Insinger TRAC 878 User manual

TECHNICAL MANUAL
Installation, Operation and Maintenance Instructions
TRAYWASHER TRAC 878
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
800-344-4802
Fax [phone]
www.insingermachine.com

Thank you for purchasing a quality Insinger product.
In the space provided below please record the model,
serial number and start-up date of this unit:
Model:__________________________________
Serial Number:___________________________
Start-Up Date:____________________________
When referring to this equipment please have this
information available.
Each piece of equipment at Insinger is carefully tested
before shipment for proper operation. If the need
for service should arise please contact your local
Authorized Insinger Service Company.
To nd your local authorized Service Company please
visit our web site, www.insingermachine.com or call
Insinger at 800-344-4802.
For proper activation of the Insinger Limited Warranty,
a SureFireTM Start-up should be completed on your
machine. Refer to the Introduction section in this
manual for an explanation of Insinger’s SureFireTM
Start-up and Check-out Program.
Please read the Insinger Limited Warranty and all
installation and operation instructions carefully before
attempting to install or operate your new Insinger
product.
To register your machine for warranty, or for answers to
question concerning installation, operation, or service
contact our Technical Service Department.
TECHNICAL SERVICE CONTACTS
Toll-Free 800-344-4802
Fax [phone]
e-mail [email protected]
Web site www.insingermachine.com
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
TABLE OF CONTENTS
Part 1
Technical Information
• Specication Sheets
• Introduction
• Denitions
• Safety Summary
• Warranty
1-4
Part 2
Installation Instructions
• General Installation Instructions
• Installation Drawings
5-7
Part 3
Operation Instructions
8
Part 4
Cleaning Instructions
• Daily Cleaning Instructions
• Weekly Cleaning Instructions
Part 5
Maintenance and Repair Procedures
• Maintenance Requirements
• Maintenance Procedures
• Troubleshooting
Part 6
Parts and Assemblies
• Assembly Drawings with Parts Lists
9
10-19
20-48
Part 7
Electrical Schematics and Parts
• Electrical Schematics
• Control Panel Layouts
49-56
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PART 1 TECHNICAL INFORMATION
TRAC 878
Automatic Triple Tank Tray Washer
Automatic conveyor, triple tank tray washer with recirculating
pre-wash, wash and rinse and fresh water final rinse.
197 gallons/hour final rinse consumption
Capacity is up to 878 trays per hour (based on a 15” tray)
OPTIONS
Stainless steel steam coil tank heat
Steam booster
Electric booster
Pressure reduction valve and line strainer
Chemical sanitizer injector package for low temperature operations (pump by
others)
Security package
Insulated hood
Tray Dryer
Tray Stacker
6245 State Road • Philadelphia, PA 19135 • PH: 800-344-4802 • FX: 215-624-6966 • www.insingermachine.com
CSI - 11400 _____________
Approval _______________
Date ___________________
Project ________________
Item __________________
Quantity _______________
Insinger’s tray washers were developed specifically
to optimally clean and sanitize ware by reaching all
corners and crevices with a vertical spray.
STANDARD FEATURES
Tank heat: 16 kW electric immersion heater or steam injector
Capillary thermometers for wash and rinse
In-line thermometer for final rinse
Vacuum breaker on all incoming water lines
Manifold clean-out brush
Vents with adjustable damper controls
SureFire®Start-Up & Check-Out Service
Single point electrical connection: motors, controls and tank heat (Booster
requires a separate connection)
Inspection doors
S/S frame, legs and feet
S/S front enclosure panel
Automatic tank fill
Low water protection
Detergent connection provision
Top mounted NEMA 12 control panel
Simplified scrap screen design
Door safety switch
Standard frame TEFC motors
Override switch for de-liming
End caps/pipe plugs secured to prevent loss
Tray unload table
TRAC 878
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802

PART 1 TECHNICAL INFORMATION
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
TRAC 878
Automatic Triple Tank Tray Washer
SPECIFICATIONS
CONSTRUCTION- Hood and tank constructed of 16 gauge type
304 S/S. Hood unit of all welded seamless construction. S/S
frame, legs and feet. All internal castings are non-corrosive lead
free nickel alloy, bronze or S/S.
DOORS- Extra large die formed 18-8 type 304 S/S front
inspection door riding in all S/S channels. A triple ply leading
edge on the door channels made of S/S with no plastic or nylon
sleeves or liners used. Two intermediate S/S door-safety stops
on the door.
CONVEYORS- One S/S roller conveyor chain with tray cradles.
Width between guide rails is factory-adjustable from 1.5” to
3.7”. Conveyor accommodates trays up to 14” high. Conveyor
drive system includes direct drive gear motor with frictionless,
trouble-free overload system. Trays conveyed automatically
through washing and rinsing systems. Powered by independent
conveyor motor.
PUMP- Centrifugal type “packless” pump with a brass petcock
drains. Ceramic seal and a balanced cast impeller on a precision
ground stainless steel shaft, extension or sleeve. All rotating
parts mounted and removed as an assembly without disturbing
pump housing. 1/2 hp pre-wash motor, 3 hp wash motor and 2
hp rinse motor, all standard TEFC C-face frame, with ball-bearing
construction.
CONTROLS- Top mounted control cabinet, NEMA 12 rated with
heat insulation provided between hood and control cabinet,
housing motor controls and overload protection, transformer,
contactors and all dishwasher integral controls. All controls safe
low voltage 24 VAC.
SPRAY SYSTEM- All spray systems are made of 304 stainless
steel pipe. Pre-wash, wash and rinse assemblies removable
without the use of tools.
PRE-WASH- Two vertical spray arms (one on each side of
conveyor), each with 5 V-jet nozzles.
WASH AND RINSE- Four spray arms threaded into S/S manifold.
(2 on each side of conveyor). Each arm designed with 8 high
pressure action cleansing slots. The slots are precision milled
for water control producing a fan spray.
FINAL RINSE- Two vertical spray arms (one on each side of
conveyor), each with 6 V-jet nozzles. Arms enclosed in shrouded
final rinse chamber to maximize heat transfer to trays.
DRAIN- Drain valve externally controlled. Overflow assembly
with skimmer cap is removable without the use of tools for drain
line inspection. Heater is protected by low water level control.
UNLOAD TABLE- a stainless steel tray unload table receives
clean trays. Table constructed with guide rails which ease the
trays onto table.
Capacity Per Hour 878 trays
Tank Capacity 11.2 gallons (pre-wash)
15.3 gallons (wash)
11.5 gallons (rinse)
Motor Size 1/2 hp (pre-wash)
3 hp (wash)
2 hp (rinse)
1/8 hp (conveyor)
Electric Usage 8 kW wash tank
8 kW rinse tank
24 kW booster 40° rise
36 kW booster 70° rise
Steam Consumption
at 20 psi min.
54 lbs./hour tank
70 lbs./hour booster 40° rise
122 lbs./hour booster 70° rise
Final Rinse Peak Flow
at 20 psi min.
3.28 gallons/minute
Final Rinse Consumption
at 20 psi min.
197 gallons/hour
Exhaust Hood Requirement 100 CFM Load
300 CFM unload
Peak Rate Drain Flow 23 gallons/minute
Shipping Weight 1100 lbs.
Note: Due to product improvement we reserve the right to change information and specications without notice.
3_2012
6245 State Road • Philadelphia, PA 19135 • PH: 800-344-4802 • FX: 215-624-6966 • www.insingermachine.com
Machine Electrical*
Motors, Controls, Tank Heat Steam Electric
without booster
208/3/60
240/3/60
480/3/60
380/3/50
22.7
20.6
12.5
10.2
67.1
59.0
36.9
29.4
*Booster heater wired separately. Machine load only listed above.

TRAC 878 TRAYWASHER
INTRODUCTION
This manual contains all pertinent information to
assist in the proper installation, operation, cleaning,
maintenance, and parts ordering for the TRAC 878
traywasher.
The installation instructions are intended for qualied
equipment installers.
The operation and cleaning instructions are intended
for the daily users of the equipment.
The maintenance and drawing sections are intended
for qualied service and/or maintenance technicians.
Replacement parts may be ordered directly from our
factory or from your local Authorized Insinger Service
Company.
SurereTM Start-Up Program
Insinger is proud to o󰀨er our exclusive SurereTM
Start-up & Check-out Program to our commercial
customers. This service is included in the purchase
price of your new Insinger dishwasher. We will provide
an authorized factory service technician for the initial
start-up of your new Insinger dishwasher to ensure it is
running correctly. Please call the factory or your local
Insinger Sales or Service Representative to schedule
this service.
NSF 3 requirements for detergent and
chemical sanitizer dispensers
This machine must be operated with an automatic
detergent feeder and, if applicable, an automatic
chemical sanitizer feeder, including a visual means
to verify that detergents and sanitizers are delivered
or a visual or audible alarm to signal if detergents
and sanitizers are not available for delivery to the
respective washing system. Please see instructions
for electrical and plumbing connections located in this
manual and in the feeder equipment manual.
Intended Use
The Insinger traywashers may only be used for
cleaning institutional trays.
Any change in design or use of the dishwasher carried
out without the written permission of Insinger, will lead
to warranty nullication.
If damage is caused to the dishwasher due to failure
to observe the instructions given in this manual, no
claims under the warranty agreement can be submitted
to lnsinger Machine Company.
PART 1 TECHNICAL INFORMATION
CAUTION:
Indicates potential equipment damage.
WARNING:
Indicates potential physical danger.
▲
!
NOTE:
Indicates helpful operating hints or tips.

DEFINITIONS
Throughout this guide you will nd the following terms:
WARNING, CAUTION, & NOTE.
WARNING indicates potential physical danger.
CAUTION indicates potential equipment damage.
NOTE indicates helpful operating hints or tips.
You will visually be able to identify each as shown
below:
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
SAFETY SUMMARY
The following are general safety precautions that
are not related to any specic procedures. These
are recommended precautions that personnel must
understand and apply during many phases of operation
and maintenance.
Keep Away From Live Circuits
Operating personnel must at all times observe all
safety regulations. Do not replace components or
make adjustments inside the equipment with the power
supply turned on. Under certain conditions, dangerous
potentials may exist when the power control is in the
o󰀨 position. To avoid casualties and injuries, always
remove power, red tag and lockout machine, and
ground a circuit before touching it.
Do Not Service or Adjust Alone
Under no circumstances should any person reach into
or enter the enclosure for the purpose of servicing or
adjusting the equipment except in the presence of
someone who is capable of rendering aid.
Resuscitation
Personnel working with or near high voltages should
be familiar with modern methods of resuscitation.
Such information may be obtained from the Bureau of
Medicine and Surgery.

INSINGER MACHINE COMPANY LIMITED WARRANTY
PART 1 TECHNICAL INFORMATION
to perform normal and routine maintenance
as set out in the instruction booklet (operating
instructions) or for improper operation or failure to
follow normal operating instructions (as set out in
the instruction booklet). Insinger is not responsible
nor liable for any conditions of erosion or corrosion
caused by corrosive detergents, acids, lye or other
chemicals used in the washing and or cleaning
process.
Service must be done by either Insinger Appointed
Service Agencies or agencies receiving prior
authorization from Insinger.
All warranty work must be done during normal
working hours, unless purchaser receives prior
authorization from Insinger.
There are no other express warrants except
as set forth herein and any applicable implied
warranties of merchantability and tness are
limited in duration to the period of coverage of
this express written limited warranty. This limited
warranty supersedes all other express warranties,
implied warranties of merchant-ability and tness
or limited warranties as of this date, January 1,
1998. Some states do not allow limitation on how
long an implied warranty lasts so this limitation
may not apply to you.
Insinger is not liable for any special, indirect or
consequential damages. Some states do not
allow the exclusion or limitation of incidental or
consequential damages, so this limitation nor
exclusion may not apply to you.
Insinger does not authorize any person or company
to assume for it any other obligation or liability in
connection with the sale, installation, use, removal,
return or replacement of its equipment: and no
such representations are binding on Insinger.
Insinger Machine Company, Inc. (Insinger) hereby
warrants to the original retail purchaser of this
Insinger Machine Company, Inc. product, that if
it is assembled and operated in accordance with
the printed instructions accompanying it, then
for a period of either 15 months from the date
of shipment from Insinger or 1 year (12 months)
from the date of installation or start-up that said
Insinger product shall be free from defects in
material and workmanship. Whichever one of the
two aforestated limited warranty time periods is the
shortest shall be the applicable limited warranty
coverage time period.
Insinger may require reasonable proof of your
date of purchase; therefore, you should retain
your copy of invoice or shipping document.
This limited warranty shall be limited to the repair or
replacement of parts which prove defective under
normal use and service and which on examination
shall indicate, to Insinger’s satisfaction, they
are defective. Any part that is claimed to be
defective and covered by this limited warranty
must be returned to Insinger. An RMA# must be
obtained from the Insinger Warranty Department
before returning any material. Return may be
done through an Authorized Service Agency.
Furnish serial number of machine and RMA # with
shipment and send to:
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
If Insinger’s inspection conrms the defect and
the claim, Insinger will repair or replace such
part without charge and return it to you freight or
postage prepaid.
This limited warranty does not cover any failure or
accident,abuse,misuse,alteration,misapplication,
improper installation, re, ood, acts of God
or improper maintenance or service, or failure
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802

PART 2 INSTALLATION INSTRUCTIONS
TRAC 878 TRAYWASHER
INSTALLATION INSTRUCTIONS
These installation instructions are intended for qualied
equipment installers.
PLACEMENT
Carefully uncrate the machine. Take caution not to
damage components which may be mounted on the
top or sides of the machine.
Set the unit in place and adjust the feet to level the
machine.
TABLING
Load and unload tables should be pitched towards the
machine to return excess water into the machine.
Fasten the tables to the load and unload side of the
machine. Most installations require fastening the turn-
down lip of the dish tables to the side of the machine
with athead countersunk screws.
The table design should provide horizontal clearance
of 30” for servicing. Install rack guides on exit table
using mounting studs provided.
ELECTRICAL CONNECTIONS
Connect electrical lines sized for the correct voltage,
current and phase of the machine. These should
agree with the machine requirements indicated on the
nameplate and labels on the control panel.
Machines not provided with a single-point connection
require two separate electrical connections for:
1. pumps and control circuit
2. wash tank heater(s)
If an electrical booster is provided, connect the booster
directly to power source.
CAUTION:
Connections must be made to a circuit breaker or
fused disconnect as provided by the end-user and
required by local codes. A laminated wiring diagram
is inside the control panel.
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MECHANICAL CONNECTIONS
All lines must be ushed prior to use to remove debris.
Connect a 110°F (for 70°F rise) or a 140°F (for 40°F
rise) water line for tank lls and booster as tagged and
noted on the installation drawings.
If machine is provided with steam heat connect the
steam lines and steam condensate lines as tagged
and noted on installation drawings.
Connect the drain lines. Drain lines must be as speci-
ed on installation drawings.
If a booster is provided, a 110°F (for 70°F rise) or a
140°F (for 40°F rise) water connection is necessary. A
steam booster also requires a condensate line.
CAUTION:
As with any 3 phase system, an electrician must
check all motors for proper phasing, i.e., Pump
motors must be running in direction indicated by
arrow on housing.
CAUTION:
Drain lines must be as specied on installation
drawings. Drain line should be properly vented and
should have fall of not less than 1/4” to the foot of
proper ow.
CAUTION:
Some area plumbing codes require drains to ow
into an open gap with an opening twice the diameter
of the pipe. Check with your local plumbing codes for
the type of drain connection required.
CAUTION:
Do not reduce the size of lines as specied in
installation drawings. All lines are sized to facilitate
necessary ows, pressures, etc.

PART 2 INSTALLATION INSTRUCTIONS
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
HVAC
Ventilation system should be sized to provide adequate
ventilation per machine specs. Refer to spec sheet.
Stainless steel, watertight ducting should be connected
to the vent cowls on each end of the machine. Refer to
spec sheet and installation drawing.
CHEMICALS
Upon completed installation of the traywasher,
contact a local detergent/chemical supplier for the
correct chemicals for your machine.
Electrical connection points for the detergent
dispenser and rinse injector are located inside the
control panel. Refer to the machine wiring diagram
for the proper connection points.
Dispensers may be connected on either the primary
voltage side of the machine or the 24VAC control
voltage side.
The detergent density probe should be placed in the
hole provided.
CAUTION:
When connecting on the 24VAC control voltage
side of the transformer, total KVA must not exceed
50VA.

PART 2 INSTALLATION INSTRUCTIONS
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
Installation Drawing : TRAC 878 (Left to Right Feed)
INSTALLATION CONNECTIONS
LTR DESCRIPTION SIZE
A Hot Water to Auto Fill - 110OF1/2” FIPS
B Hot Water to Steam Booster - 110OF/140OF1/2” FIPS
C Hot Water to Electric Booster - 110OF/140OF1/2” FIPS
D Hot Water to Final Rinse - 180OF1/2” FIPS
E Drain Connection - Common 1 1/2” FIPS
F Electric Service - 16kW + 5.6 HP 67.1 FLA
G Electric Service - Booster 36 kW 101 FLA
H Cold Water - PW Tempering 1/2” FIPS
JSteam to Tanks 3/4” FIPS
K Steam to Steam Booster (40Oor 70O)1/2” or 1” FIPS
L Condensate Return - Coils Only 1/2” FIPS
M Condensate Return - Steam Booster 1/2” FIPS
NOTES:
1. Electrical Voltage: 208V/3PH/60Hz.
Total Amp Draw is 168.1 FLA.
2. Totally enclosed motors furnished.
3. Stainless Steel Frame, Legs, Tray
Unload Furnished.
4. Vents 4 x 12 (500CFM) & 4 x 5
(50CFM) with Adjustable Dampers
Furnished at Ends of Washer.
REV A - 09/03/01

WASHING A TRAY
1. Place the tray on the conveyor belt. The tray will
pass through the machine cycles.
PART 3 OPERATION INSTRUCTIONS
8
TRAC 878 TRAYWASHER
OPERATION INSTRUCTIONS
These instructions are intended for the daily users of
this machine.
PREPARING MACHINE
1. Place drain overow tube in drain basket. Close all
tank drain valves. One drain is provided for each
tank of the traywasher.
2. Check for proper installation and cleanliness of all
internal, removable components such as suction
strainers, scrap screens, and spray manifolds.
3. Ensure all water and steam lines are open.
4. Ensure electrical circuits are on.
5. Close machine doors.
SHUTDOWN
1. Press the RED stop button to turn the pumps and
conveyor OFF.
2. Move the Power toggle switch to the “OFF”
position.
3. Drain the machine.
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
NOTE:
An interlock is provided to shut the
machine down if the doors are open,
therefore the machine will not run if
doors are opened. Machines provided
with the optional Security Package do
not have this feature.

STARTING MACHINE
1. Move the power switch to the “ON” position.
The power light will illuminate. The tank(s) will
automatically ll. When the tanks are full the tank
heat will operate automatically.
CAUTION:
Ensure the Power toggle switch is in the “OFF”
position before draining the machine.
NOTE:
To ensure proper operation of the auto
tank ll feature and the tank heaters,
the level oat located in each tank
MUST be cleaned daily.

2. Press the GREEN button to start the pumps and
conveyor.
3. The system is now ready for operation. All ware
should be properly scrapped.
NOTE:
The photo-eye located at the entrance
chute of the machine should be
cleaned daily of lime build-up for proper
operation of the energy saver feature
and the nal rinse.

4. Refer to the CLEANING INSTRUCTIONS for
proper clean-up of the dishmachine.
5. Report any unusual occurrences to qualied
service personnel.

9
PART 4 CLEANING INSTRUCTIONS
®
TRAC 878 TRAYWASHER
CLEANING INSTRUCTIONS
DAILY CLEANING
The following cleaning procedures should be done
daily, at the end of the shift:
1. Remove all internal removable parts including
spray manifolds, scrap screens, drain overow
tubes, suction strainers and curtains.
2. Remove the end caps from the spray manifolds
and clean with the brush provided. Flush the
manifolds.
3. Flush scrap screens of matter.
4. Clean drain overow tube.
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
CAUTION:
V-cup seal on the drain overow tube may become
gummed which will not allow the overow tube to
seat properly. This will cause the drain to leak water.
Remove any build-up on the V-cup seal. When the
seal becomes worn, replace.
5. Clean suction strainers of build-up.
6. Clean tank level oats (1 per tank) with a plastic
abrasive pad. DO NOT use steel wool.
CAUTION:
Improper cleaning of suction strainers will cause
the pumps to cavitate. This will cause poor washing
results.
7. Clean curtains. When curtains are beyond cleaning
or torn they should be replaced.
8. Final rinse nozzles should be cleaned of matter.
9. Clean the photo-eye lenses with a damp, soft cloth.
10. Doors should be left open to allow drying of interior
surfaces.
WEEKLY CLEANING
1. The entire machine should be wiped down using
an industrial grade stainless steel cleaner.
2. Under the supervision of your detergent supplier
the machine interior must be properly de-limed.
CAUTION:
Level oats must be cleaned daily. Build-up of
grease and scum will cause faulty operation of tank
ll and heating system.
NOTE:
The water quality in some areas
requires de-liming to be done more
frequently. Contact your detergent
supplier for recommended de-liming
frequency.

DE5-60: Liquid Level Float

10
TRAC 878 TRAYWASHER
MAINTENANCE REQUIREMENTS
This section is intended for qualied service and/or
maintenance technicians.
The following maintenance should be conducted
quarterly:
1. Remove and clean the strainer screens on water
and steam lines. If the screens cannot be cleaned,
replace.
2. Inspect the condition of the ll solenoid valve seats
and diaphragms. Replace as necessary.
3. Inspect drain 0-Rings for leakage. Replace where
necessary.
4. Adjust conveyor chain tension using adjustment
bolts located at machine entrance chute.
MAINTENANCE PROCEDURES
Solenoid Valve Disassembly (SK-5825)
1. Disconnect the power supply to the machine.
2. Turn o󰀨 the water supply.
3. Remove cap on top of the coil. Remove the coil.
4. Remove the 4 hex bolts and lift bonnet from valve
body. Note positioning of spring and plunger.
5. Remove main piston.
6. Inspect for dirt, wear or lime build-up. Clean or
replace as required.
7. Reassemble in reverse of disassembly.
Line Strainer Disassembly
1. Shut o󰀨 water supply.
2. Remove large hex nut on bottom of strainer body.
3. Remove strainer screen. Inspect and clean or
replace as necessary.
4. Reassemble in reverse of disassembly. Water ow
must be same direction as arrow on line strainer
body. Use new gaskets to insure a tight seal.
Pump Disassembly
1. Before disassembling pump ensure there are no
obstructions in the pump intake by removing and
cleaning the suction strainer (inside tank).
PART 5 MAINTENANCE & REPAIR PROCEDURES
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
2. Remove the pump motor and impeller adaptor by
removing the 4 hex bolts attaching them to the
pump housing.
3. Repair or replace the pump parts as required.
4. Reassemble in reverse of disassembly.
Final Rinse
The nal rinse is actuated by a photo-eye located on
the entrance chute (not used on machines with the
security package option). As a tray passes the photo-
eye the beam is broken. The Final Rinse timer (P/N
DE7-27) will energize the nal rinse solenoid. The
nal rinse water will then ow.
The Energy Saver timer (P/N DE7-28) is also reset
keeping the machine running.
Both timers are adjustable by turning the
potentiometer located on the timer board. The nal
rinse timer is adjustable between 0-60 seconds.
The energy saver timer is adjustable between 0-300
seconds.
NOTE:
It is not necessary to remove the
pump housing from the machine to
disassemble the pump.

Line Strainer Assembly

11
PART 5 MAINTENANCE & REPAIR PROCEDURES
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TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
Tank Heat Temperature Adjustment
A temperature control board is provided in the control
panel for easy adjustment of tank temperature.
Though tank temperature is set during factory testing
it is sometimes necessary to re-adjust the temperature
at start-up.
1. Locate the temperature control board (P/N DE9-
251). Use the Control Panel Layout drawing
located in PART 7, Electrical Schematics and
Parts.
2. Adjust the tank temperature to the correct
temperature by turning the potentiometer located
on the temperature control board. An arrow on the
potentiometer indicates increase.
NOTE:
Correct temperatures are:
Prewash - below 140oF
Wash - minimum 150oF
Final Rinse - 180oF to 195oF

Troubleshooting Tank Temperatures
If the temperature does not change follow the below
procedures.
Electric Heat:
1. Check the temperature control board (P/N DE9-
251) for proper operation. If the temperature
control board is faulty, replace.
2. Verify tank heat contactor is working correctly. If
not, replace.
3. Verify all immersion heaters are working properly
and are not limed. If not, replace.
Steam Heat:
1. Check the temperature control board (P/N DE9-
251) for proper operation. If the temperature
control board is faulty, replace.
2. Verify steam pressure per machine specications.
3. Verify steam trap is not clogged. If so, clean and/or
replace.
Immersion Heater Replacement (SK-4703)
1. The immersion heater MUST be completely
submerged at all times. If this is not the case
contact a qualied service technician. The heated
surface should never be in contact with sludge.
2. Remove the housing covering the wiring
terminations. Disconnect the immersion heater
wires.
3. Remove the immersion heater by loosening and
removing the large hex nut.
4. Install in reverse of removal.
DE9-251: Tank Temperature Control Board
NOTE:
Use plumbers putty as gasketing
around the immersion heater
installation nut.


12
PART 5 MAINTENANCE & REPAIR PROCEDURES
®
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
Level System
The level control system consists of one level timer
(P/N DE7-35) and one level oat (P/N DE5-60) in the
wash tank and one level oat (P/N DE5-60) in the
prewash tank.
When the system is powered-up, the tank(s) will
begin to ll (assuming no water is in the tanks).
Once the level oat is actuated, the timer begins to
time-out and continues the lling process until the
tank(s) is full.
CAUTION:
Dirty level oats will cause the tank heat to energize
with no water in the tanks. Level oats MUST be
cleaned daily.
Motor Overloads
All motors used on Insinger Machines are provided
with motor overloads. Motor overloads are adjusted
when the machines are factory tested. Should it be
necessary to adjust the motor overloads in the eld
rst verify the motor current draw for the voltage the
machine is using.
Refer to the Control Panel Layout drawing located in
PART 7 to identify the overload, adjust by turning the
dial to the appropriate AMP draw.
Motor Overload Relay
DE7-35: Liquid Level Timer

13
®
PART 5 MAINTENANCE & REPAIR PROCEDURES
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
SK-5825 : Final Rinse Solenoid Valve

TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-480214
®PART 5 MAINTENANCE & REPAIR PROCEDURES
SK-2462 : 1 HP Pump
ITEM PART NO. DESCRIPTION QTY
1 Motor 1 HP 1
2 D431 Adapter 1
3 D436 Impeller 3 7/8” 1
4 D434 Casing 1
5 D2-532 O-Ring 1
6 D2-533 Flinger 1
7 D2-534 Seal Assembly 1
8 D329-5 Drain Petcock 1/4” IPS 1
9 D3-808 Impeller Retaining Nut 1
NOTE:
Complete Pump & Motor Part #:
Single Phase - D2365-1
Three Phase - D2465-3
REV C - 03/25/04

15
®
PART 5 MAINTENANCE & REPAIR PROCEDURES
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
SK-2923 : 2 HP Pump
ITEM PART NO. DESCRIPTION QTY
1 Motor 2 HP 1
2 D431 Adapter 1
3 D443 Impeller 4 3/8” 1
4 D434 Casing 1
5 D2-532 O-Ring 1
6 D2-533 Flinger 1
7 D2-534 Seal Assembly 1
8 D329-5 Drain Petcock 1/4” IPS 1
9 D3-808 Impeller Retaining Nut 1
REV C - 03/08/18

16
®
PART 5 MAINTENANCE & REPAIR PROCEDURES
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
SK-4835 : 3 HP Scot 17 Pump
ITEM PART NO. DESCRIPTION QTY
1 Motor 3 HP 1
2 104.000.165 Flinger 1
3 116.000.117 O-Ring, Shaft 1
4 110.000.178 Shaft Sleeve, Bronze 1
5 132.000.194 Adapter, Iron - JM140/180 1
6 101.000.168 Seal, 1 1/2” 1
7 104.000.175 Seal Retainer 1
8 116.000.146 Gasket, Case 1
9 - Impeller, 4 3/4” 1
10 102.000.102 Key 1
11 118.000.111A Impeller Retainer 1
12 130.000.169 Case 1
REV A - 06/06/06

17
®
PART 5 MAINTENANCE & REPAIR PROCEDURES
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802
SK-4703 : Electric Heater Installation

PART 5 MAINTENANCE & REPAIR PROCEDURES
18
®
TROUBLESHOOTING
TECHNICAL ISSUES POSSIBLE CAUSES SOLUTIONS
Machine will not operate 1. No power
2. Blown fuse or tripped breaker
3. Motor overloads tripped
1. Check power supply
2. Replace fuse; reset breaker
3. Reset overload
Tank will not hold water 1. Drain not closed
2. Drain overow not seated or
installed
3. Pump petcock opened
4. Overow v-seal dirty/worn
1. Close drain
2. Reseat or install drain overow
3. Close pump petcock
4. Clean/replace v-seal
Tank lls beyond overow 1. Obstruction in overow tube or
drain line
1. Remove obstruction
Water leaks around door 1. Doors not seating
2. Clogged spray pipe
1. Reseat doors
2. Clean spray pipe with brush
Weak or ine󰀨ective spray 1. Clogged spray pipe
2. Manifolds not installed properly
3. Obstruction in pump
4. Pump rotation reversed
5. Suction strainer clogged
1. Clean spray pipe with brush pipe
2. Ensure proper placement of upper and
lower pipes
3. Clear obstruction through pump
inspection plate
4. Arrow on pump housing indicates
direction, correct electrically
5. Clean suction strainer
Weak or ine󰀨ective nal rinse
spray
1. Lime deposits in spray nozzles
2. Low water pressure
3. Clogged line strainer
4. Closed water supply valve
1. Clean or replace nozzles
2. Adjust to 20PSI
3. Remove line strainer and clean
4. Open ball valve
Water hammer 1. Excessive water line pressure 1. Install water hammer valve
Machine vibrates or is noisy 1. Pump rotation reversed 1. Arrow on pump housing indicates
direction, correct electrically
Final rinse will not shut o󰀨 1. Final rinse solenoid valve clogged
2. Diaphragm worn
3. Solenoid valve still powered-up
1. Disassemble valve and clean internal
parts of scale or replace
2. Replace with solenoid valve repair kit
3. Check nal rinse actuating circuit for
proper operation
TRAC 878 Technical Manual 2018 www.insingermachine.com 800-344-4802