SPACER 00-57-823 CUTTER BLADE 00-14-538 00-55-311 PEENED OVER RIVET 00-55-311 00-57-823 00-14-538 VICE JAW 4. Back rivet on hard surface, making sure that all parts are snug and in position and then peen rivet over. Many light blows with a small hammer are more effective than fewer blows with a larger hammer. 5. Reinstall table assembly into the unit. BOOT SEAL REPLACEMENT FOR SMALL 1/2 HP THROUGH 1 HP MODELS Removal of the turntable exposes the water seal. This seal consists of two assemblies. The upper assembly is carried by the turntable hub and is a coined and lapped seal ring held in a sealing gasket. The lower part is a carbon wear ring carried in a rubber booted spring. Beneath this seal assembly are water and oil slingers which function as water or oil shedders in the event of a leak. Seal Kit Part Numbers: 1/2 HP and 11/2 HP Models #00-94014 3/4HP,1 HP, and 11/4 HP Models #00-94-073 INSTALLATION INSTRUCTIONS HUB AREA ON TURNTABLE RING MOUNT GASKET SEAL RING SPACER BOOT WATER AND OIL SLINGERS MOTOR HOUSING 1. Clean the cavity around the turntable hub. Slip the seal ring and ring mount gasket onto the turntable hub with the polished side of the seal ring FACING OUT. 2. Remove the water slinger and inspect the bearing. 3. Clean the seal mounting seat and replace the water slinger. 4 . Apply adhesive to the seal mounting and install the seal. 5. Reinstall the turntable. 21 DISASSEMBLY PROCEDURE FOR TRIPOD LEGS On the free standing, mid-sized and large models, 2HP through 10HP, all three legs can be removed for modification if needed. In order to remove the legs, the tripod must be turned upside down as shown. Each leg should have been torque tightened into the motor housing, so it will be necessary to use vice grips, in conjunction with a mallet, to loosen each leg. The legs on the mid-sized models have handy plastic foot caps which can be easily removed or replaced by simple tapping. THREADS ON LEGS 22 WIRING DIAGRAM FOR ONE PHASE MOTORS ONLY 1/2HP - 1HP SINGLE PHASE 50/60Hz 1/2 - 1HP SINGLE PHASE 1/2 / - 50/60Hz 1HP SINGLE PHASE 50/60Hz / SOLDER SOLDER SOLDER 2 P 1 P 1 2 P P 2 P 2 P 1 1 P 1 P T 3 P 1 T 3 P 1 P 1 3 T T 3 P 1 P 1 3 2 T 2 LL2 T T 4 T 4 T 3 3 T 4 T YELLOW YELLOW 3 T 3 T 4 INSULATE YELLOW YELLOW YELLOW 2 L2 2 T T 2 2 T T 2 INSULATE HIGHVOLTAGE VOLTAGE HIGH LOW VOLTAGE VOLTAGE YELLOW LOW T 2 T 2 T 2 P 2 P 2 T 2 T 2 P P 2 T 2 P 2 2 T 3 T 4 4 T 2 T 2 L L22 INSULATE YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW 4 T 4 T 4 T 4 T 4 T 4 2 T 4 T T 4 T 4 T T 4 L2 CONNECTIONS EXTERNAL ––– EXTERNAL CONNECTIONS ––– HIGH VOLTAGE LOW VOLTAGE T T T 3 4 YEL SPLICE YELLOW T 4 LOW T T 4 YE YE LLLO LOWT W4 T 4 T 4 T 4 2 T L1 INSULATE INSULATE YELLOW INSULATE T T 2 T T 4 2 T 3 T 3 YELLOW L2 6 MAIN MAIN L1 YELLOW YELLOW YELLOW T 4 T 3 ORANGE INSULATE INSULATE YELLOW YELLOW YELLOW T T 3 P 2 T 2 T 2 T 4 T 3 5 T 3 P 1 T 3 T 3 SPLICE SPLICE YELLOW YELLOW YELLOW T 2T T 3T T 2 4 YELLOW T MAIN ORANGE 4 ORANGE P 2 P 2 P 2 2 3 T T 3 P 2 T3 4 2 T T 2 T 2 T 2 T 2 T 2 T 3 3 INSULATE INSULATE INSULATE YELLOW YELLOW YELLOW YELLOW INSULATE T 2 T 3 2 2 T UE 1 YELLOW YELLOW P P 2 T 3 T 3 T 3 T 3 T YELLOW 3 BLUE T 2 T 3 T 3 T 3 RED LL1 1 P 2 P 1 P 2 P 2 T 3 T 3 T 3 T 3 T 3 T 3 3 BL 2 P 1 P 1 1 T 3 T 3 T 3 T 3 T 3 T 3 T 3 T 3 T 3 T 3 T 3 T 3 T 3 OW LL YE 6 5 6 T SPLICE 5 MAIN 4 1 P 2 4 T 3 T 3 T 3 UUEE BBLL 4 MAIN MAIN SOLDER YELLOW YELLOW YELLOW 2 YELLOW UE 3 3 W O OW LLLL YYEE OW LL YE 3 1 BL 2 1 3 YELLOW YELLOW BLUE PHASE BLUE YELLOW YELLOW T RREEDD RED 2 P 2 YELLOW YELLOW YELLOW YELLOW YELLOW L11 1/2 - YELLOW 1HP SINGLE PHASE 50/60Hz L1 L1 P 2 RED BLUE T 3 1 P 3 1 P 2 P 1 P 2 2 P 2 P 1 RED PHASE PHASE RED RED P 1 PHASE WHEN MOTOR IS USED ON GROUNDED CIRCUIT, YELLOW WHEN MOTOR IS USED ON GROUNDED CIRCUIT, EXTERNAL CONNECTIONS L1L1 MUST TOUNGROUNDED UNGROUNDED MUSTBEBECONNECTED CONNECTED TO SIDESIDE OFOFLINE. LINE. LOW VOLTAGE L2 YELLOW 4 YEL 4 T T 4 WHEN MOTOR IS USED ON GROUNDED CIRCUIT, CONNECTIONS SHOWN ARE FOR CCWCCW ROTATION. CONNECTIONS SHOWN ARE FOR ROTATION. L1 MUST BE CONNECTED TO UNGROUNDED SIDE MAIN OF LINE. 4 HIGH VOLTAGE T 4 ORANGE LOW T MAIN EXTERNAL CONNECTIONS T T 4 CONNECTIONS SHOWN ARE FOR CCW ROTATION.WHEN MOTOR IS USED ON GROUNDED CIRCUIT, 1-1/2HP-2HP 60Hz L1 MUST BESINGLE CONNECTED TO PHASE UNGROUNDED SIDE OF LINE. T 4 RED 1-1/2HP - 2HP SINGLE PHASE 60Hz CONNECTIONS SHOWN ARE FOR CCW ROTATION. RUN CAPACITOR 1-1/2HP-2HP SINGLE PHASE 60Hz PHASE #2 2 PHASE #2 START RUN CAPACITOR RUN CAPACITOR CAPACITOR #1 P 1 P 1 P 2 P 2 P 1 P 1 T 3 P 2 3 T 3 2 T P 2 T 2 P 2 T 2 YELLOW YELLOW YELLOW T 3 T 4 L2 T T 4 INSULATE INSULATE YELLOW 3 3 T 3 T 4 T T 4 3 3 T P 2 P 2 T 2 T 3 L2 INSULATE INSULATE YELLOW YELLOW YELLOW 2 T 2 2 T T 2 T 2 TT 22 T 2 T YELLOW YELLOW T 4 T 4 T 4 YELLOW YELLOW L2 YELLOW YELLOW T 4 TT 44 TT 44 T 4 T 4 T 4 2 T 4 T 4 T 2 T 2 2 T T 4 T 4 T 4 T T 4 INSULATE INSULATE HIGH VOLTAGE YELLOW YELLOW LL2 CONNECTIONS EXTERNAL 2 YELLOW L2 4 2 T YELLOW INSULATE LOW VOLTAGE YELLOW YELLOW YELLOW YELLOW 2 T 2 T LL2 2 YELLOW YELLOW T 2 LOW VOLTAGE VOLTAGE LOW HIGH VOLTAGE LOW VOLTAGE T 2 T 4 T 2 T 2 T MAIN MAIN T 4 MAIN T T 3 INSULATE YELLOW 4 5 T 2 T T 2 TT 2 2 YELLOW T 4 6 5 P 1 P 1 P 1 T 3 P 2 P 2 T 4T 3 T 4T 3 T 3 T 3 T4 T 3 INSULATE YELLOW YELLOW YELLOW T 2 T 2 T 2 T 2 T 2 MAIN 6 YELLOW YELLOWINSULATE L1 YELLOW YELLOW YELLOW INSULATE YELLOW YELLOW YELLOW YELLOW T 4 YELLOW 4 LL1 1 INSULATE T MAIN MAIN 3 P 1 P 1 1 T 3 T 2P 2 T 2 TP 22 2 T 2 BLUE BLUEYELLOW 2 T T 3 T 3 YELLOW 2 4 YELLOW L1 YELLOW YELLOW YELLOW T 2 P 2 T 3 T 3 3 T 3 T T T 3 3 T 3 T 3 T 3 T 3 RED/BLACK RED/BLACK YELLOW YELLOW YELLOW YELLOW P P 2 BLUE BLUE BLUE 6 1 P 2 T T 3 3 YELLOW T T 3 P 2 T 3 YELLOW YELLOW 2 P P 2 MAIN T 3 T 3 T 3 T 3 PHASE PHASE#1 #1 START START CAPACITOR CAPACITOR MAIN BLUE 4 2 5 L1 1 YELLOW YELLOW 2 P 2 RED/BLACK 1 2 P 1 P 1 P 2 P 1 PURPLE PURPLE P 2 3 SPLICE SPLICE L BLUE P P 1 1 P 2 1 YELLOW BLUE P 2 PHASE PHASE#2#2 P 3 P 1 BLACK BLACK RED/BLACK PHASE #1 1 YELLOW L1 P 2 P 1 P 2 WHITE WHITE 2 3 SPLICE T 3 START CAPACITOR 1PHASE 2 T 3 PURPLE P 2 P 1 RUN CAPACITOR TE 1-1/2HP-2HP SINGLE PHASE PH SE 60Hz YELLOW PURPLE RED RED P BLACK BLACK 1 SPLICE WHITE 4 RED WIRE DIAGRAM EXTERNAL EXTERNAL CONNECTIONS SINGLE PHASE HIGH VOLTAGE VOLTAGE HIGH EXTERNAL CONNECTIONS ––– EXTERNAL CONNECTIONS ––– T 4 T 4 T 4 T 4 T 4 T 4 T 4 T 4 FOR SUPPLY CONNECTION USE WIRING SUITABLE FOR 90°C MIN INSULATE ALL EXPOSED T3 T2 WIRE DIAGRAM EXTERNAL WIRE ENDS SINGLE PHASE DIAGRAM EXTERNAL LEAD PHASE EXTERNAL WIRE WIRING DIAGRAM – SINGLE P2 P1 SINGLE PHASE T3 T4 NUMBERS P1 P2 T2 T4 FOR SUPPLY CONNECTION USE WIRING SUITABLE FOR 90°C MIN INSULATE FOR SUPPLY CONNECTION USE WIRINGLINE SUITABLE FOR 90°C MIN ALL EXPOSED LINE LINE LINE FOR SUPPLY CONNECTION USE WIRING SUITABLE FOR 90°C T3 P2 T2 MIN. WIRE ENDS CONNECT TO LINE 100-120V CONNECT TO LINE 200-240V INSULATE INSULATE ALL ALL EXPOSED LEAD EXPOSED P1 P2 T2 T4 P2 P1 T3 T3 T2 P2 T2 T3 T4 WIRE ENDS NUMBERS WIRE ENDS P1 P1 T3 T3 T4 T4 LEAD LEAD NUMBERS NUMBERS P2 P1 P1LINE P2 T2 T4 T2LINE T4 LINE LINE CONNECT TO LINE 100-120V CONNECT TO LINE 200-240V LINE LINE LINE LINE LINE LINE LINE LINE CONNECT TOLINE LINE 100-120V CONNECT TOTOLINE 200-240V CONNECT TO 100120V CONNECT LINE 200-240V 23 DUAL VOLTAGE WYE CONNECTED MOTORS - THREE PHASE 1-1/2HP - 2HP – SINGLE PHASE, DUAL VOLTAGE, 50/60Hz SINGLE PHASE 50/60Hz 1-1/2HP-2HP SINGLE PHASE 1-1/2HP-2HP 50/60Hz RED RED WHITE WHITE RUN CAPACITOR CAPACITOR RUN PHASE #2 #2 PHASE 1-1/2HP-2HP SINGLE PHASE 50/60Hz RED PURPLE PURPLE T 3 T L1 1 10 YELLOW #11 4 14 6 2 YELLOW YELLOW#10 #10 11 5 3 YELLOW #14 YELLOW #10 15 12 1 10 5 6 3 10 11 YELLOW #2 #12 YELLOW 12 4 15 2 8 6 11 YELLOW #8 YELLOW #5 YELLOW #12 5 3 15 12 YELLOW #12 YELLOW #15 YELLOW #12 L2 5 15 3 9 5 15 16 4 5 6 7 8 9 1 2 3 LEAD INSULATE ALL CONNECT 7 14 8 15TO 9LINE 16 200-240V INSULATE ALL NUMBERS EXPOSED EXPOSED WIRE WIRE ENDS ENDS 1 2 3 LEAD LEAD NUMBERS NUMBERS CONNECTTO TOLINE LINE200-240V 200-240V CONNECT 24 4 5 7 8 9 1 2 3 6 6 16 CONNECT TO LINE 200-240V CONNECTTO TOLINE LINE380-460V 380-460V CONNECT P 1 T 4 P 1 P 1 T 4 2 T 3 T T 4 T 4 T 3 YELLOW YELLOW #3#3 #6 YELLOW LL33 YELLOW YELLOW #9#9 #16 YELLOW LYELLOW YELLOW #6#6 3 YELLOW#16 #16 YELLOW INSULATE 9 7 8 TO9LINE 380-460V CONNECT 2 3 CONNECT TO LINE 380-460V P 2 P 2 14 LL11 INSULATE 7 4 2 2 INSULATE INSULATEL 2 5 8 15 LL22 INSULATE 5 8 INSULATE 15 4 15 2 6 3 1 1 YELLOW YELLOW#8 #8 YELLOW #3 15 YELLOW YELLOW#15 #15 YELLOW #9 L3 9 EXTERNALEXPOSED WIRING DIAGRAM,16 15 T 3 L2 5 3 8 16 P 2 T 3 YELLOW YELLOW #5#5 #15 YELLOW 2 L1 7 4 YELLOW YELLOW #2#2 #8 YELLOW LL22 16 14 T 2 3 14 8 YELLOW #1 HIGH HIGHVOLTAGE VOLTAGE1 YELLOW YELLOW#4 #4 YELLOW #2 14 YELLOW #14 L2 YELLOW #14 INSULATEYELLOW #5 THREE PHASE YELLOW #16 WIRE ENDSYELLOW #16 FOR SUPPLY USE WIRING SUITABLE 4 FOR 905°C MIN. 4 CONNECTION 5 6 6 EXTERNAL EXTERNAL WIRING WIRING DIAGRAM – THREELEAD PHASE 14 ALL 14 15 DIAGRAM, 7 15 8 16 9 INSULATE 7 EXPOSED NUMBERS HIGH VOLTAGE YELLOW LYELLOW YELLOW #7#7 #14 1 YELLOW #9 FOR SUPPLY CONNECTION USE WIRING SUITABLE FOR 90 6 °C MIN. YELLOW #6 YELLOW 14 156 16 INSULATE ALL 14#6 15 16 4 1 FOR 5 FOR 2 906°90°C FOR SUITABLE C3MIN. FOR SUPPLY SUPPLYCONNECTION CONNECTIONUSE USEWIRING WIRING SUITABLE MIN. P 2 T 2 3 T P 2 2 2 8 7 4 EXTERNAL CONNECTIONS YELLOW YELLOW YELLOW #1#1 #4 LL11 1 HIGH VOLTAGE LOW VOLTAGE YELLOW #7 3 EXTERNAL WIRING DIAGRAM, 6 L3 YELLOW #916 THREE YELLOW PHASE #16 YELLOW #16 9 WIRE ENDS T 2 4 T 2 2 YELLOW#2 #158 YELLOW YELLOW #8#8 YELLOW YELLOW #5#5 YELLOW YELLOW #5 5 YELLOW #3 15 YELLOW YELLOW#15 #15 #8 YELLOW YELLOW #9 YELLOW #6 YELLOW YELLOW #3#3#15 YELLOW 4 14 YELLOW #9#9 YELLOW YELLOW YELLOW #6#6#3 YELLOW THREE PHASE P 3 YELLOW #147 YELLOW #7#7 YELLOW YELLOW #7 YELLOW #4#4 YELLOW 4 YELLOW #2 14 YELLOW #4 YELLOW #14#14 YELLOW YELLOW #8 YELLOW #14 YELLOW #5 YELLOW #2#2 YELLOW 3 YELLOW #169 YELLOW #3 P 4 T T 4 T 3 T 3 P2 P 2 T 3 T YELLOW #1 1 2 2 1 YELLOW YELLOW#11 #11 14 4 2 16 YELLOW #11 14 16 L1 7 YELLOW #7 YELLOW #4 YELLOW #1#1 YELLOW 1 7 YELLOW #714 4#4 YELLOW 16 T 3 T 3 YELLOW #1 YELLOW #10 T 2 T 4 T 4 T 2 T P 2 P2 3 T 3T T T LOW LOW VOLTAGE VOLTAGE 1 HIGH VOLTAGE LOW VOLTAGE P 1 P 1 P 1 T 2 P 1 1 P T2 TT 44 T2 T 2 P2 T 4 T 4 P2 3 T CAUTION: CAUTION: USE EXTREME EXTREME CARE USE CAREININCONNECTING CONNECTING PROTECTOR, AS PROTECTOR, ASWRONG WRONGCONNECTIONS CONNECTIONS WILL RESULT RESULT IN DAMAGE, WILL INPROTECTOR PROTECTOR DAMAGE, AND NO NO PROTECTION AND PROTECTIONOF OFMOTOR. MOTOR. P 1 P 1 1 P P 1 P 1 P 1 TT 44 3 P 2 T 3 T 3 3 T T 3 T 3 T EXTERNAL CONNECTIONS 3/4HP-2HP, THREE PHASE,50/60Hz 3HP-10HP, THREE PHASE, 50/60Hz 3/4HP -CAUTION: 2HP – THREE PHASE, DUAL VOLTAGE, LOW VOLTAGE50/60Hz USE EXTREME CARE IN CONNECTING 3HP - 10HP –ASTHREE PHASE, DUAL VOLTAGE, 50/60Hz PROTECTOR, WRONG CONNECTIONS 3/4HP-2HP, THREE PHASE,50/60Hz 3/4HP-2HP, THREE PHASE,50/60Hz WILL RESULT IN PROTECTOR DAMAGE, 3HP-10HP, THREEYELLOW PHASE, 50/60Hz AND NO 3HP-10HP, PROTECTION OF MOTOR.THREE PHASE, 50/60Hz #1 E CARE IN CONNECTING AS WRONG CONNECTIONS IN PROTECTOR DAMAGE, TECTION OF MOTOR. YELLOW T 3 T P2 T 2 T 3 3 T 2 3 T T 2 HIGH VOLTAGE LOW VOLTAGE 3 2 T 3 T YELLOW 3 T 2 INSULATE T 2 YELLOW LL22 YELLOW YELLOW LINSULATE 2 INSULATE YELLOW YELLOW YELLOW YELLOW YELLOW INSULATE INSULATE INSULATE YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW INSULATE INSULATE INSULATE YELLOW YELLOW YELLOW HIGH VOLTAGE LOW VOLTAGE LOW VOLTAGE HIGH VOLTAGE YELLOW YELLOW INSULATE CONNECTIONS INSULATE EXTERNAL ––– EXTERNAL CONNECTIONS ––– YELLOW INSULATE YELLOW YELLOW 2 T 4 T 4 T 4 P P 2 T 3 2 P2 T 3 T 2 MAIN MAIN L LL2 2 YELLOW YELLOW P2 LL11 YELLOW YELLOW L 1 YELLOW YELLOW L YELLOW YELLOW 1 YELLOW YELLOW YELLOW 2 YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW L2 P2 P2 YELLOW T2 T2 T2 T 2 4 T P 2 T 4 T 4 T 4 T 4 T 4 P2 P2 YELLOW YELLOW L1 L 1 L1 1 P3 2 P 2 T 4 T 4 4 T 2T T 4 T 4 T 4 T 4 T 4 L2 T T 4 P2 YELLOW YELLOW YELLOW YELLOW BLUE YELLOW T T 2 MAIN MAIN T 3 BLUE YELLOW P2 MAIN YELLOW P 2 3 T 4 T 2 T 4 P2 YELLOW T2 MAIN MAIN RED/BLACK MAIN P 2 2 2 SPLICE BLUE BLUE PHASE #1 BLUE BLUE T 4 BLUE T2 BLUE RED/BLACK 3 P2TT2 P 2 START RED/BLACK RED/BLACK CAPACITOR 1 P 2 YELLOW P L1 P 1 PURPLE YELLOW P BLACK 3 1 P 2 P PHASE #1 START CAPACITOR 2 SPLICE SPLICE PHASE #1 #1 PHASE PHASE #2 1 P 1 2 1 RUN CAPACITOR START START CAPACITOR SPLICE CAPACITOR T2 2 WHITE PURPLE BLACK T2 BLACK BLACK T T 2 2 PHASE #2 T 2 RUN CAPACITOR T 2 RED WHITE 3 3 INSULATE INSULATEL 16 LL33 INSULATE 9 6 16 3 9 6 INSULATE INSULATE DIAGNOSIS GUIDE DISPOSER TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE Disposer fails to start and motor is silent Disposer fails for start and motor hums Disposer running noisy Disposer grinds Entire unit slowly vibrates Unit leaks Unit operates slowly, labors, may smoke Jammed turntable, free it manually. Open winding in field. Rewind Field. See wiring connections on Page 23 or 24. Blown fuse on one leg of 3 phase motor. Check circuit. Change wiring and replace fuse. See Page 24. Cutout due to overloading. Reset overload protector. Defective control switch. Replace control switch. Blown circuit fuse or tripped circuit breaker. Replace fuse or reset circuit breaker. Foreign ungrindable material in grinding chamber. Remove obstruction. Worn bearing in motor, see Page 14. Replace seal and bearing if necessary. Worn grind ring and/or turntable caused by backwards rotation of turntable. Replace worn parts and check rotation arrow on turntable, Page 12. Reverse if needed. Impeller is stuck, free it manually. Broken seal. Replace seal and inspect bearing. See Page 13. Internal gasket leak. Replace internal gasket. Blown fuse on one leg of 3 phase motor. Check circuit, see Page 24. Change circuit if needed and replace fuse. 25 26