Service Manual
SUBWAY FRONT COUNTERS
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. 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
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
P/N 219206A
Service Manual for Subway Front Counters
2
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.
WARNING
DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND
SECURING ALL COVER AND ACCESS PANELS.
CAUTION
Observe the following:
• Provide and maintain adequate minimum clearances from all walls and combustible materials.
• Provide and maintain adequate clearance for air openings.
• Keep the equipment area free and clear of combustible material.
• Operate equipment only on the type of electricity indicated on the specifi cation plate.
• Retain this manual for future reference.
3
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
Recharging the Refrigeration System ........................................................................14
HOT FOOD UNIT ...........................................................................................................15
Infi nite Switch .............................................................................................................15
Indicator Lamp ...........................................................................................................16
Heat Element .............................................................................................................16
Capacitor ....................................................................................................................17
PURSE RAIL REPLACEMENT ......................................................................................17
DAYCOVER ....................................................................................................................19
Daycover Bulb Gasket ................................................................................................19
Gas Damper and Gas Shock Replacement ...............................................................20
End Glass – Tri-Channel unit .....................................................................................21
End Glass – Hot Food Unit .........................................................................................22
Daycover Door ...........................................................................................................23
Daycover Light ...........................................................................................................24
Daycover Light Clip ....................................................................................................25
Daycover Damage Repair ..........................................................................................25
Daycover Replacement – Cold Pan Unit ....................................................................26
Daycover Retrofi t Replacement – Cold Pan Unit .......................................................27
Daycover Replacement – Hot Food Unit ....................................................................29
Daycover Retrofi t Replacement – Hot Food Unit .......................................................29
MAINTENANCE .................................................................................................................31
Stainless Steel Care and Cleaning .................................................................................31
Cleaning the Condenser Coil .........................................................................................32
Service Manual for Subway Front Counters
4
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
Hot Food ........................................................................................................................38
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Service Manual for Subway Front Counters
SPECIFICATIONS
ELECTRICAL DATA:
GENERAL
INSTALLATION
Location
The unit represented in this manual is intended
for indoor use only. Be sure the chosen location
has a fl oor strong enough to support the total
weight of the unit. Reinforce the fl oor if necessary
to provide for maximum loading. For the most
effi cient operation, be sure to provide good air
circulation inside and out.
The outline drawing for the unit is shown below.
Provide adequate space along the front and back
taking care to not block airfl ow to the fan. Be sure
that the unit has access to ample air; avoid hot
corners and locations near stoves and ovens.
MODEL DESCRIPTION VOLTAGE AMPS PHASE
SUB-GP-L Left to Right Tri-Channel
Cold Pan
120 VAC (60 Hz)
220 VAC (50 Hz)
7.9
4.4
1
1
SUB-GP-R Right to Left Tri-Channel
Cold Pan
120 VAC (60 Hz)
220 VAC (50 Hz)
7.9
4.4
1
1
SUB-HF-L Left to Right Hot Food Unit (500 Watts) 120 VAC (60 Hz) 4.2 1
SUB-HF-R Right to Left Hot Food Unit (500 Watts) 120 VAC (60 Hz) 4.2 1
Leveling
Be sure that the units are placed on a fi rm, fl at
surface/fl oor. Check for cracks in fl ooring or tile
and avoid these areas if possible. If necessary
place support pads, properly rated for the weight
of the unit, to “bridge” uneven or cracked fl ooring.
Level unit accordingly.
The units are provided with adjustable feet. All
three units (Tri Channel, Hot Food and Cashier
Counter) must be adjusted to the same height.
First level the Tri-Channel unit. Adjust the feet
on the Hot Food Unit and Cash Unit to meet the
height of the Tri-Channel.
Subway Front Counter
Service Manual for Subway Front Counters
6
Stabilizing
Use the leg adjustments to insure that the unit is
solid to the fl oor surface at all four contact points.
Insure that the unit does not “rock” when pressure
is applied to the top corners.
Electrical Connection
The unit is designed to be operated on one 15 AMP
dedicated circuit. The unit must be grounded. The
receptacle, wired circuit and protection must meet
all required local codes for proper operation. All
electrical connections should be performed by a
certifi ed electrician and should comply with local
electrical codes for your municipality.
The Tri-Channel Cold Pan is pre-wired with a
NEMA 5-15 cord.
The Hot Food Unit is also pre-wired with a NEMA
5-15 cord.
WARNING
REFER TO THE AMPERAGE DATA
LIST IN THE SPECIFICATIONS OR
THE SERIAL TAG DATA AND YOUR
LOCAL CODE OR THE NATIONAL
ELECTRICAL CODE TO BE SURE
UNIT IS CONNECTED TO THE
PROPER POWER SOURCE. A
PROTECTED CIRCUIT OF THE
CORRECT VOLTAGE AND AMPERAGE
MUST BE RUN FOR CONNECTION
OF THE SUPPLY CORD OR
PERMANENT CONNECTION TO
THE UNIT. THE POWER MUST BE
TURNED OFF AND DISCONNECTED
WHENEVER PERFORMING
MAINTENANCE OR REPAIR
FUNCTIONS.
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Service Manual for Subway Front Counters
PARTS REPLACEMENT
TRI-CHANNEL COLD PAN
Thermostat
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Thermostat
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.
1. Disconnect the unit from its power source.
2. Unplug the Purse Rail Lights from the duplex
box located on the compressor cage inside
the unit.
3. Loosen the screws in the stainless steel top
that hold the Décor Panel in place.
CAUTION: For front counters with curved
glass, these screws fasten the
glass extrusion to the top of the
front counter. Loosen the screws
above only one panel at a time.
4. Lift up on the Décor Panel and pull the bottom
of the panel away from the front of the unit.
4. Remove the Décor Panel from the unit.
5. Move to the Operator’s side of the counter
and remove the Lower Functionality Shelf.
NOTICE: On older versions of the counter, the
Louvered Front Vent Panel is held in place with
four Phillips screws. On newer versions, the
Louvered Front Vent Panel lifts off.
6. Remove the Louvered Front Vent Panel.
Condensing Unit Slide Plate Bolt
7. Remove the slide plate bolt.
8. Slide the Condensing unit forward enough to
expose the Manifold area.
NOTICE: If the unit has a thermostat with ¼″ copper
capillary mounted on the manifold, simply change
out the thermostat. If not continue to step 9.
9. Tag and disconnect the Thermostat wiring.
Service Manual for Subway Front Counters
8
10. Cut away the foam insulation from the manifold
and pull the Thermostat wire from copper
tube.
11. Remove and discard the old thermostat.
Manifold Prepared with 1/4″ Copper Tube
12. Prepare the Manifold for ¼″ copper tube.
Secure the copper tube to the Manifold with
four zip ties. Make sure the copper tube
extends 1″ beyond the 90º bend in the Manifold
closest to the Condenser Coil.
NOTICE: Trim the excess ends off the zip ties.
13. Cover the manifold and copper tube with foil
tape.
14. Install split insulation onto the manifold; make
sure the copper tube is exposed where it
extends beyond the manifold to allow for new
Thermostat Bulb insertion.
Thermostat Bulb Inserted into Copper Tube
15. Insert the new Thermostat Capillary Bulb into
the copper tube and secure with cork tape.
NOTE: Do not kink thermostat probe.
16. Reverse steps 1 through 8 to complete this
procedure.
17. Connect unit to its power source and test for
proper operation.
NOTICE: Technical support may request a fi lled
out checklist. A copy of the check list can be
found in the SUBWAY TRI-CHANNEL STEP
ONE TROUBLESHOOTING GUIDE section of
this manual.
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Service Manual for Subway Front Counters
Digital Thermostat
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Digital Thermostat
1. Disconnect the Tri-Channel unit from its power
source.
2. Remove the Louvered Panel and the Control
Panel.
3. Tag and disconnect the Digital Thermostat
wiring.
4. Remove the Digital Thermostat Probes from
the Evaporator Coil, which is located above
the Refrigeration Assembly.
5. Remove the Digital Thermostat from the
Control Panel by pushing in the tabs on the
mounting brackets.
6. Install the replacement Digital Thermostat.
NOTICE: Do not kink Digital Thermostat
probes.
7. Install the Digital Thermostat probes onto the
Evaporator Coil.
8. Refer to the tags to reconnect the Digital
Thermostat wiring.
9. Install the Control Panel and Louvered
Panel.
10. Connect the Tri-Channel unit to its power
source and check for proper operation.
Additional adjustment to the Digital Thermostat
may be required.
Capillary Tube
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
1. Disconnect the Tri-Channel unit from its power
source.
Tap Valve Installation
2. To properly recover refrigerant, install a Line
Tap Valve on High Process side tube, see the
illustration above.
Service Manual for Subway Front Counters
10
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.
4. Remove the insulation from the Suction Line at
the Compressor. Be careful, as the Accumulator
Insulation will be reused.
Un-brazed Drier – Condenser Side
NOTICE: Note the position of the Drier; the new
Drier must be installed in the same position. See
the illustration above.
5. Un-braze the Drier from the Condenser Outlet,
see the illustration above.
Un-brazed Suction Line
6. Un-braze the Suction Line from the Compressor,
see the illustration above.
NOTICE: Care should be given to support the
Condensing unit once out of the cage.
7. Slide the Condensing unit out of the cage as
far as possible.
8. Remove the insulation from each of the
Evaporator Inlets and the Suction Line at the
Manifold.
9. Cut each Evaporator Inlet Tube 1″ from the end
of the Capillary Tube. Cut the Suction Line 4″
from the Manifold.
10. Install the new Capillary Tube Assembly onto
Condensing unit.
CAUTION: A heat sink must be used
when brazing the suction line
at the manifold to ensure that
the thermostat bulb does not
overheat.
11. Reinstall the Condensing unit; braze the
Suction Line to the Compressor and the Drier
connection to the Condenser Outlet.
12. Leak check the system.
13. Re-insulate the Evaporator Inlets, Suction Line
and Accumulator.
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Service Manual for Subway Front Counters
14. Evacuate the system to 500 microns or
below.
NOTICE: Service Bulletin Number 26 can be
found in the SERVICE INFORMATION section
of this manual.
15. Charge system according to Duke
Manufacturing Service Bulletin Number 26.
Use 14 oz of R404A for SUB-CP-TC74 or 86
and 12 oz for SUB-CT-TC48 or 60.
16. Pinch off and braze the Process Tubes
shut.
17. Using the nylon zip ties provided with the
new Capillary Tube Assembly kit, secure the
Capillary Tube to avoid abrading.
Properly Secured Capillary Tube.
18. Secure the Capillary tubing to the Vapor tubing
closest to the Accumulator. This is necessary
to allow the Courtesy Loop to extend out for
future service.
Capacitor
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Some units may not have a Capacitor installed.
1. Disconnect the unit from its power source.
2. Remove the Lower Functionality Shelf on the
operator’s side of the unit.
3. Remove the Louvered Front Panel.
4. Remove the Control Panel Cover.
5. Disconnect the incoming power cord from the
faulty Capacitor.
Properly Installed Capacitor
6. Remove the faulty Capacitor from the Power
Switch
7. Reverse these procedures to install a
replacement Capacitor.
Service Manual for Subway Front Counters
12
Evaporator
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Evaporator Coil
The Evaporator Coils are embedded in the Upper
Body of the Tri-Channel Cold Pan. They cannot
be serviced or replaced. The entire Upper Body
must be replaced if testing indicates a leak in one
of the Evaporator Coils.
Condenser Cooling Fan
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Condenser Cooling Fan
The Condenser Cooling Fan is located in the
Compressor Assembly.
1. Disconnect the unit from its power source.
2. Remove the Lower Functionality Shelf.
3. Remove the front Louvered Panel.
4. Remove the Side Louvered Panel.
5. Tag and disconnect the Fan wiring.
6. Remove the Fan Mounting Bracket screws.
7. Carefully lift the Fan, Mounting Bracket and
Shroud out of unit.
8. Remove old Fan assembly from Mounting
Bracket.
9. Reverse this procedure to install a new Fan.
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Service Manual for Subway Front Counters
Refrigeration System
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Refrigeration Assembly
The Refrigeration Assembly is normally accessed
from the operator’s side of the unit. Always replace
the Refrigeration System (Condensing unit) with
the same type of unit that is currently installed.
1. Disconnect the unit from power source.
2. Remove the Lower Functionality Shelf.
3. Remove Louvered Vent Panel.
NOTICE: Service Bulletin Number 26 can be
found in the SERVICE INFORMATION section
of this manual.
4. Using a Refrigeration-Charging Unit, evacuate
refrigerant from the system according to Duke
Manufacturing Service Bulletin Number 26.
5. Remove expansion valve and evaporator
tubing from refrigeration assembly.
6. Remove Refrigeration Assembly mounting
hardware.
7. Tag and disconnect wiring at Junction Box.
8. Slide out Refrigeration Assembly through
vent.
9. Thoroughly clean the Refrigeration Assembly
Compartment.
NOTICE: Before installing the replacement
Refrigeration Assembly, pressure check Evaporator
Coils for leaks.
10. Install replacement Refrigeration Assembly
onto Slide Bars.
11. Slide in Refrigeration Assembly to original
position.
12. Install Refrigeration Assembly Mounting
Hardware.
13. Install the Expansion Valve and Evaporator
Tubing from Refrigeration Assembly.
14. Using tags, connect the wiring at the Junction
Box.
15. Connect unit to power source and test unit.
16 . Charge system according to Duke Manufacturing
Service Bulletin Number 26.
NOTICE: Service Bulletin Number 26 can be
found in the SERVICE INFORMATION section
of this manual.
17. Install Louvered Vent Panels.
Service Manual for Subway Front Counters
14
Recharging Refrigeration System – Duke
Service Bulleting Number 26
General
To analyze the performance of a refrigeration
system, temperature readings are recorded and
converted to pressure readings using a standard
pressure/temperature chart.
When it is necessary to service a factory sealed
refrigeration system and return it to its properly
sealed condition, strictly adhere to the following
approved procedure.
Tools
Standard hand and refrigeration tools
Refrigerant Type: R-404A
Charging Procedure
NOTE: Prior to refrigeration system service,
special care must be taken during the evacuation
process to remove air, moisture and other
non-condensables from the system. Duke
Manufacturing recommends the following
triple evacuation method. Failure to follow this
procedure may result in poor refrigeration system
performance.
1. Evacuate system to 1500 microns
2. Break vacuum to 2 psig with dry nitrogen. If
dry nitrogen is unavailable, use same type of
refrigerant as used in system.
3. Evacuate system to 1500 microns.
4. Break vacuum to 2 psig with dry nitrogen. If
dry nitrogen is unavailable, use same type of
refrigerant as used in system.
5. Evacuate system to 500 microns.
The system is now ready to receive refrigerant
charge according to information on data plate.
CAUTION: Never use oxygen or acetylene
in place of dry nitrogen or
refrigerant for leak testing. A
violent explosion may result
causing property damage,
personal injury or death. When
using nitrogen to pressure test,
always use a pressure regulator.
Failure to do so will result in
extremely high pressure of the
compressor or other system
components and result in
property damage, personal injury
or death.
NOTICE: Prior to repair, ensure there is enough
process hose (approximately 12”) present to
complete the repair using the above procedure.
If not, install a new process hose before repair
sequence.
1. Install a temporary access valve on the high
and low side of process hoses as close to
factory crimps as possible.
2. Use temporary valves to perform repair. Duke
Manufacturing will not reimburse the cost of
permanently installed valves.
3. After completing repair, evacuate system using
the triple evacuation method described in Duke
Manufacturing Service Bulletin Number 26.
4. After completing proper evacuation method,
recharge system, using proper refrigerant
according to information on data plate.
5. Continue crimping process hose just below
temporary valve and again 2” below crimp.
6. With crimp tool in place, remove temporary
valve.
7. Braze shut end of process hose.
8. Allow to cool for about 5 minutes.
9. Remove crimp tool.
10. Check brazed end for leaks.
15
Service Manual for Subway Front Counters
HOT FOOD UNIT
Infi nite Switch
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Operators Side of the Hot Food Unit
The Infi nite Switch is located on the operator’s side
of the unit. The Infi nite Switch is located directly
below the corresponding pan.
1. Turn off Hot Food Unit’s Power Switch and
disconnect the unit from its power source.
Control Box Removed
2. Remove the 5 screws that secure the Control
Box to the operator’s side of the unit.
3. Remove the 4 nuts that secure the Control
Panel to the Control Box.
NOTICE: Tag and disconnect the power cable
wires to allow for complete removal of the bottom
cover.
View of Infi nite Switch Wiring
4. Tag and disconnect the Thermostat wiring.
5. Remove the knob.
6. Remove the two screws that secure the
Thermostat to the panel.
7. Remove the switch from the back of the
panel.
8. Reverse this procedure to install the new
Infi nite Switch
Service Manual for Subway Front Counters
16
Indicator Lamp
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Indicator Lamp Location
1. Move the Infi nite Control to its OFF position.
Disconnect the unit from its power source.
2. Remove the 5 screws that secure the Control
Box to the operator’s side of the unit.
Inside of Panel – Indicator Lamp and Wiring
3. Remove the 4 nuts that secure the Control
Panel to the Control Box.
4. Disconnect the Indicator Lamp wiring from the
Thermostat.
5. Remove the Indicator Lamp assembly, which
is held in place by crimp springs.
6. Reverse this procedure to install a new
Indicator Lamp.
Heat Element
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Dome Element (see image: element support
clip for more details.)
The heat element is in the bottom of the open
well pan. These units use 500 WATT 120VAC
60Hz elements.
1. Ensure that the Infi nite Switch is in OFF position
and disconnect unit from power source.
2. Remove the screws that hold the Control Box
in place.
3. Remove the Control Panel from the Control
Box.
17
Service Manual for Subway Front Counters
4. Disconnect the Element Wires from the Infi nite
Switch.
5. Remove the Element Clip and mounting
screws.
6. Carefully pull the Element out of the pan.
7. Reverse this procedure to install a new Element.
Capacitor
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Some units may not have a Capacitor installed.
1. Ensure that the Thermostat is in OFF position
and disconnect unit from power source.
2. Remove the 5 screws that secure the Control
Box to the operator’s side of the unit.
3. Remove the 5 screws securing the Control
Box to the unit.
4. Tag and disconnect the wires connected to
the Capacitor.
5. Remove the faulty Capacitor.
6. Reverse this procedure to install a replacement
Capacitor.
Capacitor Connected to Thermostat
PURSE RAIL REPLACEMENT
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Purse Rail
Location of Purse Rail
The Purse Rail is located on the front of the unit.
It is attached to the Décor Panel. Required tools
include a cordless drill, 3 pound rubber mallet,
pencil, putty knife, 5/16″ nut driver, Phillips head
screwdriver or bit and a square head bit. The square
head bit is included in the new Purse Rail Kit.
1. Unplug the Purse Rail Lights from the duplex
box located on the Compressor cage inside
the unit.
2. Loosen the screws in the stainless steel top
that hold the Décor Panel in place.
Service Manual for Subway Front Counters
18
CAUTION: For front counters with curved
glass, these screws fasten the
glass extrusion to the top of
the front counters. Loosen the
screws above only one panel at a
time.
3. Lift up on the Décor Panel and pull the bottom
of the panel away from the front of the unit.
4. Remove the Décor Panel from the unit.
5. Place the Décor Panel face up on a padded
surface to prevent damage.
6. For Décor Panels with 110 Volt lights, pull the
light cord through the grommet hole in the
panel and go to step 10. For 220 Volt lights
go to step 7.
7. Place a piece of cardboard on the graphic where
the metal light clip is mounted and remove
the metal light clip with a Phillips head screw
driver.
Two Versions of Purse Rail Light Fixtures
8. Disconnect the light cord from the fi xture.
9. Remove the wire grommet from the cord and
feed the cord out of the Décor Panel.
10. Place a piece of cardboard near each of the
Light Cover mounting screws and remove the
screws with the 5/16″ nut driver.
11. Remove the Light Assembly from the Purse Rail.
12. Turn the Décor Panel over (face down) on the
padded surface.
13. Remove the Purse Rail mounting screws.
14. Mark the location of the Purse Rail with a pencil.
15. Remove the Purse Rail.
NOTICE: Use a putty knife working from one end
to loosen the silicone sealer. It may be necessary
to tap the Purse Rail with the rubber mallet to
break the silicone loose.
17. To avoid damaging the Décor Panel, very
carefully scrape off the dried silicone.
18. Refer to the pencil marks made earlier on the
Décor Panel and place a bead of clear silicone
within the marks.
19. Run a bead of clear silicone along the edge
of the new Purse Rail.
20. Align the new Purse Rail with the pencil marks
on the Décor Panel.
21. While holding the new Purse Rail in place,
screws into each end of the Purse Rail to
secure it to the Décor Panel.
22. Turn the Décor Panel face down and install
the remaining Purse Rail screws.
Light Assembly Centered on New Purse Rail
19
Service Manual for Subway Front Counters
23. Center and attach the Light Assembly onto the
Purse Rail ensuring that the front edge of the
Light Shield covers the laminate by ¼″.
NOTICE: For 220 Volt Light Fixtures, reattach the
power cord, cord grommet and light clip.
24. Remove excess silicone from the top of the
Purse Rail with a putty knife.
25. Reinstall the Décor Panel.
26. Plug in the light cord and test for proper
operation.
DAYCOVER
Daycover Bulb Gasket
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Daycover Gasket
The Daycover Gasket is located on the operator’s
side of the Daycover and provides a seal when
the Daycover is in the closed position.
1. Remove all food products from the unit.
2. Start at the center of the Door and peel the
old Bulb Gasket out of the channel by rolling
it towards the center of the door.
3. Once it is loose, work around the perimeter of
the Door, pulling the Bulb Gasket out of the
channel.
NOTICE: Do not stretch the Bulb Gasket while
pressing it into place.
4. To install the new Bulb Gasket, start at the
corner, press the dart side of the Bulb Gasket
into the channel.
5. Continue along the perimeter of the Door.
Service Manual for Subway Front Counters
20
Gas Damper and Gas Shock Replacement
WARNING:
THE POWER MUST BE TURNED OFF
AND DISCONNECTED AT ALL TIMES
DURING MAINTENANCE OR REPAIR
FUNCTIONS.
Location of Gas Dampers and Gas Shocks
Each Daycover requires 4 Cylinders (2 Shocks
and 2 Dampers).
CAUTION: Gas damper cylinders and gas
shocks are under pressure. Best
practice is to remove these parts
in the full extended position.
1. Remove all food products from the unit.
NOTICE: If Gas Shocks are being replaced,
raise the Door to its full open position. If the Gas
Dampers are being replaced lower, the Door to is
fully closed position.
2. Ensure that the Gas Damper or Gas Shock to
be replaced is in extended position.
Gas Damper or Gas Shock Cap Opened
3. Using a fl at head screwdriver, pry the Gas
Damper or Gas Shock Lock Caps open.
4. Using a fl at head screwdriver, pry the Gas
Damper or Gas Shock off its Mounting Ball
at one end.
5. Repeat step 4 on the other end of the Gas
Damper or Gas Shock.
Lock
Cap
Post
Cylinder
End
Cylinder End Installed
6. A: When replacing Gas Shocks, press the
cylinder end of the Gas Shock onto the post
on the Door and insert the Lock Cap.
B: When replacing Gas Dampers, press the
cylinder end of the Gas Damper onto the post
on the Door Cover Pillar.
NOTICE: For ease of installation, completely
remove the Lock Cap from the piston end of the
Gas Shock.
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