Duke GES-102 Operator’S Manual With Illustrated Parts List Download Page 3

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Operator’s Manual

for the

Soft Serve Freezer

Model GES-102

Summary of Contents for GES-102

Page 1: ...Duke Son LLC P N 184559 January 2018 Printed In U S A OPERATOR S MANUAL with Illustrated Parts List Soft Serve Freezer Model GES 102 H C DUKE SON LLC 2116 8th Avenue East Moline Illinois 61244 184559...

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Page 4: ...roughout this manual When you see this symbol on your freezer or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices 2 Understand S...

Page 5: ...air the freezer until the main power supply has been disconnected Some freezers have more than one disconnect switch Contact your IDQ authorized service representative or H C Duke Son LLC Service Depa...

Page 6: ...nstruction and information decals or labels on the freezer as shown in the figure on the next page The labels have been put there to help maintain a safe working environment The labels have been desig...

Page 7: ...d 1 Turn all control switches to OFF and 2 Disconnect all power supplies Unit may have more than one power supply P N HC165025 1 P N HC165126 3 P N HC165246 2 Pressurized system Depressurize unit befo...

Page 8: ...quipment Videos 7 4 Virtual Quality Management System VQM 8 5 Part Names and Functions 10 6 Operator Controls 16 7 Operator Display Menus 18 8 Disassembly and Cleaning 22 8 1 Cleaning Accessories 23 8...

Page 9: ...Side Front View Lower Cab 5 Figure 6 1Ph Mix Transfer System RMT 6 Figure 7 3Ph Mix Transfer System RMT 8 Figure 8 Switch Box Breakdown 10 Figure 9 Spigot Switch Assemblies 12 Figure 10 Capacitor Rela...

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Page 11: ...to follow the assembly and priming procedures detailed in this manual Be sure all personnel responsible for equipment operation completely read and understand this manual before operating the freezer...

Page 12: ...icates red and or the carton is broken torn or punctured note the damage on the carrier s freight bill and notify the carrier s local agent immediately Also note on the freight bill 1 Remove the carto...

Page 13: ...on the nameplate Also on three phase systems voltage between phases must be balanced within 2 More than a 6 volt difference between any two voltage measurements at 208 230 volts indicates a possible...

Page 14: ...es located mid level behind the right side panel Important Set switch next to the connection box UP for 220 230v or DOWN for 208 219V Failure to set switch to proper voltage will cause damage to the e...

Page 15: ...2 2 5 H P 19000 BTUH 2 2 kw Motor 3 2 kw Cooling Compressor Cabinet 1 1 6HP 1000BTUH 125w Motor 190w Cooling Beater Motor 2 2 H P 1 5 kw Refrigerant 404a Charge 3 75 lb 1 7 kg Mix Capacity 6 5gal Bags...

Page 16: ...re 3 2 Data Plate The dimensions of the GES 102 are provided in Figure 3 1 below Figure 3 1 3 2 Dimensions AIR IN THROUGH BOTTOM OF FREEZER ELECTRICAL SERVICE CONNECTION ALL CONNECTIONS ARE MADE AIR O...

Page 17: ...___________ 4 Maximum Fuse Size ______________ 5 Minimum Circuit Ampacity _________ Installation Date ___________________________ Installed by ___________________________ Address _____________________...

Page 18: ...spensed Idle Run Comp Delay on break D O B timer used for the compressor when the unit is in idle mode no product being drawn Idle Run Comp Range 0 to 20 seconds Lock outs Allows the function of a spe...

Page 19: ...ing the slope temperature curve until a determined temperature is reached Once that temperature has been reached then the system will examine the curve and shut down if necessary Temp Comp Range 10 to...

Page 20: ...Soft Serve Freezer Model GES 102 10 184559 5 Part Names and Functions Figure 5 1 Head Assembly...

Page 21: ...Seals the air bleed opening in the head when closed Allows excess air to be removed from the cylinder when priming 4 O RING AIR BLEED PLUG Seals the air bleed plug in the head 5 ROD SPIGOT Starts the...

Page 22: ...Soft Serve Freezer Model GES 102 12 184559 5 Part Names and Functions continued Figure 5 2 Beater Shaft Assembly...

Page 23: ...tates in the freezing cylinder blending air and mix as it ejects product 3 BLADE SCRAPER Scrapes the frozen product from the freezing cylinder wall 4 O RING SHAFT SEAL Seals the beater shaft to the sh...

Page 24: ...E TUBE MIX INLET ADAPTER MIX BAG 1 SUPPORT ROLLER BEARING 2 3 ROLLER ASSY COMPLETE 4 KNOB HAND 5 ARM SWING CLAMP M02079rev4 6 7 8 9 CLAMP SOFT HOSE 10 COVER MTS 12 HOSE TRANSFER RED LINE 13 14 DUCKBIL...

Page 25: ...MTS pumps with mix in shelves Automatically refrigerates cabinet when positioned in front of shelves 1 SUPPORT ROLLER BEARING Holds roller assembly in place 2 SHOE ROLLER Provides an opening to insert...

Page 26: ...sing any of these buttons will activate the icon directly above in the display screen Left side L1 L2 Right Side R1 R2 2 OFF Key When this symbol is pressed the left side of unit will shut off The bea...

Page 27: ...n energy saving feature will activate and reduce product refrigeration The freezer will automatically cycle to maintain temperatures in the cylinder and hopper below 41 F and keep product from deterio...

Page 28: ...sor up or down to the desired sub menu Once the desired menu is highlighted in this example we will use Basic Settings press the select button to enter the sub menu Product Type and Temperature Offset...

Page 29: ...Temperature Left or Right Cylinder Event Log Allows the operator to look at logged events i e power switch cycle low mix etc The log will display the last 50 events with the newest event at the top Er...

Page 30: ...Cab Only Mode Y or N Cones Left 5 Screen Settings Operator can turn on or off the following functions Display Cabinet Temperature Y or N Will or will not display Cabinet temp on home screen Alternate...

Page 31: ...on As pictured below the Soft Key located below the image of the Moon will allow the machine to be switched into NIGHT refrigeration mode This feature is used at the closing of the day s business to h...

Page 32: ...tch rods and open the spigots completely 6 Inside the refrigerated cabinet remove the MTS cover loosen the shoe clamp hand knob swing back the shoe clamp and swing open the roller shoe on both mix tra...

Page 33: ...r 18 1 2 inches overall length used to clean the air meter hose the small hole in the back of the dispense head and small parts 6 HC169374 TOOL O RING REMOVAL Aids in removing o rings from plunger hea...

Page 34: ...nd pull the dispensing head 1 straight out 3 Remove the cylinder bushings and beater shafts from the cylinders 4 Remove the scraper blades and shaft seals from the beater shafts Remove the drip tray a...

Page 35: ...ose assemblies form the Mix Transfer Systems as follows figure 8 4 a remove cover b loosen the hand knob c swing back the shoe clamp d swing open the roller shoe e loosen the clamp on braided hose f r...

Page 36: ...the manufacturer s instructions to yield 100 PPM available chlorine solution example Stera Sheen Green Label Use warm water 100 110 F or 38 43 C to wash rinse and sanitize 2 Wash all the parts removed...

Page 37: ...sed place them in the sanitizing solution For proper sanitizing the parts must remain fully immersed in the sanitizer for 5 minutes Allow the parts to air dry after sanitizing 4 The following must be...

Page 38: ...m out and lifting straight up figure 8 13 Do this with the slide in retracted position not extended Bearing mounted on wall should just be wiped down IMPORTANT Clean drawers with warm dish detergent a...

Page 39: ...provided and dry thoroughly 3 Brush in between rollers Flush clean with water bottle Important Do not let shoe sit in sanitizing solution or water Corrosion will occur in bore 4 Lubricate the shoe piv...

Page 40: ...pproved sanitary lubricant such as Lubri Film Plus to the o ring and the face of the plastic washer opposite the bell portion of the seal Do not allow any lubricant to come into contact with the bell...

Page 41: ...e 9 4 Install and lubricate the o rings see o ring chart last page on the dispensing spigots 7 and insert the spigots into the head 1 Check by turning the spigots side to side making sure they move fr...

Page 42: ...MTS hose assembly as shown in figures 9 5 The transfer hose has a red locating line With the red locating line up slide the mix transfer hose onto the port and align red line to the arrow on connector...

Page 43: ...cover over stud Hose clamps should be exposed Tighten cover knob Hand tighten only 21 Loop the braided hose towards you and slide the hose over the cylinder inlet tube Tighten the clamp Make sure the...

Page 44: ...nufacturer s instructions to yield 100 PPM strength chlorine solution example Stera Sheen Green Label Use warm water 100 to 110 F or 37 to 43 C to wash rinse and sanitize 2 Wash and sanitize your hand...

Page 45: ...with Mix Stored in remote Cooler Install shelves and bags of mix in cabinet 3 Connect the bag adapters of the mix pickups tube to the mix bags 4 Tuck excess inlet hose in shelf of mix being used 5 Clo...

Page 46: ...couraged 5 Observe the level of mix throughout the day to avoid running out of product in the mix containers or bags 6 Periodically check the temperature and overrun of product and make sure it is wit...

Page 47: ...ashed spilled on shelf and on Cabinet walls perform these functions To remove frozen product from the cylinder 1 Press the L1 R1 keys to enter CLEAN mode 2 Cleaning with Mix Stored on Shelf Press UP A...

Page 48: ...tizing solution for each cylinder Sanitizing solution must be mixed according to manufacturer s instructions to yield 100PPM available chlorine solution example Stera Sheen Green Label Use warm water...

Page 49: ...any spigot extensions and spigot extension o rings that might be installed remove the drip tray assembly and clean all soiled surfaces with soap and water Fill the wash bottle HC196103 with approved s...

Page 50: ...d appear much like silk If the product appears wet or slick then it is usually an indication that the temperature is too high If the product appears pockmarked and soft it may be an indication of too...

Page 51: ...ifference by the frozen weight 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 H C Duke and Son LLC can pro...

Page 52: ...9 337 2 53 11 8 334 4 54 11 7 331 5 55 To view videos on the GES freezer visit http www electrofreeze com GES_Videos aspx 12 6 Rerun 1 International Dairy Queen does not permit the use of rerun 2 Rer...

Page 53: ...x Transfer System Important If the transfer hose is assembled improperly or replacement has been neglected it may be necessary to clean mix from the MTS due to hose failure If this happens frequently...

Page 54: ...f Wipe all surfaces with a clean dry cloth g Remove and clean shoe See figure 13 1 AS NEEDED continued Figure 13 1 WEEKLY 1 Carefully inspect all parts for wear including seals O rings mix transfer tu...

Page 55: ...ad HEAD SWITCH Freezer has a head switch or software problem Turn the power switch OFF DO NOT place the freezer in service until the problem has been corrected The head switch feature is designed to p...

Page 56: ...properly turn the switches to the OFF position disconnect the main power supply and contact your service technician or the factory DO NOT place the freezer in service until the problem has been correc...

Page 57: ...ician for service to replace drive belts and lubricate fan motor as needed 2 Call your service technician to clean the inside of the freezer including base side panels condenser etc 3 Call your servic...

Page 58: ...zer in a dry location 6 On air cooled freezers have condenser fins cleaned by authorized service technician 7 On water cooled freezers disconnect the water supply Use compressed air to blow out all re...

Page 59: ...environment use a refrigerant recovery recycling unit when removing refrigerant from the system This safety alert symbol identifies important personal safety messages in this manual When you see this...

Page 60: ...tact your Your local service company 7 Faulty selector switch 7 Contact your Your local service company 8 Disconnected or broken wire in electrical circuit 8 Contact your Your local service company Mi...

Page 61: ...our local service company 3 Spigot switch electrically or mechanically stuck closed Unit runs all the time 3 Contact your Your local service company 4 Component failure 4 Contact your Your local servi...

Page 62: ...ot operate 1 Head assembly is not installed 1 Install head assembly 2 Magnetic head switch defective 2 Contact your Your local service company 3 Component failure 3 Contact your Your local service com...

Page 63: ...act your Your local service company 2 Cabinet solenoid defective does not open 2 Contact your Your local service company 3 Cabinet switch defective 3 Contact your Your local service company 4 Door swi...

Page 64: ...Contact your Your local service company 7 Motor defective or internal overload tripped 7 Contact your Your local service company MTS will not shut off 1 Hose broken 1 Replace hose 2 Pressure switch s...

Page 65: ...between pickup tube and hose 2 Replace as needed 3 Air line hose cracked sucking air 3 Replace air line hose 4 Defective or missing duckbill valve 4 Replace valve Mix shoots out air meter 1 Swing Cla...

Page 66: ...ompatible and using the test cable does not resolve the issue then the main control board is not functioning properly and needs to be replaced Contact H C Duke Son Factory Tech Support NO COMM The U I...

Page 67: ...ce of refrigerant leak and repair 3 Locate faulty connection Wire rubbed through cut and repair as needed 4 Check Compressor Starting components and replace as needed 5 Check contactor coil for proper...

Page 68: ...check for a short and proper winding resistance check compressor starting components for failure allow compressor protector to reset and check for proper amp draw 13 Recover refrigerant change filter...

Page 69: ...aulty replace if thermistor tests o k check wire harness connections If all connections are sound possibility of control board issue Contact H C Duke Son Factory Tech Support 8 Check to see if Relay i...

Page 70: ...unit is in cabinet only mode Cabinet is in time cycle mode and both cylinders remain off 1 Faulty wire connection 2 Faulty Thermistor 3 Program Issue 1 Locate faulty connection Wire rubbed through cut...

Page 71: ...re Too cold low overrun and gear reducer operation 2 Locate Faulty wire connection and repair as needed 3 Check contactor coil for proper resistance check for voltage drop across contact points Replac...

Page 72: ...trol as needed 4 Locate and remove restriction i e restricted drier AXV closed down Solenoid valve not opening etc 5 Repair connection as needed i e faulty connection on LPCO etc 6 Locate failed compo...

Page 73: ...nection on HPCO etc 6 Fully recover refrigerant from system change the refrigerant filter drier evacuate system to at least 200 microns and weigh in Factory refrigerant charge Contact H C Duke Son in...

Page 74: ...been rectified 1 Spigot Push rod not installed 2 Spigot switch has failed in the closed position 3 Spigot Switch is out of adjustment 4 Plunger is sticking open 1 Install Spigot Push Rod and start sys...

Page 75: ...main control board Check continuity through relay contacts to ensure proper operation Repair any connections as needed 4 Contact H C Duke Son Technical Support PUMP HI PSI Displays Pump Hi PSI if the...

Page 76: ...eset the machine to return it to normal operation Please Note If the mix bag is not checked when the machine shows a mix out condition the Pump Error will occur frequently 2 Install the Duck bill chec...

Page 77: ...s are connected fully and that no wiring from the control board to the sensor has been severed 2 Change Thermistor CYL T ALARM Displays CYL T ALARM when the cylinder temperature has reached 36 degrees...

Page 78: ...has to see a mix out condition PUMP COVER Occurs if the RMT pump cover is removed or the cover switch is open Action If unit is in Freeze the affected side will be turned to standby and the affected p...

Page 79: ...munication cable are working properly and the problem lies with the U I Board 4 If 5 96 VDC is read on the black wires but the U I Board does not light up the issue might lie with the communication ca...

Page 80: ...Distributor for instructions prior to warranty compressor replacement Keep your freezer in excellent condition always contact your H C Duke Son LLC Distributor for replacement parts and maintenance sc...

Page 81: ...H C Duke Son LLC P N 1845559 01 November 2018 Printed In U S A REPLACEMENT PARTS MANUAL with Illustrations SOFT SERVE FREEZER Model GES 102 184559 01 11 18...

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Page 83: ...2116 8th Avenue East Moline Illinois 61244 Telephone 309 755 4553 or 800 755 4545 Fax 309 755 9858 E mail service hcduke com Table of Contents Figure 1 Head Assembly 1 Figure 2 Beater Shaft Assembly 2...

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Page 85: ...ad only 2 HC160583 O ring Head 3 HC115129 Bleeder Assy 4 HC160562 O ring Bleeder Assembly 5 HC136126 Rod Spigot Switch 6 HC134921 Spigot Long Single less extension 6A HC162624 Handle Black Tapered 6B...

Page 86: ...oved parts will void warranty Figure 2 Beater Shaft Assembly Item Part No Description 1 HC196079 Bushing Cylinder 2 HC113438 Shaft Assy Beater 3 HC137334 Blade Scraper Soft Serve 4 HC160500 O ring Sea...

Page 87: ...Assy Complete 4 HC138836 Hose Transfer Red 5 HC117092 Retainer Air Line 6 HC150016 Mix Cord 7 HC150536 Receptacle 8 HC150612 Switch 9 HC121798 Cover Assy Mix Pump Molded 10 HC161313 Switch Proximity...

Page 88: ...8 HC163431 18 5 HC163431 05 19 HC163432 19 5 HC163432 05 20 HC163433 20 5 HC163433 05 21 HC163434 21 5 HC163434 05 22 HC163435 22 5 HC163435 05 23 HC163436 24 HC163437 25 HC163438 26 HC163439 28 HC163...

Page 89: ...w Lower Cab 1 3 4 2 1 3 4 2 Description BOM ID Qt y HC162647 02 1 1 HC162647 01 2 1 Description BOM ID Qt y HC162137_WHEEL 4 1 HC141759 3 1 Item Part No Description 1 Slide Assembly Drawer Left 2 Slid...

Page 90: ...y original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 6 1Ph Mix Transfer System RMT Breakdown 4 8 5 32 33 13 17 23 24 22 20 21 34 31 27 11 30 9...

Page 91: ...oller 13 HC138799 Arm Swing Clamp 14 HC138797 Arm Shoe Pivot 15 HC116009 Roller Assy Complete 16 HC138800 Spacer Swing Arm 17 HC160338 Pin Dowel 1 4 Dia X 3 4 SST 18 HC160093 Screw TRPS 1 4 28x2 1 4 S...

Page 92: ...only original or authorized replacement parts with this freezer Use of unapproved parts will void warranty 24 33 16 4 3 2 25 23 7 8 21 22 34 31 32 29 30 9 28 26 27 6 13 11 20 17 19 15 18 12 14 5 10 1...

Page 93: ...612 O Ring 11 HC160628 O Ring 12 HC139751 Shoe Roller 13 HC138799 Arm Swing Clamp 14 HC138797 Arm Shoe Pivot 15 HC116009 Roller Assy Bearing 16 HC160338 Pin Dowel 1 4 Dia X 3 4 SST 17 HC138800 Spacer...

Page 94: ...184559 Use only original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 8 Switch Box Breakdown FRONT VIEW TOP VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 1...

Page 95: ...t 5 8 Circuit Board 8 HC150999 Anchor Din Rail 9 HC150098 Socket Miniature Relay DPDT 10 HC150166 Clip Miniature Relay Retaining 11 HC150044 Relay Miniature DPDT 230V Au Contact 12 HC150182 01 Breaker...

Page 96: ...Spigot Switch 7 HC160303 Ring Retaining 1 2 External 8 HC113902 Bracket Assy Spigot Switch Mtg 9 HC113901 Bracket Assy Adjusting 10 HC160267 Screw RDHM 8 32 x 7 8 Brass 11 HC160102 Nut HEX 8 32 ZN 12...

Page 97: ...High Cap 3 HC162132 01 Caster 1 14 Stem W O Brake 4 HC162131 01 Caster 1 14 Stem W Brake 5 HC121634 01 MT Assy W Relief CCW A Side or HC121634 02 3PH MT Assy W Relief CCW A Side 6 HC121634 MT Assy W R...

Page 98: ...559 Use only original or authorized replacement parts with this freezer Use of unapproved parts will void warranty Figure 12 WC Side Back View Upper Section 1 2 3 4a 5 6 7 8 9 10 11 12 13 14 15 16 12...

Page 99: ...e 7 HC155054 Drier Filter 16 Cu In 8 HC155059 Glass Sight 9 HC155459 Glass Sight 10 HC155498 Drier Filter W Access 11 HC155495 Heat Exchanger 12 HC155395 Valve Solenoid Body 3 8 ODM 12A HC151477 Coil...

Page 100: ...Cooled Remote LH Left side of freezer when facing front RH Right side of freezer when facing front Figure 13 Panel Breakdown Hardware for Panels Panel Screw Nut Speed Spacer Nut Speed on Frame Channe...

Page 101: ...141353 Trimstrip Lower 26In Not Shown HC160574 Gasket Door Magnetic HC118597 Actuator Assy Door Switch HC162071 Latch Door Panel Decals Labels Part No Description HC165119 6 Air Flow HC165025 Beater W...

Page 102: ...ranty Figure 14 Evaporator Mix Tube Assembly Item Part No Description 1 HC160320 Screw SKHC 10 24 x 1 3 4 SST 2 HC160166 Washer Lock 10 ST 3 HC160556 Gasket Mix Joint 4 HC139351 Collar Alignment 5 HC1...

Page 103: ...454 01 Valve Head Pressure Control 7 HC153420 Coupling Refr 3 8 MQC 3 8 SW 7A HC191538 Plate Coupling Mtg 8 HC153418 Coupling Refr 1 2 MQC 1 2 SW 8A HC153502 Flange Refr Coupling Mount 8B HC153503 Cap...

Page 104: ...e HC162106 Caster 1 1 4 ST PT Without Brake HC184238 Chart O Ring Laminated HC158051 Cup Overrun One Pint HC184644 DVD Training 919RMT 929RMT 959RMT HC158012 Handle Brush Fiberglass HC136567 Hose Spig...

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Page 106: ...Soft Serve Freezer Model GES 102 22 184559 O Ring Chart...

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