operator's manual - electro freeze · operator's manual with illustrated parts list twin...

H.C. Duke & Son, Inc. P/N 184662 May 1998 Printed in U.S.A.

OPERATOR'S MANUALwith ILLUSTRATED PARTS LIST

TWIN TWISTSOFT SERVE FREEZER

MODEL 957R184662 - 5/98

ii

DUKE Model 957R Soft Serve Freezer

SAFETY FIRST!

Follow these four steps to safety ....

WARNING

DANGERDANGER

When you see this symbol on your 957R or in thismanual, be alert to the potential for personal injury.Follow recommended precautions and safe operatingpractices.

The signal words — DANGER, WARNING and CAU-TION — are used with the safety alert symbol. (DAN-GER decals on the freezer may or may not have thesafety alert symbol, but the message is the same.)Decals with the words DANGER, WARNING, or CAU-TION appear on the 957R. DANGER identifies themost serious hazard. Decals with the words DANGERor WARNING are typically near specific hazards onthe 957R. General precautions are listed on CAUTIONsafety decals.

In this manual, CAUTION messages with the safetyalert symbol call attention to safety messages.

CAUTION

1. Recognize Safety Information ....Look for thissafety alert symbol throughout this manual.

2. Understand Signal Words ....

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SAFETY FIRST!

3. Follow Safety Instructions ....

4. Operate Safely ....

Read and understand all safety messages in thismanual and on your 957R. Take notice of the locationof all decals on the 957R and keep the safety decalsin good condition. Check them periodically and re-place missing, damaged, or illegible safety decals.The safety decals must remain in place and legible forthe life of the 957R. If you need new decals, use theinformation and illustrations on pages iv and v of thismanual to identify the decal and call or write to H.C.Duke & Son, Inc.

DO NOT attempt to operate the 957R Twin Twist SoftServe Freezer until you read and understand all safetymessages and the operating instructions in thismanual.

DO NOT allow untrained personnel to maintainand/or service this machine. Failure to follow thisinstruction may result in severe personal injury.

DO NOT operate the 957R until all service andaccess covers are secured with screws. DO NOTattempt to repair or maintain the 957R until themain power supply has been disconnected. Somefreezers have more than one disconnect switch.Contact your IDQ authorized service representa-tive or H.C. Duke & Son, Inc. Service Departmentfor original equipment parts.

v


Safety Decal Locations

WARNING!Hazardous moving parts.Machine starts automatically.Do not operate with panelremoved.

P/N 165126

P/N 165025

1Before removing dispense head:1. Turn all control switches to "OFF", and2. Disconnect all power supplies. Unit mayhave more than one power supply.

Hazardous rotating beater shaft. Do notoperate unit with dispense head removed.

2

iv


1 p/n 165025 Decal—Beater Warning (1)

2 p/n 165126 Decal—Panel Removal Warning (3)

Do not attempt to operate the freezeruntil all safety precautions and operatinginstructions in this manual are read andunderstood.

Take notice of all warning, caution,instruction and information decals (orlabels) on the freezer as shown in thefigure on the next page. The labels havebeen put there to help maintain a safeworking environment.

The labels have been designed towithstand washing and cleaning. Alllabels must remain legible for the life ofthe freezer. Labels should be checkedperiodically to be sure they can berecognized as warning labels.

If it is necessary to replace any label,please contact International Dairy Queen(IDQ), Inc. When ready to order you willneed to determine the (1) part number,(2) type of label, (3) location of label, and(4) quantity required, and include a returnshipping address.

You may contact IDQ as follows:

International Dairy Queen, Inc.P.O. Box 35286Minneapolis, Minnesota 55437

(800) 285-5653

or — for factory service assistance —contact H. C. Duke & Son, Inc., ServiceDepartment by phone or FAX:

Phone: (309) 755-4553FAX: (309) 755-9858

(The decals on the next page are num-bered 1 and 2. Those numbers corre-spond to the numbers in the table below.The table provides the part number,description, and quantity for each decal.)

Safety Decal Locations

No. Part No. Description (Qty.)

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TABLE OF CONTENTS

SAFETY ............................................................................................................... i

SAFETY DECAL LOCATIONS ............................................................................. iv

PART 11 INTRODUCTION ....................................................................................... 1

2 NOTE TO INSTALLER ............................................................................... 1

2.1 Uncrating and Inspection ................................................................... 1

2.2 Installation ......................................................................................... 2

2.3 Electrical Requirements ..................................................................... 3

2.4 Electrical Connections ....................................................................... 3

3 SPECIFICATIONS ..................................................................................... 4

3.1 Particulars.......................................................................................... 4

3.2 Dimensions ......................................................................................... 4

3.3 Data Plate........................................................................................... 4

4 PART NAMES AND FUNCTIONS ............................................................... 6

5 OPERATOR CONTROLS ........................................................................... 8

6 DISASSEMBLY AND CLEANING ............................................................. 11

6.1 Cleaning Accessories ...................................................................... 12

6.2 Disassembly Instructions ................................................................. 12

6.3 Cleaning Instructions ....................................................................... 14

7 ASSEMBLY ............................................................................................ 17

vii


8 STARTUP INSTRUCTIONS...................................................................... 19

8.1 Sanitizing .......................................................................................... 19

8.2 Priming ............................................................................................. 20

8.3 Dispensing Product .......................................................................... 22

9 CLOSING PROCEDURES........................................................................ 23

10 GENERAL INFORMATION....................................................................... 24

10.1 Dairy Queen Mix .............................................................................. 24

10.2 Checking the Frozen DQ Product. .................................................. 24

10.3 Product Temperature ..................................................................... 25

10.4 Overrun .......................................................................................... 25

10.5 Overrun Adjustment ....................................................................... 26

10.6 Rerun ............................................................................................. 26

10.7 Overrun Chart ................................................................................ 27

11 ROUTINE MAINTENANCE ....................................................................... 28

12 TROUBLESHOOTING TABLES ............................................................... 31

PART II

MODEL 957R REPLACEMENT PARTS w/ ILLUSTRATIONS ............................................ *

*Refer to Part II Table of Contents for help with locating part numbers and illustrations.

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2 Note to Installer

This freezer must be installed and serviced by an authorized service techni-cian in accordance with the Installation Instruction manual.

1 Introduction

The 957R Freezer is designed toproduce DQ soft serve ice cream orDQ frozen yogurt, with a productserving temperature of 18 to 19ºF (-8to -7ºC). Use of other products in thismachine is considered misuse (seeWarranty.)

This manual has been prepared toassist in the training of personnel onthe proper operation and generalmaintenance of your Duke freezer.

Your freezer will not compensate foror correct any assembly or primingerrors made during the initial start-up. Therefore, it is extremely impor-tant to follow the assembly andpriming procedures detailed in thismanual.

Name ______________________

Address_____________________

____________________________

Phone_______________________

or H.C. Duke & Son, Inc. Service Dept. forfactory service assistance.

Phone number: (309) 755-4553

Fax number: (309) 755-9858

Make sure all personnel responsiblefor equipment operation completelyread and understand this manualbefore operating the freezer. Whenproperly operated and maintained,your freezer will produce a consis-tent quality product.

If you require technical assistance,please contact your local authorizedH.C. Duke & Son, Inc. service com-pany:

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Figure 2-1 Machine bolted to Shipping Base Figure 2-2 Installing Mounting Legs

2.1 Uncrating and Inspection

CAUTIONBe sure to properly supportthe machine when removingbolts and installing legs orcasters.

When the unit is received and while thecarrier is still present, inspect the shippingcarton for any damage that may haveoccurred in transit. If the carton is broken,

torn, or punctured, note the damage on thecarrier’s freight bill and notify the carrier’slocal agent immediately.

1. Remove the carton from the pallet, andmove the machine as close as possibleto the permanent location.

2. Remove the shipping bolts on thebottom of the freezer (figure 2-1) andinstall either the legs or casters (figure 2-2).

CAUTIONAll materials and connections mustconform to local requirements andbe in compliance with the NationalElectrical Code (NEC).

1. Where codes permit, we recommendthat you install the freezer on castersand have flexible water and electricalconnections for service and cleaningability.

2. Air-cooled models require a minimum6-inch clearance on the rear panel foradequate ventilation.

3. Water cooled double head modelsrequire a minimum 6-inch clearanceon the rear panel for adequateventilation. Water-cooled models willrequire a 1/2" MPT water inlet andwater waste connection. Bothcondensers are tied together so thatone water inlet and one water wasteare all that is required. The connec-

2.2 Installation

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2.2 Installation (continued)

tions are found on the back panel andare clearly tagged - “Water Inlet" and"Water Waste". A manual shut-off valveshould be installed in the water inletline at the time of installation.

4. Place the freezer in the final locationand level the machine by adjusting thelegs or casters so that the unit is levelside-to-side, and the front is approxi-mately 1/4" lower than the rear. Thiswill allow proper drainage of thefreezing cylinder.

2.3 Electrical Requirements

2. Supply voltage must be within + 10%of voltage indicated on nameplate.Also, on three-phase systems, voltagebetween phases must be balancedwithin 2%. (More than a 6 volt differ-ence between any two voltage mea-surements at 208-230 volts indicates apossible imbalance.) Request localpower company to correct any voltageproblem.

3. An easily accessible main powerdisconnect must be provided for allpoles of the wiring to the freezer.

2.4 Electrical Connections

CAUTIONTo prevent accidental electricalshock, a receptacle with apositive earth ground isrequired.

1. Double freezers with two compressorsrequire one power supply for each sideof the freezer. Each side of the freezeroperates independently.

2. Check the data plate for fuse size,wire ampacity and electrical specifica-tions.

3. Refer to the wiring diagram provided forproper power connections.

CAUTIONTo prevent accidental electricalshock, a receptacle with apositive earth ground isrequired.

1. Always verify electrical specificationson the data plate of each individualfreezer. Data plate specifications willalways supersede the information inthis manual.

4. Electrical connections are made in thejunction box(es) located mid-levelbehind the back panel.

5. Use dual element fuses, rated at 25%over the full load amperage (FLA)rating of the freezer. Refer to the dataplate on the rear panel. As mentionedbefore, all double head machinesshould be wired and fused as indi-vidual units. Use a flexible connectionwhen permissible. All materials andconnections must conform to localcodes and/or the National ElectricalCode.

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3 Specifications

Always check and verify voltage and amperage on the dataplate located on the back panel of each freezer.

957R

Width-in./cm 16/40.6

Height-in./cm 58/147.3

Depth-in./cm 36/91.4

Weight-lbs./kg 680/308.4

Compressor 2 H.P. /9500 (BTUH)

1.5 kw (Motor)

2.8 kw (Cooling)

Beater Motor 2 H.P/1.5 kw

Refrigerant 404a

Charge 3.75 lb/1.70 kg

Cylinder 4 Qts./3.8 Liters

*Contact factory for other voltages.

3.1 Particulars

Figure 3-1

3.2 Dimensions

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Write inReference Informa-tion HERE!

3.3 Data Plate

The data plate provides important information thatthe operator should record and have available forparts ordering, warranty inquiries, and service re-quests. Fill in the following information below assoon as you receive the 957R. (The item num-bers—encircled, below—correspond with thecallout numbers above.)

IMPORTANT: Complete for reference:

1 Model Number: _______________

2 Serial Number: _______________

3 Electrical Spec: Voltage ______

Phase _______ Hertz ________

4 Minimum Circuit Ampacity: __________

5 Maximum fuse size: _____________

Installation Date ________________

Installed by ______________________

Address ________________________

_______________________________

Phone __________________________

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4 Part Names and Functions

6 KNOB - HANDSecures the head to the freezing cylinder.

7 EXTENSION - SPIGOT (Accessory)Extends the product opening downto aid in forming and shapingproduct.

8 O-RING - HEADSeals the head to the freezingcylinder. Must be lubricated.

9 PLUG - AIR RELIEFSeals the air relief opening in the headwhen closed. Allows excess air to beremoved from the cylinder when priming.

10 O-RING - PLUG

1 HEADEncloses the freezing cylinder andprovides an opening for product tobe dispensed.NOTE: Beater Motors will notoperate with the head removedfrom the freezer.

2 SPIGOT ASSEMBLYSeals the product opening in the headwhen closed. Allows product to flow whenopen.

3 O-RING - SPIGOTSeals the spigot in the head. Must belubricated to seal and slide properly.

4 O-RING - SPIGOT EXTENSIONHolds the extension on to thespigot.

5 ROD - SPIGOTStarts the freezer when dispensing.Must be in place before freezer willoperate.

Figure 4-1

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14 SEAL - SHAFTSeals the opening between the freezingcylinder and the beater shaft. Do notlubricate rubber cup portion.

15 O-RING-SEALSeals the beater shaft to the shaft seal.Is inserted into the seal bushing. Mustbe lubricated.

16 REMOTE MIX TRANSFER (RMT)SYSTEM with Shelf (Accessory)Transfers mix and air from cooler to thefreezing cylinder. See (RMT manual.)

Part Names and Functions (cont’d)

11 SHAFT - BEATERRotates in the freezing cylinder, blendingair and mix and ejecting product.

12 BUSHING - CYLINDERHolds the beater in place at thefront of the cylinder.

13 BLADE - SCRAPERScrapes the frozen product from the

freezing cylinder wall.

16

Figure 4-3 Duke Remote Mix Transfer System (RMT)

Figure 4-2 Beater Shaft

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5 Operator Controls

A. “CLEAN” (Left Position) - Thisposition operates the beater only(no refrigeration). Always use thisposition for cleaning and sanitizingprocedures.

B. “OFF” (Center Position) - In thisposition the beater motor andrefrigeration system will not oper-ate.

5.1 Selector Switch 1

C. “AUTO” (Right Position) - Thisposition activates both the beatermotor and refrigeration unit. This isthe normal operating position.

IMPORTANT:DO NOT use the AUTO position withwater or sanitizer in the cylinder. Thefreezer will be damaged.

Figure 5-1

CAUTIONTest operation of the headswitch prior to placing thefreezer in service. SeeSection 11, RoutineMaintenance, Monthly.

The following paragraphs describe theoperator controls and indicators. Refer tofigure 5-1 for location of these controlsand indicators on the freezer.

NOTE: The head must be in place beforethe beater will operate.

This three-position switch controls the functions of your freezer.

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5.2 Pump Switch 2

Although this dial thermometer is notmeasuring actual product temperature, itshould be observed for its normal oper-ating reading. It should read 5° to 15°F

This control will bypass the thermostat,forcing the compressor and beater motorto run for approximately 3 minutes. Usethe timer for quick start-ups or fastrecovery when dispensing large por-tions.

This two-position switch controls the operation of the mix pump located in the walk-incooler. Pump must be plugged into the receptacle located on the back panel of thefreezer.

A. “ON” (Left Position) - Use thisposition to fill the cylinder with mixor sanitizer when the freezer is inthe normal operating mode and/orwhen removing product from thecylinder.

B. “OFF” (Right Position) - In thisposition the pump will not operate.

(-15° to -9°C) when product is beingdispensed at 18°F (-8°C).

5.3 Reset - Overload 3

5.4 Timer 4

5.5 Thermometer 5

IMPORTANT:Excessive use of the timer causesfreeze-up and damage to the freezer.

Operator Controls (continued)

This control protects the beater motoragainst failure from an overload conditionby automatically shutting down thefreezer. To restart properly, turn theselector switch to the "OFF" position,wait 2-3 minutes, then depress the redreset button and turn the selector switchback to the "AUTO" or "CLEAN" position.Repeat as needed until beater motorrestarts.

IMPORTANT:If the overload trips frequently, yourfreezer should be checked for properproduct temperature, overrun, andvoltage. Contact H. C. Duke & Son,Inc. or your authorized service center.

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Important:Do NOT USE these outlets for anyequipment requiring more than 15amps. If power for these outlets isobtained from a neutral and one leg ofpower from the freezer, do not usethese outlets for equipment requiringmore than 5 amps.

This is a 115v receptacle provided for mix pumps or spindles.

5.7 Outlet 7

Operator Controls (continued)

A. Amber — this light indicates thebeater motor is operating.

5.6 Pilot Lights 6

B. Red — this light indicates thecompressor is operating.

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CAUTIONMake sure freezer isdepressurized beforeproceeding.

Safety InformationThis freezer uses pressure to assureconsistent product quality. It is importantfor your safety that the freezer is depres-surized slowly and completely wheneverthe freezer is to be drained, disas-sembled, cleaned, or serviced. Thesafety instructions in this manual willremind you when to check to make surethe freezer is depressurized. When yousee this CAUTION statement

the following steps should be taken:

1. Make sure both pump switches andboth selector switches are in the“OFF” position.

2. Place a clean bucket under the dis-pense head.

3. Slowly open the spigots by pullingright to left each of the dispensehandles, allowing any pressurizedproduct, cleaning solution, or air toescape.

4. Open the spigots completely by pullinghandles fully to the left.

Following these steps will assure that thesystem is depressurized.

6 Disassembly and Cleaning

CAUTIONTo avoid electrical shock orcontact with moving parts,make sure all switches arein the “OFF” position andthe main power supply isdisconnected. Somefreezers have more thanone disconnect switch.

It is important that the freezer bedisassembled, washed, lubricatedand sanitized before operation.

The cleaning and sanitizing instructionsexplained in this manual are required tomaintain a clean, sanitary freezer. IDQrequires that the freezer be disas-sembled, cleaned, reassembled, lubri-cated and sanitized daily to ensure thebest possible product quality and freezeroperation.

Persons assembling, cleaning, or sanitiz-ing the freezer must first wash andsanitize hands and forearms with anapproved sanitizer.

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6.2 Disassembly Instructions

Figure 6-1 Head Assembly(ACCESSORY)

5. Brush, 1/4 inch diameter with 6-1/2inch handle: used to clean air meterhose.

6. Lubricant, Lubri-Film: approvedlubricant for moving parts and O-rings.

7. Kit, O-ring: contains all O-rings andseals needing replacement on aregular basis.

8. Sanitizer, Sample: approved sani-tizer, Stera-Sheen, also available in 4lb. jar.

6.1 Cleaning Accessories

1. Hose, Spigot Drain: attaches to spigotfor draining product into bucket.

2. Brush, Cylinder, 4 inch diameter with36 inch handle: used to clean thecylinder.

3. Brush, 7/16 inch diameter with 12 inchhandle: used to clean transfer hose,braided hose, and pickup tube.

4. Brush, 9/16 inch diameter with 36 inchhandle: used to clean drain tube.

The following accessories shipped with the freezer are necessary for cleaning,sanitizing, and disassembly/assembly:

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— continued

CAUTIONTo avoid electrical shock orcontact with moving parts,make sure all switches are inthe “OFF” position and themain power supply isdisconnected. Some freezershave more than onedisconnect switch.

CAUTIONMake sure freezer isdepressurized beforeproceeding.

CAUTIONTo prevent bacteria growth,remove ALL O-rings whendisassembling for cleaning.Failure to do so couldcreate a health hazard.

1. If there is product in the freezer,refer to Closing Procedures,Draining Product.

2. Remove the spigot rods by liftingup and swinging the bottom outand down. Remove hand knobsand pull the dispensing headstraight out. (See figure 6-1.)

3. Remove the cylinder bushings andbeater shafts from the cylinders.Then remove the scraper bladesand shaft seals from the beatershafts. (See figure 6-2.) Removethe drip tray and insert.

4. Remove the cup seals and O-ringsfrom the bushings on the shaft sealassemblies. (See figure 6-3.)

5. Remove the spigot assemblies, airrelief plugs, and O-rings from thehead and spigot assemblies.

6.2 Disassembly Instructions - continued

FIgure 6-3

FIgure 6-2

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CAUTIONElectrical shock hazard. Donot splash water onswitches or allow water toflow onto electricalcomponents inside themachine.

CAUTIONTo prevent bacteria growth,remove ALL O-rings whendisassembling for cleaning.Failure to do so couldcreate a health hazard.

NOTE: It is your responsibility to beaware of, and conform to, the require-ments for meeting federal, state andlocal laws concerning the frequencyof cleaning and sanitizing the freezer.

1. Prepare a three compartment sinkfor washing, rinsing, and sanitizingparts removed from the freezer, perapplicable local health codes. Alsoprepare a clean surface to air-dryall parts.

Important:Do not use unapproved sanitizer orlaundry bleach. These materials maycontain high concentrations of chlo-rine and will chemically attack freezercomponents.

NOTE: The sanitizer should be mixedaccording to the manufacturer’s instruc-tions to yield 100PPM available chlorinesolution (example: Stera-Sheen GreenLabel.) Use warm water (100° to 110°For 38° to 43°C) to wash, rinse, andsanitize.

FIgure 6-4

6.3 Cleaning Instructions

FIgure 6-5

— continued

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— continued

FIgure 6-6

Figure 6-7

6.3 Cleaning Instructions (continued)

2. Wash all parts removed from thefreezer thoroughly with dish deter-gent soap. Clean the followingparts with the appropriate suppliedbrush:

a. The mix containers, hoses, andbag adaptors (if used).

b. The dispense head spigotopenings, center spigot ports, O-ring grooves, dispense nozzles,and mix ports. (Figure 6-4)

c. The shaft cup seals, bushings,and O-rings, spigot O-ring grooves(Figure 6-5), and any nozzles orextensions used. (Figure 6-4)

d. The air relief plug O-ringgrooves.

e. The beater shaft and the scraperblade pin holes. (Figure 6-7)

Important:Do not leave parts in sanitizer formore than 15 minutes.

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Figure 6-8

Figure 6-9

Replace worn brushes. Useonly original or authorizedreplacement parts. See Ac-cessories Parts list in Part IIof this manual to order new

brushes.

6.3 Cleaning - continued

3. After all parts are washed, rinseand then place them in the sani-tizer solution. For proper sanitizing,the parts must remain fully im-mersed in the sanitizer for 5minutes. Allow parts to air-dry aftersanitizing.

4. Use the sanitizing solution andbrush to thoroughly brush the mixfeed tubes, from the top of thetubes to the cylinders as shown infigure 6-8. Also, brush both ends ofthe mix feed hose.

5. Brush the inside of the cylinders,making certain to clean back walls.

6. Brush the inside of the drain tube,as shown in figure 6-9. Dip thebrush in clean water and force intothe tube until it stops. Repeat untilclean.

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7 Assembly

Figure 7-1

Figure 7-2

Figure 7-3

— continued

Correct assembly of the freezer is essen-tial to prevent leakage of the product anddamage to the freezer. To assemble thefreezer you will need an approved lubri-cant (such as Lubri-Film). Make sure allparts of the assemblies have beenwashed and sanitized before assembling.Persons assembling the freezer mustfirst wash and sanitize their hands andforearms with an approved sanitizer.

CAUTIONTo avoid electrical shock orcontact with moving parts,make sure all switches arein the “OFF” position andthat the main power supplyis disconnected. Somefreezers have more than onedisconnect switch.

1. To assemble the shaft seal, installthe cup seals and O-rings on thebushings. Apply a moderate amountof approved sanitary lubricant (suchas Lubri-Film) to the O-ring and theface of the plastic bushings oppositethe bell portion of the seals. Do notallow any lubricant to come in con-tact with the bell-shaped rubberportion of the seals. (Figure 7-1)

2. Install the shaft seals over the rear ofthe beater shafts, with the bell-shaped portion facing the rear.

3. Place the scraper blades on thebeater shafts, making sure theblades are installed properly. (Figure7-2) Proper blade installation isshown at right, with the flat side ofthe blade against the cylinder wall.(Figure 7-3)

4. Insert the assembled beater shaftsinto the cylinders by placing the rearblades on the bottom of the cylin-ders. This will center the beaters andallow alignment with the drivecouplings. Rotate the beater assem-blies while pushing, until the shankhas engaged the couplings.

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Figure 7-4

(ACCESSORY)

5. Lubricate the inside surface of thecylinder bushing and place it on theend of the beater shaft assembly.The bushing will slide on one wayonly.

6. Install and lubricate the O-rings(see O-ring chart, last page) on thedispensing spigots and insertspigots into the head. Check byturning the spigots side-to-side,making sure they move freely.

7. Install and lubricate the 4" head O-rings.

8. Install and lubricate the O-rings onthe air relief plugs. Insert the plugsin the head assembly.

IMPORTANT:ALWAYS make sure the cylinderbushing is positioned on the beatershaft properly. Operating the freezerwith a missing or badly worn bushingwill damage the beater and cylinder.

9. Install the dispensing head onto thefreezer by aligning the studs withthe holes in the head and slidingtoward the freezer. Finger-tightenthe hand knobs evenly.

IMPORTANT:Excessive force will damage the head.Do not use tools to tighten.

10. Install the spigot rods. If usingyogurt, install the nozzles on themix outlet at the bottom of thespigot before sanitizing.

11. Assemble and lubricate RMT asoutlined in the manual.

Assembly - continued

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8 Start-up Instructions

NOTE: It is your responsibility to be awareof, and conform to, the requirements formeeting federal, state and local laws con-cerning the frequency of cleaning and sani-tizing the freezer.

IMPORTANTNever let the sanitizer remain in thefreezer for more than 15 minutes.

— continued

8.1 Sanitizing

CAUTIONTo prevent bacteria growth,use only approvedsanitizers to sanitize themachine. Sanitizing must bedone just prior to startingthe machine. Failure to doso could create a healthhazard.

The washing and sanitizing instructionsexplained in this manual are importantprocedures to remove bacteria andmaintain a clean, sanitary freezer. IDQrequires that the soft serve freezer bedisassembled and washed daily accord-ing to the instructions in the manualbefore sanitizing to insure the bestpossible cleanliness.

IMPORTANT:Do not use unapproved sanitizer orlaundry bleach to clean or sanitizeyour freezer. These materials maycontain high concentrations of chlo-rine and will chemically attack freezercomponents.

CAUTIONThe RMT will bepressurized duringoperation. Make sure allcomponents and fastenersare secure before start-up.

1. Prepare 4 gallons (15.2 liters) ofsanitizing solution for each cylinder.Sanitizing solution must be mixedaccording to manufacturer’s instruc-tions to yield 100 PPM strengthchlorine solution (example: Stera-Sheen Green Label). Use warmwater (100° to 110°F or 38 to 43°C)to wash, rinse, and sanitize.

2. Clean the interior mix containerwalls and the underside of thecontainer covers with sanitizingsolution and the appropriate brushprovided.

3. Insert the pickup tubes into thesanitizing solution and clean theoutside portion. If plastic mix bagsystems are used, be sure alladaptors and items that will come incontact with mix are sanitized.

4. Place an empty container under thedispensing head.

5. Open the spigots and the air reliefplugs by lifting up until the plugstouch the bottom of the switch box.

6. Reconnect the main power suppliesto the freezer. Turn the pump switchto “ON”. This will push the sanitizerup into the cylinders.

7. When the sanitizing solution flowsout the spigot, leave open for 2minutes. Then close the spigot.

8. When sanitizer flows out the bottomof the head, close the air relief plug.

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8.1 Sanitizing (continued)

1. Holding the top 6” portion only,insert the pickup tubes into thesanitized mix containers.

2. Fill the mix containers with mix.Install covers.

3. Insert the pressure relief tube inthe sanitized container.

4. If a multiple hookup of "Bare Bag-In-Case" is used, the pumpingarrangement must be as shown infigure 8-2, with one case stackedlower than the others and all hosesapproximately the same length.

5. Place an empty container on thedrip tray under the dispensinghead.

6. Open the spigots and air reliefplugs.

7. Turn the pump switches to "ON"and allow the mix to push theremaining sanitizer from the tubingand freezer.

8. Close the spigots when pure mix iscoming out.

Priming the freezer removes excess air from the freezing cylinder and sets the properoverrun for the first cylinder of product. To prime the freezer, follow these steps:

8.2 Priming

Figure 8-1

— continued

11. Leaving the spigots open, turn theselector switches to the “OFF”position. Leave the pump switchesin the “ON” position and allow thepump to push all remaining sani-tizer out of the freezing cylinder.When the sanitizer quits flowing,turn the pump switch to the “OFF”position.

NOTE: Some sanitizer will remain inhoses and cylinders.

12. Turn the pump switches to “OFF”.

13. Remove the pickup tubes, holdingthe top 6” portion only.

14. Remove the mix containers andempty any remaining sanitizer.

IMPORTANT:DO NOT use the “AUTO” positionwith sanitizer in the cylinder. Thefreezer will be damaged.

9. Turn both selector switches to“CLEAN” and allow the beaters torun for 10 minutes. At this timecheck for leaks around the head,drain tube, clamps and pumps.

10. Slowly open and close the spigotten times. Open the spigot andallow the pump to push the sani-tizer out of the cylinder.

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Figure 8-2 “Bag-in-Box” setup

8.2 Priming (continued)

IMPORTANT:Failure to completely remove sanitizeror water from the freezing cylinderbefore placing in "AUTO" will damagethe freezer.

9. Wait 40-45 seconds for "DairyQueen" mix (30-40 seconds foryogurt mix), then close the air reliefplugs and wait for the pumps to fillthe cylinders and shut off.

10. After the cylinders are pressurizedand the pumps have cycled off, turnthe selector switches to "AUTO".

11. Allow the freezer to cycle for 15minutes. The product should now beready to serve.

12. The product temperature should be18°F (-8°C) and have an overrun of40-45%. If the temperature is incor-rect by only a small margin, (lessthan 2°F or 1°C) allow the machine afew extra minutes to regulate itself.

13. If the overrun is incorrect (see sec.10.4), do not make any adjustmentsuntil another reading has been madeafter one full cylinder of mix hasbeen served. Overbleeding orunderbleeding of the air through theair relief plug can cause slightlyincorrect overrun for the first cylinderof product. Also see Section 10,General Information.

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8.3 Dispensing Product

5. For shakes, large sundaes, floats andother similar products, this practice ofdrawing off a small amount into aseparate container is not necessaryand should be discouraged.

6. Observe the level of mix throughoutthe day to avoid running out ofproduct in the mix containers or bags.

7. Periodically check the temperatureand overrun of product (see section10.3, 10.4) and make sure it is withinthe specified limits.

IMPORTANT:If proper mix level is not main-tained, a freeze-up may occur andcause damage to the freezer.

1. To dispense product, grasp the spigothandle, hold the container which is tobe filled with product below the spigot,and slowly open the spigot untilproduct is dispensed at a comfortablerate.

2. When the proper portion has beendispensed, close the spigot.

3. The freezer will continue to run a shorttime (approximately 12 seconds)following the dispensing of theproduct. If a large portion has justbeen dispensed, a longer period oftime may be required for the freezer toshut off.

4. If the freezer has not been used formore than two and a half minutes,and the product requires a firm base,then a small amount of mix in thespigot must be drawn into a separatecontainer.

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9 Closing Procedures

To remove frozen product from the cylinder(s):

1. Place the selector switches in the"CLEAN" position.

2. Let the beaters run for 5 minutes. Thiswill allow the product in the cylinders tosoften.

3. Place a clean, sanitized containerunder the dispensing nozzles.

4. Remove the pickup tubes from the mix.

5. Very slowly open the spigots anddispense the semi-frozen product untilit quits. Use this product for makingpints, quarts, and/or novelties.

6. Close the spigots and place the pickuptubes into a container of warm water,allowing the pumps to fill and pressur-ize the cylinders.

7. Very slowly dispense the warm water.Repeat until the dispensed water isclear.

8. Drain off the warm water and place theselector switches and pump switchesin the “OFF” position.

9. Prepare 4 gallons (15.2 liters) ofsanitizing solution for each cylinder.Sanitizing solution must be mixedaccording to manufacturer’s instruc-tions to yield 100PPM available chorinesolution (example: Stera-Sheen GreenLabel). Use warm water (100-110°F or38 to 43°C) to sanitize.

10. Insert the pickup tubes into the sani-tizer solution.

11. Open the spigots and open the air reliefplugs by pulling up until the plugs

9.1 Draining Product

At the end of each day of operation, the freezer must be rinsed and disassembled. The partsmust be washed, rinsed, sanitized, and prepared for reassembly.

touch the bottom of the switch box.Place the pump switch in the “ON”position. When sanitizer flows out thespigot, leave open for 2 minutes, thenclose the spigot. When sanitizer flowsout the bottom of the head, close theplugs and allow the cylinders topressurize.

Important:Do NOT use the “AUTO” position withsanitizer or water in the cylinder. Thefreezer will be damaged.

12. Place the selector switch in the“CLEAN” position and allow the beaterto run for 10 minutes.

13. Slowly open and close the spigots tentimes. Open the spigots and allow thepump to push the sanitizer out of thecylinder. Leaving the spigots open,turn the selector switches to the“OFF” position.

14. Leave the pump switches in the “ONposition and allow the pumps to pushall remaining sanitizer out of thecylinders. When the sanitizer quitsflowing, turn the pump switches to the“OFF” position.

CAUTIONMake sure freezer is depres-surized before proceeding.

15. Refer to Disassembly and CleaningInstructions.

24 184662


10 General Information

10.1 Dairy Queen® Mix

10.2 Checking the Frozen DQ® Product

like silk. If the product appears "wet" or"slick" then it is usually an indication thatthe temperature is too high. If the productappears pockmarked and soft, it may be anindication of too much overrun. If theproduct appears grainy and hard, it is anindication of either too low overrun or toolow temperature.

In any of the above cases, always measuretemperature and overrun to see if they fallinto normal operating ranges.

Two measurements of product consistencyare temperature and overrun. Severalobservations can be made by looking at andtasting the product, but actual measurementof temperature and overrun provides preciseinformation concerning the condition of theproduct being served and the operation ofthe freezer and the pump.

Standard Dairy Queen® product should bebetween 17° and 18.5°F (-8° and -7°C).It should have an overrun of 40 to 45%. Itsappearance should be dry and appear much

1. Standard approved Dairy Queen® mixweight is approximately 9.25 lbs. pergallon (1.1 kilograms per liter).

2. The mix, when delivered, should be:

a.at a temperature of no more than40°F (4.4°C).

b.displaying no separation such asclear or semi-clear liquid layer on top.

c.nearly free of foam in a freshlyopened container.

3. Mix should be used within seven daysfrom the date of delivery and shouldnot be over seven days old whendelivered.

4. Store mix at a temperature of 35° to38°F (2 to 3°C).

5. Check both taste and smell of mix,and thoroughly stir or agitate mix priorto use. Make sure any stirring deviceis properly sanitized before coming incontact with the mix.

6. The mix container must be identifiedby a tag or label which states that it isDairy Queen® mix and a code identify-ing its age.

7. The mix used to produce DairyQueen® product must be furnished byan approved mix supplier.

Report any mix problems to the mix sup-plier. If the problem persists, contact IDQFood Products Department.

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temperature variation of only 1.5°F (1°C) ona product temperature of 18°F (-8°C). Thecontrol panel dial thermometer should showa measurement of 5° to 15°F (-15 to -9°C)when product is being dispensed at 18°F (-8°C). Although this dial thermometer is notaccurate for measuring product tempera-ture, it is wise to accustom the operators toobserve the dial thermometer for its normaloperating reading.

10.4 Overrun

H. C. Duke and Son, Inc. can provide ascale (part #158049) that is graduated inoverrun percentage.

Section 10.7 is an overrun chart whichshows the net weight of one measure pint offrozen Dairy Queen® product in grams,ounces, and their corresponding percentageof overrun.

NOTE: Each person who operates thefreezer should know what overrunis, and how to calculate it.

The product temperature should be mea-sured by a calibrated thermometer. If yoususpect that the thermometer is out ofcalibration, test it by filling a cup with iceand water and inserting the thermometerinto it. After a few minutes, the thermometershould read exactly 32°F (0°C).

The freezer should maintain a product

10.3 Product Temperature

“Weight of liquid mix minus weight of frozenproduct. Divide the difference by the frozenweight.”

Example:

Weight of one pint of mix =18 oz.

Weight of one pint frozen product =12 oz.

Difference 6 oz.

6.0 oz. divided by 12 oz. = .5

.5 x 100 = 50% overrun

As mix is being frozen in the freezingcylinder, air is incorporated into the mix toincrease its volume as well as the taste andappeal of the finished product. The increasein volume is called overrun. Forty fivepercent overrun means a volume increase of45%—10 gallons of liquid mix has become14.5 gallons of finished product.

Controlled overrun is important in maintain-ing consistency in product quality. Toomuch overrun (air) results in a light, fluffyproduct lacking the cold, refreshing appeal ofa quality product. Too little overrun results ina grainy, heavy product.

To correctly measure the overrun,

1. Take a pint container and adjust yourscale to zero with the container on thescale.

2. Fill the container with liquid mix, even withthe top of the container and record theweight.

3. Then fill the container with frozen product,leaving no voids or air spaces in thecontainer. Strike off the excess product soit is even with the top of the container andweigh it.

4. Use the following formula to figure overrunpercentage:

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10.5 Overrun Adjustment

10.6 Rerun

correct any overrun variation, allow one fullcylinder of product to be dispensed prior totaking another reading and making anyfurther corrections to the pump settings. Ifyou have any problems with the aboveprocedure, contact the seller ormanufacturer of the pump and/orInternational Dairy Queen® EquipmentDivision Service Department.

Rerun is product that has been drawn through the freezer into a container and has melteddown to be reprocessed.

For further information contact the ServiceDepartment of H. C. Duke & Son, phone(309) 755-4553.

1. International Dairy Queen® does notpermit the use of rerun.

2. Rerun product is unable to accept thesame amount of air as fresh product;therefore, you cannot produce aquality product with rerun mix. Productmay appear grainy and icy, andoperational problems may result fromthe use of rerun.

After the machine has run long enough todispense at least one full cylinder of prod-uct, you will have the overrun that themachine will hold the remainder of the day.The control of the overrun is almost exclu-sively adjusted by the settings on the mixpump. Depending on the make and themodel of the mix pump, the overrun controlmay be regulated by operating pressure, airintake meter, or length of piston stroke.Malfunctions of the pump can causevariations from normal operating overrun.Consult the operations manual for the pumpfor any adjustments.

After making an adjustment of the pump to

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10.7 Overrun Chart

Net Wt. Net Wt.

1 Pint of 1 Pint of

Dairy Queen Dairy Queen Percentage

in Ounces in Grams of Overrun13.7 388.4 35

13.6 385.5 36

13.5 382.7 37

13.4 379.9 38

13.3 377 39

13.2 374.2 40

13.1 371.4 41

13.0 368.5 42

12.9 365.7 43

12.8 362.9 44

12.7 360 45

12.6 357.2 46

12.5 354.3 47

12.4 351.5 48

12.3 348.6 49

12.2 354.8 50

12.1 342.9 51

12 340.1 52

11.9 337.2 53

11.8 334.4 54

11.7 331.5 55

AcceptableRangeforOverrun

28 184662


H. C. Duke & Son, Inc. recommends the following schedule to help maintain your equip-ment in like-new operating condition, as well as help protect your investment. Take thetime to learn and perform these routine procedures and receive in return many years ofvaluable service from your freezer. Protect your investment!

11 Routine Maintenance

WEEKLY1. Carefully inspect all parts for wear,

including, seals, O-rings, mix tubes, andblades. Replace as required.

Replace blades if worn 3/16" or more.

2. Check the beater shank for wear.

A worn shank will have a nonparallelshape on the drive opening.

CAUTIONTo prevent bacteria growth,remove all O-rings whencleaning. Failure to do so couldcreate a health hazard.

1ST MONTH OF OPERATION

1. Have gear reducer oil changed.

The initial gear reducer oil change should be at the end of 240 hours of operation (30 days for 8 hoursper day service, 15 days for 16 hours service, 10 days for 24 hours service).

D A I L YD A I L YD A I L YD A I L YD A I L Y1. Disassemble, wash, rinse, sanitize, air-

dry, reassemble and sanitize all partsthat come into contact with mix orproduct.

`2. Clean the cylinder and drain tube with theappropriate brushes.

3. Upon cleaning, inspect and lubricate allseals and O-rings as described whichcome in contact with mix. Replace worn,torn, or loose-fitting ones.

4. Wipe all exterior surfaces of the freezer,removing any splattered mix.

5. Check overrun and temperature of theproduct.

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MONTHLY


1. Test Head Switch

The head switch feature is designed to prevent thebeater shaft from being accidentally activated. It isessential that the proper operation of this switchbe verified on a routine basis. Use the followinginstructions to test for proper operation:

A. Be sure all switches are in the "OFF"position.

B. Disconnect the main power supply. Thefreezer may have more than one discon-nect switch.

C. Remove the dispense head and beatershaft assemblies.

D. Connect the main power supply.

E. Turn the selector switches to the"CLEAN" position.

CAUTIONMoving parts. DO NOT placehands in the freezing cylinder.Severe personal injury couldresult.

F. Look inside the freezing cylindertoward the rear. The beater drive shaftshould NOT be turning. Turn theswitches off and disconnect the mainpower supply.

G. If the beater drive shaft is turning, oryou are unable to determine whether ornot the shaft is turning, turn theswitches to the "OFF" position,disconnect the main power supply andcontact your local authorized servicecompany. DO NOT place the freezerin service until the problem has beenfixed.

2. Air Condenser

IMPORTANT:Never use a screwdriver or sharp object toclean between condenser fins.

Have air-cooled condenser fins cleaned byauthorized service technician.

3. Water Condenser

Check the outlet water temperature of watercooled condensers at the floor drain. Watertemperature should be about 95ºF (35°C) with a70°F (21.1°C) water inlet temperature.

30 184662


WINTER STORAGE

To protect the unit during seasonal shut-down, it is important that the freezer bestored in the proper manner. Use thefollowing procedures.

1. Disconnect all power to the freezer.

2. Disassemble and wash all parts that comein contact with the mix with a warm milddetergent solution. Rinse in clear water anddry all parts thoroughly.

3. Store the loose parts, such as the headassembly, beater assembly, and pumpparts in a safe, dry place.

4. Do not lay heavy objects on the plastic orrubber parts.

5. Cover the freezer and all loose parts toprotect them from dust or other elementsthat could contaminate them while instorage. Place the freezer in a dry location.

6. On air cooled freezers, have condenser finscleaned by a qualified refrigeration techni-cian.

7. On water-cooled freezers, disconnect thewater supply. Use compressed air to blowout all remaining water in the condenser.

IMPORTANT:

The water valve must be opened in orderto blow out the condenser. Failure topurge the freezer of water can result insevere damage to the cooling system.Call your IDQ authorized service techni-cian for service.

USE ONLY ORIGINAL OR AUTHORIZED REPLACEMENT PARTS WITH THIS FREEZER.

(See your Illustrated Replacement Parts Manual)

Should you have any questions on items that are not included in this maintenance schedule, orproblems where service assistance is needed, please call H. C. Duke & Son, Inc. Service

Department, for factory service assistance.Phone: (309) 755-4553.Fax: (309) 755-9858

QUARTERLY

1. Have a refrigeration technician check therefrigeration system and make the necessaryadjustments.

SEMIANNUALLY

1. Have oil changed in the gear reducer by anauthorized service technician.

NOTE: Under normal conditions, after theinitial change, the oil should be changedafter every 2500 hours of operation orevery six months, whichever occurs first.

ANNUALLY

CAUTIONTo avoid electrical shock or contactwith moving parts, make sure allswitches are in the "OFF" position andthat the main power supply is discon-nected. Some freezers have morethan one disconnect switch.

1. Call your IDQ authorized service technician toreplace drive belts.

2. Call your IDQ authorized service technician toclean the inside of the freezer including base,side panels, condenser, etc.

3. Call your IDQ authorized service technician tocheck water-cooled condensers and flushclean to remove scale and deposits if neces-sary.


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12 Troubleshooting Table

THIS SAFETY ALERT SYMBOL IDENTIFIES IMPORTANT PERSONALSAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL,BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY. DO NOTATTEMPT TO CONTINUE UNTIL THE SAFETY PRECAUTIONS ARETHOROUGHLY UNDERSTOOD.

CAUTIONAll maintenance adjustments must be done by an authorizedservice technician.

CAUTIONTo avoid electrical shock or contact with moving parts, make sureall switches are in the "OFF" position and that the main powersupply is disconnected. Some freezers have more than onedisconnect switch.

NOTE: For water-cooled freezer connected to glycol cooling systems, freezer mustbe switched to city water prior to troubleshooting freezer.

IMPORTANT:

Some refrigerants are hazardous to the earth's atmosphere. To protect ourenvironment, use a refrigerant recovery/recycling unit whenever removingrefrigerant from the system.

32 184662


Dispensedproduct toosoft (Producttemperatureabove19°F[-7.2°C] )

1. Blades installed upside down. 1. Install properly - flat side to cylinderwall.

2. Dirty or blocked condenser, restrictedair flow.

2. Contact your local authorized servicecompany.

3. Component failure. 4. Contact your local authorized servicecompany.

4. Leak in refrigeration system resultingin little or no refrigeration

5. Contact your local authorized servicecompany

Unit does notoperate.

1. Freezer unplugged. 1. Plug in freezer.

2. Fuse or breaker blown at maindisconnect.

2. Make sure your freezer is connected toa separate circuit independent fromany other electrical equipment.Contact your authorized servicecompany for service.

3. Beater motor out on overolad. 3. Press overload reset button. Checkproduct temperature and overrun.Call your authorized service companyfor service.

4. Off on high pressure cut-out control. 4. Contact your authorized servicecompany for service.

5. Off on low pressure cut-out control. 5. Contact your authorized servicecompany for service.

6. Component failure. 6. Contact your authorized servicecompany for service

Mix leaking atdispensinghead.

1. Faulty head o-ring. 1. Replace o-ring.

2. Head not properly installed. 2. Install head properly. Replace o-ringif pinched.

Mix or water isleaking fromdrain tube todrip tray.

1. Damaged beater shaft seal or installedimproperly.

1. Replace cup seal or o-ring insidebushing. Install properly.

2. Beater shaft pitted or damaged whereo-ring rides.

2. Replace beater shaft.

3. Beater shaft end play not set properly. 3. Call your authorized service companyfor service.

12 Troubleshooting Table

PROBLEM PROBABLE CAUSE REMEDY

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Troubleshooting Table - continued

Productdispensesslowly outdispensinghead.

1 Product too cold. 1 See Dispensed product too hard (thissection).

2 Reverse rotation on beater. 2 Have electrician correct rotation toclockwise as viewed from the front offreezer.

3. Pump problem. 3. See pump Trouble-Shooting Chart.

Dispensedproduct toohard.

1 Cylinder thermostat erratic or set toocold.

1 Adjust thermostat or contact yourauthorized service company forservice.

2 Faulty time delay (unit runs all thetime.)

2 Contact your authorized servicecompany for service.

3 Low suction pressure. 3 Contact your authorized servicecompany for service.

4 Low overrun. 4 Check overrun. If low, see PumpManual, Troubleshooting Table.

5 Spigot switch electrically ormechanically stuck closed.


Machine runscontinuouslyand productcontinues toget colder.

1 Spigot switch rod engaged. 1 Close spigot completely.

2 Spigot switch out of adjustment ordefective.


3. Faulty thermostat or bulb not deepenough in well.


4 Starter or relay contacts stuck. 4 Contact your authorized servicecompany for service.

5 Faulty time delay. 5 Contact your authorized servicecompany for service.

6 Suction pressure too low. 6 Contact your authorized servicecompany for service.


34 184662


Poor or slowproductrecovery.

1. Dirty or blocked condenser, restrictedair flow - high ambient temperature.

1. Lower ambient temperature; Contactyour local authorized servicecompany.

2. Thermostat cut in point out ofadjustment or malfunctioning.


3 Component or compressor failure. 3. Contact your local authorized servicecompany

Beater motordoes notoperate.

1. Head assembly is not installed. 1. Install head assembly.

2. Magnetic head switch defective. 2. Contact your local authorized servicecompany.

3. Component failure. 3. Contact your local authorized servicecompany.

Compressorand beatermotor operateonly whendispensing.

1. Cylinder thermostat, setting too warm,or thermostat defective.


Compressorand beatermotor do notoperate whendispensing.

1. Spigot switch(es) defective or out ofadjustment.

1 Contact your local authorized servicecompany.

2. Time delay defective. 2. Contact your local authorized servicecompany.

Troubleshooting Table - continued


TWIN TWIST

QUALITY PARTS

PROTECTYOUR

EQUIPMENT

REPLACEMENTPARTS

MANUAL

TWIN TWISTSOFT SERVE FREEZERMODEL957R184662-01 - 5/98

KEEP YOUR FREEZER IN EXCELLENT CONDITION. ALWAYS CONTACT

H. C. DUKE AND SON FOR REPLACEMENT PARTS.

Figure 1 Head Assembly ............................................... 1

Figure 2 Beater Shaft Assembly .................................... 2

Figure 3 Contactor Box ................................................. 2

Figure 4 Electrical Box .................................................. 3

Figure 5 Switch Assemblies .......................................... 4

Figure 6 Gear Reducers ................................................ 5

Figure 7 Side View ......................................................... 6

Figure 8 Condensing Unit Assembly-Air Remote .......... 8

Figure 9 Panels .............................................................. 9

Accessories ...................................................................... 10

O-Ring Charts ................................................................... 11

Replacement Parts OrdersYou must have the serial number of your freezer when ordering parts—parts may differ with aparticular serial number of the same model.

Parts are listed on each page using terminology that best fits the function of the part. It is veryimportant to know the serial number of the machine when ordering parts because some partsare not interchangeable from one serial number to another of the same model. The illustrationsin this manual can be used as a reference for obtaining the correct part description and partnumber.

All parts listed in the manual should be ordered through:

H. C. Duke & Son, Inc.2116 - 8th AvenueEast Moline, Illinois 61244Telephone: (309) 755-4553Fax: (309) 755-9858

Table of Contents

1

Use only original or authorized replacement parts with this freezer.


184662-01

FIgure 1 Head Assembly

Item Part No. Description

* 114765 Head Assembly Complete1 115905 Head - Less Parts2 114313 Spigot Ass'y. - Side3 159295 O-Ring - Spigot4 160584 O-Ring - Extension5 136794 Rod - Spigot6 162625 Knob - Hand6A 114341-01 Stud Ass'y. 3 3/16"7 136713 Extension - Spigot - Cakes7A 137870 Adapter - Yogurt Nozzle (Not Shown)7B 196185 Star - Nozzle Adapter (Not Shown)8 160583 O-Ring - 4" - Head9 160562 O-Ring - Air Relief Plug

10 115129 Plug - Air Relief11 162626 Handle - Black Tapered12 160372 Screw #10-24 x 5/8 SST13 137018 Spigot Only - Center13A 136618 Handle - Rod Only - Center

184662-012


DUKE DUKE DUKE DUKE DUKE MMMMModelodelodelodelodel 9 9 9 9 957R Soft Serve Freezer57R Soft Serve Freezer57R Soft Serve Freezer57R Soft Serve Freezer57R Soft Serve Freezer

Item Part No. Description1 150106 Contactor-Compressor1A 150108 Coil Only


1 114752 Beater - Shaft2 137334 Blade3 111875 Shaft Seal Complete3A 160557 Cup - Seal3B 133098 Bushing - Seal4 160500 O-Ring Shaft Seal (Included in 111875)5 196079 Cylinder Bushing

Figure 2 Beater Shaft

Figure 3 Contactor Box

3


DUKE MDUKE MDUKE MDUKE MDUKE Modelodelodelodelodel 957R S 957R S 957R S 957R S 957R Soft Serve Freezeroft Serve Freezeroft Serve Freezeroft Serve Freezeroft Serve Freezer

184662-01

Figure 4 Electrical Box


1 150106 Contactor-Motor Starter1A 150108 Coil2 Overload Ass'y. (Order by Freezer Serial Number3 150215 Timer-Force Freeze3A 162604 Knob-Timer4 115524 Lever - Ass'y. - Reset4A 115523 Lever - Reset4B 159036 Button - Reset4C 160001 Screw - Lever5 113903 Switch Ass'y. Spigot - Side5A 150456 Switch - Spigot6 159235 Switch - Pump7 150463 Switch - ON OFF AUTO8 114486 Switch Ass'y. Spigot - Center8A 150479 Switch - Spigot9 150208 Timer* 150553 Light - Amber Pilot Beater Motor (Not Shown)* 150552 Light - Red Pilot Compressor (Not Shown)* 161026 Thermometer (Not Shown)

* Not shown on this drawing.

184662-014




* 113903 Switch Ass'y. Side1 150456 Switch2 160393 Washer - Flat #63 160392 Washer - Ext. Tooth4 160296 Screw #6 - 32 x 1-1/45 162321 Spring6 136124 Button - Actuator7 160303 Ring - Retaining8 113902 Bracket - Mtg.9 113901 Bracket - Adjusting

10 160267 Screw #8 - 32 x 7/811 160102 Nut #8 - 3212 115744 Insulator12 135744 Insulator - Switch


114486 Switch Ass'y Center1 114485 Bracket - Mtg.2 150479 Switch3 162320 Spring4 136124 Button - Actuator5 114484 Bracket - Adjusting6 160099 Screw #8 - 32 x 1 1/87 160102 Nut #8 - 328 160393 Washer Flat #69 160392 Washer - Ext. Tooth

10 160296 Screw #6 - 32 x 1 1/411 160303 Ring - Retaining

Figure 5 Switch Assemblies

5



184662-01

Ref P/N Description

1 153014 Cup-High Speed 2 ea. req. per side2 153015 Bearing-High Speed 2 ea. req. per side3 153011 Cup-Slow Speed. 2 ea. req. per side4 153012 Bearing-Slow Speed 2 ea. req. per side5 153051 Seal-Slow Speed 2 ea. req. per side6 153053 Seal-High Speed 2 ea. req. per side7 153349 Gear-Bronze 1 ea. req. per side8 153350 Shaft-Slow Speed 1 ea. req. per side

153000 Output-Shaft Assembly (Slow Speed)9 137836 Shaft-High Speed 1 ea. req. per side10 114874 Gasket Set 1 ea. req. per side11 111964 Coupling-Drive

158055 Oil-Gear Reducer 51001 Special Synthetic (Per Quart)153322 Key-3/16" High (in)153323 Key-1/4" Slow (out)

(Order by freezer serial number)Model — Wintwin

137118 Wintwin 10 - 1 Ratio A and B Side

Figure 6 Gear Reducers

184662-016



Figure 7 957R Freezer Breakdown (1 of 2)

7



184662-01

Figure 7 957R Freezer Breakdown (2 of 2)


1 117018 Compressor - AHA 2490 2XF1A 116973 Compressor - AHA 2490 2XD1B 155047 Valve Service - Rotalock RH2 151356 Capacitor Relay Assembly (1 Phase H.D.)

150361 Capacitor - Start150362 Capacitor - Run150363 Relay

3 155410 Valve - Water3A 155444 Kit - Water Valve Repair - RH - LH4 155400 Valve - Automatic Expansion (Flare)

155448 Valve - Automatic Expansion (Sweat)5 155050 Drier (Flare)

155054 Drier (Sweat)5A 159203 Glass - Sight (Flare)

155059 Glass - Sight (Sweat)6 155040 Receiver Tank - (Self-contained-unit) (Flare)

155057 Receiver Tank - (Self-contained unit) (Sweat)6A 155042 Receiver Tank - (Remote Air Cooled) (Flare)

155064 Receiver Tank - (Remote Air Cooled) (Sweat)7 155422 Valve - Solenoid (Flare)

155421 Valve - Solenoid (Sweat)7A 155434 Kit - Solenoid Valve Repair8 153626 Pulley - Motor8A 153323 Key - Pulley8B 160495 Screw - Set9 151052 Beater - Motor - 2 Hp 208-230/3/60 Hz9A 151075 Beater - Motor - 2 Hp 230/1/60 Hz 8.5 AMP

10 150872 Capacitor - Start, 1 Phase Only150873 Capacitor - Run, 1 Phase Only150877 Switch - Centrifugal

11 153171 Belt-V - RH - B Side12 153625 Pulley - Reducer12A 153322 Key - Pulley12B 160033 Screw - Set13 137118 Reducer - Gear 10:1 Wintwin14 111964 Coupling - Drive14A 153323 Key14B 160495 Screw - Set15 150106 Contactor - Compressor16 153161 Belt -V - LH - A Side17 114571 Cylinder - Assembly17A 114341-01 Stud - Cylinder17B 115004-01 Tube - Drain Assembly17C 161302-01 Switch - Head18 155425 Cut Out - High Pressure (Water/Air Remote)19 155403 Cut Out - Low Pressure20 155039 Condenser - Water21 155442 Thermostat - Cylinder22 151094 Fan - Rear Panel22A 151095 Guard - Finger (Not Shown)

184662-018



Figure 8 Air-cooled Remote Condensing Unit

REF. PART No. DESCRIPTION

* 116781 Condenser Ass'y. - Complete1 155120 Condenser - Air2 151072 Motor - Fan 50W 230V 60Hz3 159020 Blade - Fan 11" Dia 36°4 155454 Valve - Head Pressure Control5 150732 Box - Electric 2-3/4 x 4-1/2 x 26 117197 Bracket - Assy Electric Box7 153415 Flange - Refr Coupling Mount 1/28 153410 Coupling - Refr 1/2 M w/ Stub9 153414 Flange - Refr Coupling Mount 3/8

10 153413 Coupling - Refr 3/8 M w/ Stub11 137632 Bracket - Fan Condenser12 137629 Support - Condenser13 138465 Shroud - Fan

117207 Cover - Ass'y. - Condenser (not shown)

INS 821 (Installation Instructions, notshown)

9



184662-01

Figure 9 Panels


1 115581 Panel - Switch Box (Trim Strip Assembly)1A 165194 Label - IDQ (Available only through IDQ)2 161026 Thermometer3 150552 Light - Red Pilot - Compressor4 150553 Light- Amber Pilot - Beater Motor5 165201 Label - Switches6 137186 Panel - Dispense7 115004-01 Tube - Drain7A 199016 Grommet - Drain Tube8 115346 Panel - Welded Front - Stepped9 136944 Panel - Lower Front9A 160372 Screw - Lower Front Panel & Trim Strip9B 159132 Nut - Speed - Lower Front Panel & Trim Strip

10 196119-01 Tray - Drip11 159050 Receptical - 115V12 114740 Panel - Top13 199016 Grommet - Rubber (Mix Inlet Tube) Top Panel14 132277 Panel - Side14A 138456 Spacer - Side Panel14B 160117 Nut - Speed - Rear Panels14C 159219 Screw - Side Panel14D 160114 Nut - Speed - Side Panel15 137010 Panel - Upper Rear15A 160048 Screw - Rear Panel16 136946 Panel - Rear Corners17 137011 Panel - Lower Rear (Water Cooled)17A 137457 Panel - Lower Rear (Air Cooled Remote)18 162106 Caster (Without Brake)19 162105 Caster (With Brake)19A 150736 Nut-Caster

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Accessories

Part No. Description

196103 Bottle Wash

158004 Brush - 4" Cylinder w/ Handle

158009 Brush - 4" Cylinder w/o Handle

158020 Brush - 2 3/4" Dia. w/9" Handle

158021 Brush - 5/8" Dia. w/6 Ft. Handle - Mix Line

158022 Brush - 1/4" Dia. w/6 1/2" Handle

158077 Brush - 9/16" Dia. w/36" Handle - Drain Tube

162105 Caster With Brake

162106 Caster Without Brake

184208 Chart - O-Ring - Laminated

158051 Cup - Aluminum - Overrun - One Pint

136567 Hose - Spigot Drain

115538 Kit - O-Ring - Head

112978 Leg-6"

158000 Lubricant-Petrol Gel (12 tube carton)

158000A Lubricant-Petrol Gel (per tube)

158014 Sanitizer-Stera Sheen (per case)

158014A Sanitizer-Stera Sheen (per jar)

158049 Scale-Overrun Z32

158043 Stir Rod

161000 Thermometer-Pocket 1" Dial

169374 Tool-O-Ring Removal

184774 Video-Operational

196006 Tee-Plastic Hose Connection

113129 Tube-Mix Can 5/8" Dia. 24" Long

130092 Tube-Mix Container 5/8" Dia. 13 5/8" Long

196061 Tubing-Mix Line-Std.-.600ID x .850OD PVC

196062 Tubing-Mix Line-H.D.-.600ID x .975OD PVC

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operator's manual - electro freeze · operator's manual with illustrated parts list twin...

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