SAFETY PRECAUTIONS SAFETY PRECAUTIONS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY (a) Do not operate or allow the oven to be operated with the door open. (b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source, and make repairs as necessary.
Service Manual for Speed Oven Model DSO 500 TABLE OF CONTENTS SAFETY PRECAUTIONS ........................3 INTRODUCTION ..........................6 MAIN FEATURES ..........................7 INSTALLATION ...........................8 UNPACKING OVEN ........................8 RADIO INTERFERENCE ......................8 OVEN PLACEMENT........................8 ELECTRICAL INFORMATION .......................8 EARTHING INSTRUCTIONS ......................9 EXTERNAL EQUIPOTENTIAL ......................9 SPECIFICATIONS ..........................10 INPUT POWER ...........................10...
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POWER OUTPUT MEASUREMENT ..................45 MICROWAVE LEAKAGE TEST ....................45 COMPONENT TESTING ........................47 POWER TRANSFORMER TEST ....................47 DISCHARGING THE HIGH VOLTAGE SYSTEM ON THE DUKE SPEED OVEN......48 HIGH VOLTAGE CAPACITOR TEST ..................49 HIGH VOLTAGE RECTIFIER TEST ....................50 MECHANICAL RELAYS AND INTERLOCK SWITCHES ............51 REPAIR PROCEDURES ........................53...
MAIN FEATURES 6. DOOR AND HEAT SHIELD The door is pulled downwards and towards you The main features of the Model DSO 500 Speed to open. The door is designed with interlocks for Oven are identified in Figure 1 and described microwave safety.
Service Manual for Speed Oven Model DSO 500 INSTALLATION UNPACKING OVEN A. Allow at least 3” (7.62 cm) of clearance around the sides of oven. Proper airflow • Inspect oven for damage such as dents around the oven cools electrical compo- in door or inside oven cavity.
This oven should be plugged into a separate TO AVOID RISK OF ELECTRICAL SHOCK OR circuit with the electrical rating as provided in DEATH, THIS OVEN MUST BE GROUNDED product specifications (available on Duke’s AND PLUG MUST NOT BE ALTERED. Wavelink website). WARNING...
Service Manual for Speed Oven Model DSO 500 SPECIFICATIONS Table 2 lists the specifications for the Model DSO 500 Speed Oven. Table 2. Specifications MODEL NO. DSO 500 INPUT POWER Operating Voltage 208 – 240 VAC, 60 Hz Current 29 Amps...
EQUIPMENT OVERVIEW PREVENTIVE MAINTENANCE CLEANING Early signs of stainless steel breakdown can consist of small pits and cracks. If this has begun, clean thoroughly and start to apply stain- Stainless Steel Care and Cleaning less steel cleaners in attempt to restore the To prevent discoloration or rust on stainless steel passivity of the steel.
Service Manual for Speed Oven Model DSO 500 SERVICING PROCEDURES GENERAL NOTE: Remember this overview is only intended to provide a brief discussion on each com- The service section of this manual includes a ponent. Details for testing, adjusting and section called component overview.
COMPONENT OVERVIEW COMPONENT OVERVIEW STIRRER MOTOR AND GEARBOX Surface Components The stirrer motor and gearbox, Figure 3, is located near the front of the oven upper cham- ber above the upper jetplate. The stirrer motor Safety issues rotates the stirrer blade at 20 rpm. The rotating stirrer blade evenly distributes the microwave •...
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Service Manual for Speed Oven Model DSO 500 Test procedure Replacement Check 208/240 VAC is present on the motor After removing the side and top panels and power connections, wires 47 and 49, as above. disconnecting the power cord, the stirrer motor power leads can be disconnected.
COMPONENT OVERVIEW HIGH VOLTAGE TRANSFORMERS Safety Issues The transformers, Figure 4, step up the input line WARNING voltage to 2.5 kV. This voltage is rectified by the high voltage diodes and the high voltage capaci- THE HIGH VOLTAGE CAPACITORS RETAINS tors for operation of the magnetrons.
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Service Manual for Speed Oven Model DSO 500 Test Procedure Replacement WARNING WARNING HIGH VOLTAGE CAPACITOR MUST BE THE HIGH VOLTAGE CAPACITOR RETAINS DISCHARGED BEFORE SERVICING. RE- THE 2.5 kVDC CHARGE EVEN AFTER THE FER TO DETAILED PROCEDURE IN THE OVEN IS DISCONNECTED.
COMPONENT OVERVIEW HIGH VOLTAGE RECTIFIERS Safety Issues The high voltage diodes, Figure 5, rectify the WARNING incoming 2.5 kV voltage and doubles it providing 5kVDC for magnetron operation. THE HIGH VOLTAGE CAPACITOR RETAINS THE 2.5 kVDC CHARGE EVEN AFTER THE OVEN IS DISCONNECTED.
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Service Manual for Speed Oven Model DSO 500 Test Procedure Replacement WARNING WARNING HIGH VOLTAGE CAPACITOR MUST BE HIGH VOLTAGE CAPACITOR MUST BE DISCHARGED BEFORE SERVICING. RE- DISCHARGED BEFORE SERVICING THE FER TO DETAILED PROCEDURE IN THE TRANSFORMERS COMPONENT TESTING SECTION BEFORE TESTING.
COMPONENT OVERVIEW HIGH VOLTAGE CAPACITORS Safety Issues The high voltage capacitors, Figure 6, store the WARNING rectified high voltage (2.5 kVDC) for operation of the magnetrons. THE HIGH VOLTAGE CAPACITOR RETAINS THE 2.5 kVDC CHARGE EVEN AFTER THE OVEN IS DISCONNECTED. THIS CAPACI- Location and Access.
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Service Manual for Speed Oven Model DSO 500 Test Procedure Replacement WARNING WARNING HIGH VOLTAGE CAPACITOR MUST BE HIGH VOLTAGE CAPACITOR MUST BE DISCHARGED BEFORE SERVICING. RE- DISCHARGED BEFORE REPLACEMENT. FER TO DETAILED PROCEDURE IN THE COMPONENT TESTING SECTION BEFORE Capacitor must be discharged before removal.
COMPONENT OVERVIEW MAGNETRONS Safety Issues The magnetron filament voltage of 4.5 VAC WARNING is supplied from the high voltage transformer filament winding. The operating voltage of 5000 THE HIGH VOLTAGE CAPACITOR RETAINS VDC is provided by the rectified output from the THE 2.5 kVDC CHARGE EVEN AFTER THE transformer high voltage winding.
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Service Manual for Speed Oven Model DSO 500 Test Procedure Replacement WARNING WARNING HIGH VOLTAGE CAPACITOR MUST BE HIGH VOLTAGE CAPACITOR MUST BE DISCHARGED BEFORE SERVICING. RE- DISCHARGED BEFORE MAGNETRON FER TO DETAILED PROCEDURE IN THE REPLACEMENT. COMPONENT TESTING SECTION BEFORE TESTING.
COMPONENT OVERVIEW MAGNETRON THERMAL Safety Issues SWITCHES WARNING The magnetron thermal switches, Figure 8, are THE HIGH VOLTAGE CAPACITOR RETAINS used to monitor the magnetron temperature and THE 2.5 kVDC CHARGE EVEN AFTER THE open the high voltage supply when the tempera- OVEN IS DISCONNECTED.
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Service Manual for Speed Oven Model DSO 500 Test Procedure Replacement WARNING WARNING HIGH VOLTAGE CAPACITOR MUST BE HIGH VOLTAGE CAPACITOR MUST BE DISCHARGED BEFORE SERVICING. RE- DISCHARGED BEFORE MAGNETRON FER TO DETAILED PROCEDURE IN THE THERMOSTAT REPLACEMENT. COMPONENT TESTING SECTION BEFORE TESTING.
COMPONENT OVERVIEW SOLID STATE RELAYS Tools required • Flat blade screwdriver to remove side Five solid state relays are used. Three relays panel, relay attaching screws, and termi- (K1, K2, and K3) are used to control the heating nals connections. elements.
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Service Manual for Speed Oven Model DSO 500 SOLID STATE RELAYS - NOTES...
COMPONENT OVERVIEW MECHANICAL RELAYS AND Safety Issues. INTERLOCK SWITCHES • Electrical supply of 208/240 VAC to the control transformer when POWER switch Three mechanical relays are used. These are is in ON position K6, K7, and K8. The mechanical relays are operated by the door interlock switches “P”, “S”, •...
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Service Manual for Speed Oven Model DSO 500 MECHANICAL RELAYS AND INTERLOCK SWITCHES - NOTES...
COMPONENT OVERVIEW HEATERS AND THERMAL CUTOUTS The three heaters, Figure 11A, are used to heat the oven. These heaters are controlled by the control board through relays K1, K2, and K3. The high limit and aux thermal cutouts, Figure 11B, are connected in series with the heaters and the input power source through the line fuses.
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Service Manual for Speed Oven Model DSO 500 Figure 11B. Thermal Cutouts Test Procedure Close oven door. Check for operating voltage Operational Testing across heater terminals. Unplug oven and check continuity across heater coils. If a heater coil The heating elements require the control board to shows high resistance coil is probably open.
COMPONENT OVERVIEW LINE FUSES Tools required • Flat blade screwdriver to remove panels The line fuses, Figure 12, are in the circuit go- and remove fuses from fuse clips. ing to the heater elements and the magnetron circuits and are not in the POWER switch cir- cuit Operational Testing The line fuses must be operational for the heat-...
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Service Manual for Speed Oven Model DSO 500 LINE FUSES - NOTES...
COMPONENT OVERVIEW JET PLATES Tools required • Upper Jet Plate: The jet plates are used to direct the hot airflow Allen wrench 5/32 inch at high speed over the food in the cook chamber of the oven. The upper jet plate is transparent to •...
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Service Manual for Speed Oven Model DSO 500 JET PLATES - NOTES...
COMPONENT OVERVIEW CABINET COOLING FANS • Electrical supply of 208/240 VAC to the control transformer when POWER switch The cabinet cooling fans provide air circulation is in ON position for cooling the cabinet. Two fans are used to • Main POWER switch and fuses have draw air into the cabinet and one fan is used to 208/240 VAC present on the input side exhaust the air.
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Service Manual for Speed Oven Model DSO 500 CABINET COOLING FANS - NOTES...
COMPONENT OVERVIEW MAGNETRON COOLING FANS Safety Issues The magnetron cooling fans, Figure 15, provide WARNING air circulation for cooling the magnetrons and high voltage transformer. This is a twin blower fan. WHEN THE TOP IS REMOVED THE HIGH VOLTAGE CAPACITOR IS EXPOSED. THE HIGH VOLTAGE CAPACITOR RETAINS THE Location and Access 2.5 kVDC CHARGE EVEN AFTER THE OVEN...
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Service Manual for Speed Oven Model DSO 500 Test Procedure Replacement Turn on POWER switch and check that the fan is Unplug oven from power source. Remove top operating. If the rear panel fans are operation but cover. Disconnect wires to the defective fan. Re- the magnetron cooling fan is not operating check move nuts then remove fan.
COMPONENT OVERVIEW CABINET THERMAL SWITCH Tools required • Flat blade screwdriver to remove side The cabinet thermal switch, Figure 16, closes panel when the cabinet temperature exceeds 40°C. When the POWER switch is set to the OFF • #2 Phillips screwdriver to remove screws position, the thermal switch maintains operat- securing thermal switch to top side of ing voltage to the cooling fans until the cabinet...
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Service Manual for Speed Oven Model DSO 500 COOLING FAN THERMAL SWITCH - NOTES...
COMPONENT OVERVIEW KEYPAD/CONTROL BOARD Safety Issues • Electrical supply of 208/240 VAC to the The keypad/control board, Figure 17, is program- control transformer when POWER switch mable for different menus, temperature settings, is in ON position variable fan speed microwave power connection only, microwave and convection combination and •...
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Service Manual for Speed Oven Model DSO 500 KEYPAD/CONTROL BOARD - NOTES...
COMPONENT OVERVIEW INVERTERS Tools required • Flat blade screwdriver to remove side The inverters drive the upper and lower convec- panel tion blower motors. These inverters must be programmed when first installed. • #2 Phillips screwdriver to remove screws securing inverters to right side of oven Location and Access Operational Testing The inverters, Figure 18, are located on the right...
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Service Manual for Speed Oven Model DSO 500 INVERTERS - NOTES...
POWER OUTPUT MEASUREMENT 6. The actual power output in Watts can be cal- culated by multiplying the water temperature The Model DSO 500 Speed Oven power output in Celsius by 70. is 1600 Watts for a properly operating oven. Temperature Rise (°C)
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Service Manual for Speed Oven Model DSO 500 WARNING ON A USED OVEN THE LEAKAGE AROUND DOOR SHOULD NOT EXCEED 4mW/cm². When measuring the leakage, use the probe supplied with the instrument. Always hold the probe at right angles to the oven and point of measurement.
AT THESE WINDING. IT IS VERY DANGER- THE HIGH VOLTAGE SYSTEM ON THE OUS TO WORK NEAR THIS PART WHEN DUKE SPEED OVEN. THE OVEN IS ON, OR IF THIS CIRCUITRY HAS BEEN SWITCHED OFF. 3. Remove all connections from the Power Transformer.
Service Manual for Speed Oven Model DSO 500 DISCHARGING THE HIGH Approximately 12 inches of high voltage insulated cable of the type used for the high voltage wiring. VOLTAGE SYSTEM ON THE The conductor should be bared at each end to a MODEL DSO 500 length of 0.5 inch.
THE HIGH VOLTAGE CAPACITOR RETAINS THE HIGH VOLTAGE SYSTEM ON THE THE 2.5 kVDC CHARGE EVEN AFTER THE DUKE SPEED OVEN. OVEN IS DISCONNECTED. THIS CAPACI- TOR MUST BE DISCHARGED BEFORE 4. Ensure that the High Voltage Capacitor is fully WORKING ON ANY COMPONENTS IN THE discharged before commencing work.
Service Manual for Speed Oven Model DSO 500 HIGH VOLTAGE RECTIFIER TEST Test Procedure 1. Disconnect the oven from the power WARNING source. THE HIGH VOLTAGES AND CURRENTS AT 2. Remove top cover and right side panel to THE HIGH VOLTAGE RECTIFIER ARE EX- access the high voltage diodes (rectifiers).
COMPONENT TESTING MECHANICAL RELAYS AND with no output contact closure. If no output contact closure is detected at relay K7 check INTERLOCK SWITCHES for presence of coil voltage. If coil voltage is Mechanical relays K6, K7 and K8, Figure 19, are not present check for proper activation of door part of the door interlock circuit and are activated switch “M”...
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Service Manual for Speed Oven Model DSO 500 COMPONENT TESTING - NOTES...
REPAIR PROCEDURES REPAIR PROCEDURES RELAY AND SWITCH 4. Remove the two screws securing the relay to the panel and remove the relay. REPLACEMENT 5. Be sure replacement relay is oriented prop- erly then attach relay with the two mounting General screws.
Service Manual for Speed Oven Model DSO 500 LINE FUSE REPLACEMENT Replacement Procedure WARNING General THE FUSE HOLDER WILL REMAIN ALIVE The two line fuses are mounted in a fuse block UNLESS THE OVEN IS DISCONNECTED on the lower left side of the oven as shown in FROM THE POWER SOURCE.
REPAIR PROCEDURES INVERTER REPLACEMENT Replacement Procedure 1. Disconnect the oven from the power source. General 2. Remove the right side panel to access the The two inverters are mounted on the right inverters. side of the back panel of the oven as shown in Figure 23.
Service Manual for Speed Oven Model DSO 500 BLOWER MOTOR REPLACEMENT General The upper and lower Blower Motors are located directly behind the oven rear panel and are accessed through the oven left side panel. The “squirrel cage” fan is attached to the motor shaft and can be removed as a complete unit.
Service Manual for Speed Oven Model DSO 500 ELECTRICAL PANEL 6. Install the new control panel and attach to oven with the mounting screws. REPLACEMENT 8. Reconnect connectors J1, J2, J3, and J4. General 9. Reinstall the right side panel.
AFTER SHUTDOWN OF HIGH VOLTAGE SYSTEM. 3. Discharge the high voltage capacitor as described in the paragraph DISCHARGING THE HIGH VOLTAGE SYSTEM ON THE DUKE SPEED OVEN. 4. Remove cooling duct. (Right side magnetron only). 5. Unplug spade connectors from the terminal housing.
Service Manual for Speed Oven Model DSO 500 STIRRER MOTOR REPLACEMENT Replacement Procedure General 1. Disconnect and isolate the oven from the power source. The Stirrer Motor, Figure 29, is located under the oven top panel in the approximate center of...
REPAIR PROCEDURES HEATER ELEMENT REPLACEMENT 1. Disconnect and isolate the oven from the power source. 2. Remove the oven top panel. 3. Remove the oven right and left panels. 4. Loosen the remaining lower central bolt on the rear panel. 5.
Service Manual for Speed Oven Model DSO 500 CABINET THERMAL SWITCH Replacement Procedure REPLACEMENT 1. Disconnect and isolate the oven from the power source. General 2. Remove the oven top panel to gain access to the thermal switch. The cabinet thermal switch is located on top of the oven, behind the oven top panel.
VOLTAGE SYSTEM. 3. Discharge the high voltage capacitor as described in the paragraph DISCHARGING THE HIGH VOLTAGE SYSTEM ON THE DUKE SPEED OVEN. 4. Unplug and label all spade connectors from the transformer. 5. Note orientation of transformer, then remove transformer mounting screws and remove transformer unit.
Service Manual for Speed Oven Model DSO 500 FRONT THERMAL COOLING FAN Replacement Procedure REPLACEMENT 1. Disconnect and isolate the oven from the power source. General 2. Remove the oven top panel to gain access to the thermal cooling fan motor and “squirrel The front thermal cooling fan, Figure 33, is lo- cage”...
REPAIR PROCEDURES INTAKE AND EXHAUST FANS Replacement Procedure REPLACEMENT 1. Disconnect and isolate the oven from the power source. General NOTE: The three fans are attached to the back panel. When removing back panel take The two intake fans and the one exhaust fan, care not to break any wires attached to Figure 34, are located on the back of the unit.
Service Manual for Speed Oven Model DSO 500 ADJUSTMENTS Door Interlock Adjustment The Speed Oven will not operate unless the interlock switches, Figure 35 and Figure 36, are properly engaged. Make no attempt to mechani- cally or electrically override the interlock circuit.
TROUBLESHOOTING TROUBLESHOOTING Error Codes INFORMATION TO BE PROVIDED Figure Error Code Displays Troubleshooting Table The troubleshooting table provides a list of Symptoms in the left-hand column. The center column lists the probable causes for the indicated Symptom. The right-hand column provides procedures to remedy the Symptom.
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Service Manual for Speed Oven Model DSO 500 SYMPTOM POSSIBLE CAUSE REMEDY Solid State Relays Check for 12 VAC supply voltage to solid state relays K4 and K5. If present check for L2 voltage at terminal L1. If L2 voltage is present check for L2 output at terminal T1.
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TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Magnetrons operate Current sensors detect unit(s). If current is above normal operat- intermittently overload state ing specs, replace magnetron unit(s). If magnetrons are operating check stirrer Stirrer motor will not Stirrer Motor motor wire connections and confirm that operate supply voltage is present at stirrer motor terminals.
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Service Manual for Speed Oven Model DSO 500 SYMPTOM POSSIBLE CAUSE REMEDY Electronic control board Control Transformer Check for 208/220-240 VAC supply volt- inoperative age to the transformer primary terminals. If no voltage is present trace the wiring back through the master switch and check all connections.
Service Manual for Speed Oven Model DSO 500 SPARE PARTS LIST This list details most of the replacement parts required for service the oven. PART NUMBER PART NUMBER Magnetron & Thermal Switch 168100 High Voltage Transformer 167503 High Voltage Diode...
APPENDIX A APPENDIX A INVERTER PROGRAMMING The following procedure must be used to program 6. After confirmation of last parameter, change the inverters. The inverter must be installed in the mode back to “Run” mode until green LED oven before proceeding with programming. “FREF”...
Service Manual for Speed Oven Model DSO 500 INVERTER SETTINGS PARAMETER NAME SETTING DEFAULT REMARKS Parameter to access/ac- All parameters can be cess prohibition of param- monitored/edited. eters to be edited Operation mode selection Multi function inputs at control circuit terminals enabled.
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APPENDIX A INVERTER SETTINGS (Cont.) PARAMETER NAME SETTING DEFAULT REMARKS Acceleration time 1 0.6s Acceleration from 0% to 100% speed Acceleration time 1 0.6s Acceleration from 0% to 100% speed Acceleration time 2 0.6s Acceleration from 0% to 100% speed in conjunction with speed references Acceleration time 2 0.6s...
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Service Manual for Speed Oven Model DSO 500 INVERTER SETTINGS (Cont.) PARAMETER NAME SETTING DEFAULT REMARKS Frequency inching com- 6 Hz 6 Hz Multi-step operation to allow mand operation at discrete frequency steps Frequency reference up- 100% 100% Determines max upper...
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APPENDIX A INVERTER SETTINGS (Cont.) PARAMETER NAME SETTING DEFAULT REMARKS Analog frequency 0.1s 0.1s Digital filter with first-order lag for reference time analog reference frequencies Analog monitor output Setting of output frequency to be monitored Analog output monitor Set the characteristics of gain monitored output signal Carrier frequency...
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Service Manual for Speed Oven Model DSO 500 INVERTER SETTINGS (Cont.) PARAMETER NAME SETTING DEFAULT REMARKS Stall prevention level dur- 170% 170% Deceleration enabled ing acceleration Automatically stops acceleration for stall prevention during acceleration by set level of percentage on rated current of...
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APPENDIX A INVERTER SETTINGS (Cont.) PARAMETER NAME SETTING DEFAULT REMARKS OMRON reference Not to be changed under normal programming OMRON reference Not to be changed under normal programming OMRON reference Not to be changed under normal programming OMRON reference Not to be changed under normal programming OMRON reference Not to be changed under normal...
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Duke Manufacturing Company 2305 N. Broadway St. Louis, MO 63102 Phone: 314-231-1130 Toll Free: 1-800-735-3853 Fax: 314-231-5074 www.dukemfg.com...
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