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SUBWAY FRONT COUNTERS
Please read this manual completely before attempting
This document is prepared for trained Duke service technicians. It is not to be used by anyone not
properly qualifi ed to perform these procedures.
This Service Manual is not all encompassing. If you have not been trained on servicing this product,
be sure to read the manual completely before attempting servicing. Be sure all necessary tools, test
equipment, and skills are available. Those procedures for which you do not have the proper skills
and test equipment must be performed only by a qualifi ed Duke trained service technician.
This manual is Copyright © 2007 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
to install, operate or service this equipment
trademark of the Duke Manufacturing Co.
Duke Manufacturing Co.
2305 N. Broadway
St. Louis, MO 63102
Phone: 314-231-1130
Toll Free: 1-800-735-3853
Fax: 314-231-2460
www.dukemfg.com
Service Manual
P/N 219206A
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Table of Contents
Troubleshooting
Related Manuals for Duke SUBWAY Series
Summary of Contents for Duke SUBWAY Series
- Page 1 Please read this manual completely before attempting to install, operate or service this equipment This document is prepared for trained Duke service technicians. It is not to be used by anyone not properly qualifi ed to perform these procedures. This Service Manual is not all encompassing. If you have not been trained on servicing this product, be sure to read the manual completely before attempting servicing.
- Page 2 Service Manual for Subway Front Counters IMPORTANT WARNING AND SAFETY INFORMATION WARNING READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT. WARNING FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. WARNING DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
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Page 3: Table Of Contents
Service Manual for Subway Front Counters TABLE OF CONTENTS GENERAL ...........................5 SPECIFICATIONS ......................5 INSTALLATION ......................5 Location ........................5 Leveling ........................5 Stabilizing ........................6 Electrical Connection ....................6 PARTS REPLACEMENT ....................7 TRI-CHANNEL COLD PAN ....................7 Thermostat .........................7 Digital Thermostat ......................9 Capillary Tube ......................9 Capacitor ........................11 Evaporator ........................12 Condenser Cooling Fan .....................12 Refrigeration System ....................13... - Page 4 Service Manual for Subway Front Counters TABLE OF CONTENTS (CONTINUED) SERVICE INFORMATION ....................33 Duke Service Bulletin 26 ....................33 Refrigeration System Evacuation Process ..............33 TROUBLESHOOTING PROCEDURES ................34 Troubleshooting Guide ....................34 Tri-Channel Step One Troubleshooting Guide .............35 Leak Testing .........................37 SCHEMATIC DIAGRAMS ....................38 Tri-Channel ........................38...
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Page 5: General
Service Manual for Subway Front Counters GENERAL SPECIFICATIONS ELECTRICAL DATA: MODEL DESCRIPTION VOLTAGE AMPS PHASE SUB-GP-L Left to Right Tri-Channel 120 VAC (60 Hz) Cold Pan 220 VAC (50 Hz) SUB-GP-R Right to Left Tri-Channel 120 VAC (60 Hz) Cold Pan 220 VAC (50 Hz) SUB-HF-L Left to Right Hot Food Unit (500 Watts) -
Page 6: Stabilizing
Service Manual for Subway Front Counters Stabilizing Use the leg adjustments to insure that the unit is WARNING solid to the fl oor surface at all four contact points. REFER TO THE AMPERAGE DATA Insure that the unit does not “rock” when pressure is applied to the top corners. -
Page 7: Parts Replacement
Service may be performed from the front or back of the counter. It may be easier to access the compressor from the front of the counter. This can only be done on counters with Duke Décor Panels installed. Condensing Unit Slide Plate Bolt 1. - Page 8 Service Manual for Subway Front Counters 10. Cut away the foam insulation from the manifold and pull the Thermostat wire from copper tube. 11. Remove and discard the old thermostat. Thermostat Bulb Inserted into Copper Tube 15. Insert the new Thermostat Capillary Bulb into the copper tube and secure with cork tape.
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Page 9: Digital Thermostat
Service Manual for Subway Front Counters Digital Thermostat 7. Install the Digital Thermostat probes onto the Evaporator Coil. 8. Refer to the tags to reconnect the Digital Thermostat wiring. WARNING: 9. Install the Control Panel and Louvered THE POWER MUST BE TURNED OFF Panel. - Page 10 Service Manual for Subway Front Counters NOTICE: Using a Refrigeration-Charging Unit, evacuate refrigerant from the system according to Duke Manufacturing Service Bulletin Number 26. Refrigerant must be recovered in accordance with Federal, State and Local regulations. 3. Removal of the Lower Shelf if necessary to pull the Condensing unit out from under the unit.
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Page 11: Capacitor
SERVICE INFORMATION section of this manual. THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES 15. Charge system according to Duke DURING MAINTENANCE OR REPAIR Manufacturing Service Bulletin Number 26. FUNCTIONS. Use 14 oz of R404A for SUB-CP-TC74 or 86 and 12 oz for SUB-CT-TC48 or 60. -
Page 12: Evaporator
Service Manual for Subway Front Counters Evaporator Condenser Cooling Fan WARNING: WARNING: THE POWER MUST BE TURNED OFF THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR DURING MAINTENANCE OR REPAIR FUNCTIONS. -
Page 13: Refrigeration System
Refrigeration System of this manual. 4. Using a Refrigeration-Charging Unit, evacuate WARNING: refrigerant from the system according to Duke Manufacturing Service Bulletin Number 26. THE POWER MUST BE TURNED OFF 5. Remove expansion valve and evaporator AND DISCONNECTED AT ALL TIMES tubing from refrigeration assembly. -
Page 14: Recharging The Refrigeration System
Duke 2. Use temporary valves to perform repair. Duke Manufacturing recommends the following Manufacturing will not reimburse the cost of triple evacuation method. Failure to follow this permanently installed valves. -
Page 15: Hot Food Unit
Service Manual for Subway Front Counters HOT FOOD UNIT 2. Remove the 5 screws that secure the Control Box to the operator’s side of the unit. Infi nite Switch 3. Remove the 4 nuts that secure the Control Panel to the Control Box. WARNING: NOTICE: Tag and disconnect the power cable wires to allow for complete removal of the bottom... -
Page 16: Indicator Lamp
Service Manual for Subway Front Counters 4. Disconnect the Indicator Lamp wiring from the Indicator Lamp Thermostat. 5. Remove the Indicator Lamp assembly, which is held in place by crimp springs. WARNING: 6. Reverse this procedure to install a new THE POWER MUST BE TURNED OFF Indicator Lamp. -
Page 17: Capacitor
Service Manual for Subway Front Counters 4. Disconnect the Element Wires from the Infi nite PURSE RAIL REPLACEMENT Switch. 5. Remove the Element Clip and mounting screws. WARNING: 6. Carefully pull the Element out of the pan. THE POWER MUST BE TURNED OFF 7. - Page 18 Service Manual for Subway Front Counters CAUTION: For front counters with curved 10. Place a piece of cardboard near each of the glass, these screws fasten the Light Cover mounting screws and remove the glass extrusion to the top of screws with the 5/16″...
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Page 19: Daycover
Service Manual for Subway Front Counters 23. Center and attach the Light Assembly onto the DAYCOVER Purse Rail ensuring that the front edge of the Daycover Bulb Gasket Light Shield covers the laminate by ¼″. NOTICE: For 220 Volt Light Fixtures, reattach the WARNING: power cord, cord grommet and light clip. -
Page 20: Gas Damper And Gas Shock Replacement
Service Manual for Subway Front Counters Gas Damper and Gas Shock Replacement WARNING: THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS. Gas Damper or Gas Shock Cap Opened 3. Using a fl at head screwdriver, pry the Gas Damper or Gas Shock Lock Caps open. -
Page 21: End Glass - Tri-Channel Unit
Service Manual for Subway Front Counters End Glass – Tri Channel Unit WARNING: THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS. Piston End Installed 7. Exert up-ward pressure on the piston end of the Gas Shock or Gas Damper while mounting it onto is Mounting Ball. -
Page 22: End Glass - Hot Food Unit
Service Manual for Subway Front Counters 3. Remove and discard old glass, gaskets and extrusion. Extrusion Line up with holes in unit Top Glass Holder Removed 3. Remove top Glass Holder. Proper Placement of Extrusion. 4. Reverse this procedure to install a replacement End Glass. -
Page 23: Daycover Door
Service Manual for Subway Front Counters 2. Remove the End Glass from both sides of the Daycover Door that requires replacement. Refer to END GLASS – TRI CHANNEL replacement instructions in the PARTS REPLACEMENT section of this manual. Properly Installed End Glass 5. -
Page 24: Daycover Light
Service Manual for Subway Front Counters Daycover Light WARNING: THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS. Daycover Pylon Gasket 8. Remove the rubber gaskets from the Daycover Pylons. 9. Carefully lift the Daycover away from the unit. -
Page 25: Daycover Light Clip
Service Manual for Subway Front Counters Daycover Light Clip 2. Remove all food product from the area to be worked on and disconnect the unit from its power source. 3. Remove the Gas Dampers and Gas Shocks. WARNING: Refer to GAS DAMPER AND GAS SHOCK replacement in the PARTS REPLACEMENT THE POWER MUST BE TURNED OFF section of this manual. -
Page 26: Daycover Replacement - Cold Pan Unit
Service Manual for Subway Front Counters NOTICE: Refer to DAYCOVER BULB GASKET replacement in the PARTS REPLACEMENT section of this manual. 7. Remove the Bulb Gasket from the door. NOTICE: The Reinforcement Bracket Kit includes a right and left bracket. Ensure the correct bracket is placed into the correct position before drilling any holes into the Daycover Door frame. -
Page 27: Daycover Retrofi T Replacement - Cold Pan Unit
Service Manual for Subway Front Counters 4. Lift one of the Daycovers enough to expose 4. Lift one of the Daycovers enough to expose the electrical connection. the electrical connection. 5. Disconnect the wiring harness. 5. Disconnect the wiring harness. CAUTION: The Daycover is heavy, a CAUTION: The Daycover is heavy, a minimum of two people are... - Page 28 Service Manual for Subway Front Counters NOTICE: It is best to start with a smaller ⅛″ bit 15. Remove the Front Filler from the side of the and gradually make the hole larger. Pylon where the Light Wire harness is located. The fi...
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Page 29: Daycover Replacement - Hot Food Unit
Service Manual for Subway Front Counters Daycover Replacement – Hot Food Unit Daycover Retrofit Replacement – Hot Food Unit WARNING: WARNING: THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES THE POWER MUST BE TURNED OFF DURING MAINTENANCE OR REPAIR AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS. - Page 30 Service Manual for Subway Front Counters CAUTION: The Daycover is heavy, a 16. Insert a Grommet over the wire and snap it minimum of two people are into place in the hole. required to lift it. NOTICE: If the old terminal was cut off, a new one 6.
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Page 31: Maintenance
Service Manual for Subway Front Counters MAINTENANCE For routine cleaning, use warm water, mild soap STAINLESS STEEL CARE or detergent and a sponge or soft cloth. Cleaning For heavy-duty cleaning, use warm water, a degreaser and a plastic, stainless steel or Scotch- Stainless steel contains 70-80% iron, which will Brite pad. -
Page 32: Cleaning The Condenser Coil
Service Manual for Subway Front Counters CLEANING THE CONDENSER COIL WARNING THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES DURING MAINTENANCE OR REPAIR FUNCTIONS. Failure to maintain a clean condenser coil can cause high temperatures and excessive run times. -
Page 33: Service Information
When service of the refrigeration system is necessary, care must be giving during the evacuation process to ensure removal of air, moisture, and other non-condensables from the system. To evacuate a system properly, Duke Manufacturing recommends a triple evacuation procedure outlined below. Failure to follow this process could cause poor performance of the refrigeration system. -
Page 34: Troubleshooting Procedures
Service Manual for Subway Front Counters TROUBLESHOOTING PROCEDURES TRI-CHANNEL UNIT Symptom Cause Remedy Cabinet too warm Unit not plugged in Plug unit in Thermostat set too low Set thermostat to a higher number for a colder temperature Thermostat switch stuck open in coldest Replace thermostat position Evaporator fan not running... -
Page 35: Tri-Channel Step One Troubleshooting Guide
Service Manual for Subway Front Counters TRI CHANNEL STEP ONE TROUBLE SHOOTING GUIDE This guide is designed as the fi rst step in evaluating the operating condition of the refrigeration system on a Tri-Channel cold pan. Every effort should be made to evaluate and solve the equipment issue before tapping into the refrigeration system. - Page 36 Service Manual for Subway Front Counters Check for visible frost on the unit and record fi ndings, yes or no in the boxes below. There should be frost accumulating at the top of each of the rails, though it is not unusual for the frost to be patchy.
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Page 37: Leak Testing
1. Charge the unit using the instructions in the RECHARGING THE REFRIGERATION SYSTEM SECTION OF THIS MANUAL, and DUKE SERVICE BULLETIN 26. 2. Turn the unit on and run it through a full cycle. 3. While the unit is operating, remove the... -
Page 38: Schematic Diagrams
Service Manual for Subway Front Counters SCHEMATIC DIAGRAMS TRI CHANNEL HOT FOOD... - Page 39 Service Manual for Subway Front Counters NOTES:...
- Page 40 Service Manual for Subway Front Counters Duke Manufacturing Co. 2305 N. Broadway St. Louis, MO 63102 Phone: 314-231-1130 Toll Free: 1-800-735-3853 Fax: 314-231-2460 www.dukemfg.com P/N 219206A...
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