February 2012 Operation & Service Manual VKI Publication #N016487
CAFFÈ MIO – OPERATION AND SERVICE Page 2 of 110
T A BLE OF C ONT ENTS SECTION 1 - INTRODUCTION ............................................................................................... 3 Equipment Overview .......................................................................................................... 4 Equipment Specifications................................................................................................... 6 Using Coffee Packets.............................................................................................
S E CT I ON 1 - I NT RODUC TI ON E q u i pm en t O ve r v i ew Hot Water Tank Powder Dispenser Water Tank Overflow Cup Coffee Dispenser Coffee Packet Chute Dispenser Spouts Zuma Brewer Brewer Spout Grounds Container CAFFÈ MIO – OPERATION AND SERVICE Powder Whipper Assembly Cup Stand Sensor and Overflow Sensor Page 4 of 110
S E CT I ON 1 - I NT RODUC TI ON E q u i pm en t O ve r v i ew Place your cup Choose a beverage HIDDEN BUTTONS SCROLL ‘UP’ AND ‘INCREASE’ BUTTON SCROLL ‘DOWN’ AND ‘DECREASE’ BUTTON Choose a cup size to start The diagram above illustrates the selection panel layout on the front door of the Caffè Mio. Use this diagram as reference when installing the decals onto the selection buttons. Also, note that there is only one button on the interior control panel.
S E CT I ON 1 - I NT RODUC TI ON E q u i pm en t S p e ci fi c at i on s WARNING: This equipment is designed for INDOOR USE ONLY. Placing the unit outdoors is extremely dangerous. VKI Technologies is not responsible for any damage or injury resulting from outdoor placements of these coffee makers. E LE CT RI CA L S P E CS Power Consumption (Heater): Maximum Current Draw: Power Source: 1100 wa tts 12.5 amps 115 Volts AC @ 60Hz O V ER A L L D I M EN S I O N S Height: Width: Depth: 26.5 in 13.5 in 19.
S E CT I ON 1 - I NT RODUC TI ON Us i n g C o f fee P a ck et s To brew a cup of coffee using a packet, follow these simple instructions. 1. Press the “PACKET ” button on the front selection panel. 2. Open the packet door on the top front of the machine. 3. Open the coffee packet and pour the contents into the packet opening on the top of the machine. 4. Close the packet door. 5. Press the pre-selected cup size button for the packet to start the brew cycle. The LED for this cup size will be flashing.
S E CT I ON 2 - I NSTA L LA TI ON Un pa ckin g NOTE: Prior to signing for the delivery, check the shipping carton for damage. Indicate any damage on the delivery slip and have the driver sign acknowledging it. Damages during shipping must be claimed with the carrier, and not with VKI Technologies. 1. Remove the coffee maker from its shipping carton. 2. Lift and place the coffee maker onto your workbench. WARNING: DO NOT lift the coffee maker by placing your hand underneath the front door.
S E CT I ON 2 - I NSTA L LA TI ON P l u m b i n g t h e Un i t NOT E: The shut-off valve must be easily accessible by the customer, who must be informed of its location during the installation.
S E CT I ON 2 - I NSTA L LA TI ON In st all in g a Fl o -Je t Pu m p In certain locations, it may not be possible to connect the equipment to a direct water source. In such cases, a FLOJET Bottled Water Dispensing System needs to be used. The FLOJET Bottled Water Dispensing System is designed to pump water from a commercially available 5 gallon water bottle. The system delivers the water under pressure to the equipment on which it is connected.
S E CT I ON 2 - I NSTA L LA TI ON In st all in g th e S c al eha m me r 3. Wrap the antenna wire around the pipe in a very tight coil. A minimum of 18 full coils is required for best results. Apply the supplied tape to assure that the coils are securely maintained on the pipe. Overlap the coils at least ¾ of an inch (2cm), applying two coats of tape. For best results, each antenna coil must be wound in very tight turns snuggly fitted against each other using up the entire antenna and held secure.
S E CT I ON 2 - I NSTA L LA TI ON C u p H ol d e r I n st al la ti on 1. Install two screws into the threaded clinch nuts on the top right wall of the coffee maker. 2. Place the cup holder onto the two screws making certain the screws enter the key-hole shaped slots of the cup holder. 3. Slide the cup holder downwards onto the two screws. 4. Tighten the two screws to secure the cup holder in position. C o n di me nt St an d I n s tal la ti on 1.
S E CT I ON 2 - I NSTA L LA TI ON A d d in g P ro d u ct s 1. Open the front door. 2. Raise the machine lid open. 3. Lift and remove the coffee and chocolate dispenser lids. 4. Pour fresh ground coffee into the coffee dispenser (left side). 5. Pour chocolate powder into the chocolate dispenser (right side). 6. Re-install the coffee and chocolate dispenser lids. 7. Close the machine lid. 8. Close the front door.
S E CT I ON 2 - I NSTA L LA TI ON T e s tin g E qui p m ent O pe r at i on 1. With the front door open, place a cup directly below the brewer spout. 2. Press the “COFFEE” button on the selection panel. 3. Press “START” to begin the brew cycle. 4. Visually verify the operation of the brewer, coffee dispenser and coffee water valve. 5. Verify the quantity of liquid dispensed into the cup. If the level is too high or too low, make the necessary water and/or product adjustments. 6.
S E CT I ON 2 - I NSTA L LA TI ON P u bl i ci t y G r a p hi c s I n st al la ti on The front door of the Caffè Mio is designed to easily accept (and replace) publicity graphics that can be viewed by the public. From time to time, new graphics may become available and you may want to replace the existing graphics in the equipment. The procedure for replacing the publicity graphics on the Caffè Mio door is outlined below. 1. Open the front door of the Caffè Mio. 2.
S E CT I ON 2 - I NSTA L LA TI ON S o ft wa re Me nu s PRESS SET-UP BUTTON INSIDE FRONT DOOR There is only one button on the inner board panel. It is used to access the SET- UP mode, and to return to the main menu after a setting has been changed. MAIN MENU LCD MESSAGE DESCRIPTION OF ITS FUNCTION TO OPEN BREWER PRESS PRODUCT Press the COFFEE button to open the brew chamber. Press the COFFEE button once more to close the brew chamber.
S E CT I ON 2 - I NSTA L LA TI ON MAIN MENU LCD MESSAGE PROCEDURE ENTER CODE CODE: An access code must be entered to get into SET-UP mode. The access code is: 'SET-UP' SET PROD. COFFEE 1. 2. 3. COFFEE + PACKET + CHOCOLATE + COFFEE Press the COFFEE button to enter this menu. Select COFFEE or COFFEE STRONG and a CUP size. Increase or decrease the product timing using the hidden scroll buttons. To test the coffee quantity to be dispensed, press the HOT W ATER button.
S E CT I ON 2 - I NSTA L LA TI ON MAIN MENU LCD MESSAGE PROCEDURE 'SET-UP' CLEAR COUNTERS 1. 2. Press the COFFEE button to enter this menu. An access code must be entered to reset counters. The access code is: COFFEE + PACKET + CHOCOLATE + COFFEE + SMALL CUP To return to the main menu, press 'SET-UP' SET PRI CE 1. 2. 1. 2. 3. 4. mode button. Press the COFFEE button to enter this menu. Increase or decrease the price of the selections by using the hidden scroll buttons.
S E CT I ON 3 - M A I NT E N A NC E D ai l y Cu st om e r M ain ten an ce Print or make copies of this section to use as a checklist for daily customer maintenance. You can leave a copy of this page with the customer as a reminder of the daily maintenance that needs to be performed. Empty the Waste Bin 1. 2. Open the front door. Open the inner door. 3. 4. 5. Pull out the waste bin. Discard the contents of the bin. Rinse the waste bin with warm running water and dry it thoroughly. 6.
S E CT I ON 3 - M A I NT E N A NC E P re ven ta ti ve Ma int en an ce Print or make copies of this section to use as a checklist during a preventative maintenance visit. If any problems are identified with the equipment, they must be corrected before you leave the account. Empty the Waste Bin 1. 2. 3. Open the front door. Open the inner door. Pull out the waste bin. 4. 5. 6. Discard the contents of the bin. Rinse the waste bin with warm running water and dry it thoroughly. Re-install the waste bin.
S E CT I ON 3 - M A I NT E N A NC E P re ven ta ti ve Ma int en an ce Clean Brew Chamber 1. 2. 3. Rotate the coffee dispenser spout (left dispens er) so that it is in a horizontal position. Press the “SET-UP” button on the interior panel. Press the “COFFEE” button on the front selection panel to open the brewer. 4. 5. 6. Lift the releas e latch on the front of the brew chamber and pull the chamber out. Rinse the brew chamber (and wiper) with warm running water to clean it.
S E CT I ON 3 - M A I NT E N A NC E P re ven ta ti ve Ma int en an ce Clean Chocolate Whipper 1. 2. 3. Rotate the chocolate dis penser spout so that it is pointing upwards. Lift the whipper vacuum funnel off the whipper bowl. Lift the whipper bowl off the whipper chamber and disconnect the water hose from the whipper bowl. 4. 5. Remove the plastic clamp securing the whipper chamber outlet elbow to the whipper chamber.
S E CT I ON 3 - M A I NT E N A NC E P re ven ta ti ve Ma int en an ce Clean Drip Tray 1. 2. 3. Pull the drip tray straight out. Empty the contents of the tray into a sink. Separate the grill from the tray. 4. 5. 6. Rinse the grill under warm running water. Rinse the drip tray under warm running water. Place the grill back onto the drip tray. 7. Slide the drip tray back into the position on the front door. Empty Overflow Cup 1. 2.
S E CT I ON 3 - M A I NT E N A NC E P re ven ta ti ve Ma int en an ce Temperature Adjustments (if required) 1. 2. 3. Press the “SET-UP” button on the interior control panel. Using the hidden scroll buttons, scroll “UP” until the “ ENTER CODE” menu appears on the display. Enter the access code button sequence: 1 – COFFEE, 2 – PACKET, 3 – CHOCOLATE, 4 – COFFEE 4. 5. Scroll until “SET TEMPERATURE” appears on the display. Press the “COFFEE” button to ent er this menu. 6. 7. 8.
S E CT I ON 3 - M A I NT E N A NC E Br e w e r A dj u st me nt s Brew Chamber Tension Adjustment • When adjusting the tension on the brewer, add full shims (K011950) or ha lf shims (K011191) between the T-bar and the H-frame, as illustrated below. These shims must be added one at a time. Do not add several shims at once as the tension may be inc reased too much. In most cases, this simple procedure is enough to stop the leaking.
S E CT I ON 3 - M A I NT E N A NC E Br e w e r A dj u st me nt s Brew Chamber Installation • The correct removal and installation procedure for the brew chamber is crucial. Although the assembly can be easily removed for cleaning (by lifting up the latch bar in front of the chamber), the re-installation requires some precision. The wiper assembly on the chamber must be inserted between the two stainless steel arms located at the rear of the brewer.
S E CT I ON 3 - M A I NT E N A NC E Br e w e r A dj u st me nt s Zuma Brewer – Brew Chamber Tension Adjustment Figure 1 Figure 2 Too Loose – Side View Too Loose – Front View The wiper is not touching the surface of the cylinder and filter screen. No bend on the wiper because it is not touching the surface of the cylinder and filter screen. Figure 3 Figure 4 Perfect Tension – Side View Perfect Tension – Front View The wiper is gently touching the surface of the cylinder & filter screen.
S E CT I ON 3 - M A I NT E N A NC E Br e w e r A dj u st me nt s Zuma Brewer – Brew Chamber Tension Adjustment BREWER TENSION IS TOO LOOSE Figure 1 As the wiper moves across the top of the cylinder, it does not make contact with the filter screen. This will leave a layer of coffee grounds on the screen. A brewer adjusted this way may also leak when the brew chamber is closed. If the leak is severe enough, it can result in a loss of vacuum and possible brewer flooding on larger cup sizes.
S E CT I ON 3 - M A I NT E N A NC E D o wnl o a din g S o ft wa r e U p d at e s For updating the software in the Caffè Mio, it is necessary to purchase a VKI Data Link downloader. A DB9 cable, a phone jack harness, and an auxiliary downloading harness are required to interface the Data Link to the coffee maker. Updates to the software will be provided on an EPROM (from VKI Technologies) which needs to be inserted into the Data Link Downloader.
S E CT I ON 3 - M A I NT E N A NC E D o wnl o a din g S o ft wa r e U p d at e s 2. Switch off the power to the machine. 3. Remove the front board access panel on the inside of the front door. a) Loosen the access panel screw. b) Lift and pull out the access panel. Front Board Access Pane l Loosen c) Connect one end of the auxiliary harness to the rear board (Data Link connector), and the other end to the Data Link downloader. d) Disconnect the phone jack cable from front board.
S E CT I ON 3 - M A I NT E N A NC E D o wnl o a din g S o ft wa r e U p d at e s e) Connect the phone jack cable to the Data Link. f) Switch on the power to the unit. g) Press the “ START ” button on the Data Link to begin the downloading operation. Please note that the new factory settings must be downloaded as well. WARNING: Do not interrupt this procedure once it is in progress as data being transferred may become corrupted, creating problems with the operation of the equipment.
S E CT I ON 4 - T RO U B LE S H O OT I N G I n d i ca t o r M e s sa g e s MESSAGE BEVERAGE BEING PREPARED BREW ER HOME ERR PRESS PRODUCT POSSIBLE CAUS E CORRECTIVE ACTION Brewing cycle is in progress. The message reverts to the standby message once the current brew cycle is complete. The brewer is not in the home or starting position. Press product button to cycle the brewer. The home switch may be defective or needs to be re-adjusted or cleaned.
S E CT I ON 4 - T RO U B LE S H O OT I N G I n d i ca t o r M e s sa g e s MESSAGE EMPTY WATER TANK PRESS PRODUCT ERROR – CALL FOR SERVICE ERROR - CHECK STUCK BUTTON POSSIBLE CAUS E CORRECTIVE ACTION The “EMP TY W ATER TANK ” function has been accessed. To empty the water tank, press and hold the “COFFEE” and “HOT W ATER ” buttons simultaneously. An error is present with the machine. If this message appears, the caretaker needs to call a technician for service.
S E CT I ON 4 - T RO U B LE S H O OT I N G I n d i ca t o r M e s sa g e s MESSAGE PLEASE CHECK WATER SOURCE POSSIBLE CAUS E Indicates a problem with the main water supply not getting to the water tank. CORRECTIVE ACTION At this point, the water tank is not full and this message has to be reset. To reset it, switch the power off and on. If the problem persists, check all components on the water line (water filter, tubing, fittings, etc.).
S E CT I ON 4 - T RO U B LE S H O OT I N G T ro u b le sh o o tin g Coffee Bitter ► ► ► ► ► ► ► / Too Strong Coffee setting may be too high – decrease the coffee setting. “TOP PAUSE ” setting may be too high – decrease the “TOP PAUSE ” setting. Brewer may require a thorough cleaning – clean the brewer. Coffee may be stale or not within specifications – replace coffee. Coffee blend may be too strong – replace the blend. Water filter may need to be replaced. Water tank may need to be delimed.
S E CT I ON 4 - T RO U B LE S H O OT I N G T ro u b le sh o o tin g Coffee Water Short C up Dispe nsed ► Water setting may be too low – increase the water setting. ► Water tank may not be filling quickly enough – verify main water pressure, hoses and inlet valve. ► Water filter may be clogged – replace water filter. ► If a self-piercing saddle valve was used to tap into the water supply, the valve may have an obstruction – close and open the valve.
S E CT I ON 4 - T RO U B LE S H O OT I N G T ro u b le sh o o tin g Fuses 5 Amp F use Blowing ► If fuse blows when machine is powered-up, check the following; o Exhaust fan o Front board o Rear board o Wiring ► If fuse blows when a “COFFEE ” is brewed, check the following; o Coffee valve o Coffee dispenser motor o Brewer motor o Inlet valve o Wiring ► If fuse blows when a “CHOCOLATE ” is brewed, check the follow ing; o Whipper motor and/or transformer o Chocolate dispenser motor o Chocolate valve o Inlet
S E CT I ON 4 - T RO U B LE S H O OT I N G T ro u b le sh o o tin g Bre wer Overflow ► Water setting may be too high – reduce the water setting. ► Bottom pause setting may need to be increased. ► Coffee setting may be too high – reduce the coffee setting. ► Coffee may be stale or not within specifications – replace coffee. ► Water temperature may be too high – reduce the temperature. ► Screen assembly may be dirty and clogged – clean or replace the brewer screen assembly (P/N - K310306).
S E CT I ON 4 - T RO U B LE S H O OT I N G T ro u b le sh o o tin g Zuma Brewer Grounds Not Being Wipe d ► Brew chamber may not be installed properly. Open the brewer and re-install the brew chamber – the wiper must be positioned between the two brewer arms. ► Brew chamber assembly may be damaged – repair or replace the brew chamber assembly (P/N - M044065). ► Wipe arm may be damaged – replace the wipe arm (P/N - E210285). ► Triple cam may be damaged – replace the triple cam (P/N - K033001).
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Outlet Valve(s) 1. Turn off the water supply to the machine. 2. Switch off the power to the machine. 3. Remove the waste bin. 4. Drain the water tank to a level below the valves. a) Remove the clip from top of the drain plug. Remove locking clip b) Gently push the drain plug upwards to open it.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s c) Place the clamped end of the brown drain hose into a heat-resistant and leak-proof container. Drain Hose Hose Clamp d) Carefully open the large clamp and drain water into the container. CAUTION: Water coming out of the drain hose may be extremely hot. Use caution when draining the water tank. e) Once emptied, close the large clamp on the drain hose.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 5. Remove the valve cover. a) Loosen (but do not remove) the two screws securing the valve cover to the right wall of the machine. Valve Cover Loosen Remove Loosen b) Remove the screw securing the left side of the cover. c) Pull the valve cover straight out, clearing the loosened screws on the right wall. 6. Disconnect the wires from the valve that needs to be removed.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 7. Pull the old valve(s) out towards you making certain to leave the silicone valve support in place. CAUTION: A small quantity of water will drip out when a valve is removed and this water may be extremely hot. Use caution when removing the outlet valves. Silicone Support 8. Insert the new valve(s) into the appropriate outlet of the hot water tank.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 10. Attach the hoses. a) The brown hose goes onto the coffee valve, the hose to the whipper goes onto the chocolate valve, and the hose going to the door goes onto the hot water valve. 11. Reconnect the coffee hose (brown) to the brewer. Coffee Hose Bre wer 12. Turn on the water supply to the machine. 13. Switch ON the power to the machine. 14. Allow the water tank to fill and check for leaks. 15.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Brewer Screen 1. Open the front door and inner door. 2. Press the "S ET-UP" button on the interior panel. a) The display now reads “TO OPEN BREWER – PRESS PRODUCT”. Set-Up Button Interior Pane l 3. Press the “COFFEE” button on the front selection panel. a) The brewer motor will now cycle and stop with the brew chamber in the open position. 4. Remove the brewer spout. 5. Remove the brew chamber. 6.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 7. Insert the tip through the pour spout on the cylinder. 8. Gently push extractor tool towards rear of cylinder and slide tip up until contact is made with rear of filter screen's plastic frame. 9. Once tip is centered under rear section of filter screen's frame, pry handle section to force tip upward. Resulting force will dislodge the filter screen, which can then be removed. 10.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Brewer 1. Press the "S ET-UP" button on the interior panel. a) The display now reads “TO OPEN BREWER – PRESS PRODUCT”. Set-Up Button Interior Pane l 2. Press the “COFFEE” button on the front selection panel. a) The brewer motor will now cycle and stop with the brew chamber in the open position. 3. Release the brewer lock pin. a) Lower the lock pin by pulling it down all the way.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 5. Place the new brewer onto the brewer bracket. a) Make sure that the brew chamber is open. b) Make sure that the brewer drive pin aligns with the coupling on the brewer motor. Location Fla nge Rear Support Motor Coupli ng Brewe r Drive Pi n c) Gently grasp the brewer, with one hand on the top, and the other hand on the bottom.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 7. Connect the coffee hose to the top of the brewer. Coffee Hose Bre wer 8. Press the “COFFEE” button on the front selection panel. b) The brewer motor will now cycle and stop in the home (starting) position. 9. Press the "S ET-UP" button on the interior panel to exit the set-up mode.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Brewer Bracket / Brewer Motor 1. With the machine power OFF, remove the brewer. a) See “Replacing the Brewer” section for more details. 2. Remove the brewer bracket. a) Loosen, but do not remove, the three screws from the left side of the brewer bracket. Loosen Loosen Bre wer Bracket Loosen b) Lift the bracket clear of the screws and pull it away from the wall.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 3. Loosen the two upper screws securing the motor to the bracket. 4. Remove the two lower screws securing the motor to the bracket. Bre wer Bracket Loosen Loosen Bre wer Motor Remove Remove 5. Remove the brewer motor assembly from the brewer bracket. 6. Disconnect the power wires (#8 and #9) from the brewer motor. 7. Remove the switch plate assembly from the old brewer motor.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 8. Install the brewer motor onto the brewer bracket. a) Install the brewer motor to the brewer bracket using four screws – the stack of the brewer motor should be towards the right side. b) Tighten all four screws. Bre wer Bracket Inst all Inst all Bre wer Motor Stack Inst all Inst all 9. Re-connect the power wires to the brewer motor. a) Wires #8 and #9. 10.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 11. Re-connect the two brewer harnesses and the ground wire to the rear board. Rea r C irc uit Board Brewe r Ha rness Brewer Harness Ground Wire 12. Re-install the brewer bracket assembly onto the left wall of the machine. a) Make sure the bracket goes over the three loosened screws. b) Tighten the screws to secure the bracket to the wall. Tighten Tighten Bre wer Bracket Tighten 13. Replace the brewer.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Water Tank 1. Switch the coffee maker "OFF". 2. Open the front door and open the machine lid. 3. Remove the water tank access panel on top of the machine. a) Remove the screw securing the access panel to the top of the machine. Machine Lid Ingredie nt Dispense rs Wate r Ta nk Access Pane l Remove b) Slowly lift the front of the water tank access panel and disconnect the ground wire connected inside the panel.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 4. Drain the water tank. a) Have a heat-resistant and leak-proof container ready for draining the water tank. b) Remove the top clip on the drain fitting and push the drain plug upwards. Push Plug Upwards Remove Lock Clip CAUTION: Water coming out of the water tank may be extremely hot. Use caution when draining the water tank or when removing the outlet valves. 5. Remove the brewer.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 7. Remove the valve cover on the water tank. a) Loosen (but do not remove) the two screws securing the valve cover to the right wall of the machine. Valve Cover Loosen Remove Loosen b) Remove the screw securing the left side of the cover. c) Pull the valve cover straight out, clearing the loosened screws on the right wall. 8. Remove the hoses from all three outlet valves.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 10. Disconnect the temperature probe harness from the rear board. Temp. Probe Har ness 11. Disconnect the wires from the tank lid. #1-2 #4-3 #5-2 #11-2 #14 12. Carefully pull the old water tank up and out the top of the machine. 13.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 14. Connect the temperature probe harness to the rear circuit board. a) Route the harness down the front of the water tank and connect it to the rear circuit board. Temp. Probe Har ness 15. Connect the wires identified in the table and photo below.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 16. Connect the inlet valve hose to the inlet fitting (rear fitting) at the bottom of the water tank, and use a hose clamp to secure it in place. Make sure the drain plug is also down and locked. Drain Plug Down Install Clamp Inlet Hose 17. Connect the respective hoses to all three outlet valves. a) Remove the coffee hose from the brewer and connect it to the coffee valve. 18.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 19. Install the brewer. a) Refer to the "Replacing the Brewer" instructions in this manual 20. Connect the coffee hose to the brewer. Coffee Hose Bre wer 21. Replace the valve cover. a) Slide the right side over the two loosened screws. b) Secure the left side with another screw. c) Tighten the two screws on the right side.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 22. Replace the water tank access panel. a) Slide the rear of the access panel into the area around the rear of the tank. The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel. b) Connect the ground wire (#13-3) to the grounding tab on the inside front of the access panel.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Water Tank Lid WARNING: To avoid severe burns, make absolutely certain that the heater element is not hot before proceeding! 1. With machine power OFF, remove the water tank access panel on top of the machine. a) Open the front door and the machine lid. b) Remove the screw securing the access panel to the top of the machine.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 2. Disconnect the wires from the tank lid. #1-2 #4-3 #5-2 #11-2 #14 3. Remove the old lid assembly. a) Press the lock latch on the lid to free it. Lock Latch b) Lift the assembly up and out of the water tank. 4. Lower the new lid assembly into the water tank. a) Slide the back of the lid into the tank first, and push the front down until the latch engages.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 5. Connect the wires identified in the table and photo below. #1-2 #4-3 #5-2 #11-2 #14 WIRE # #11-2 #14 #1-2 #4-3 #5-2 CONNECT ED TO: Heater element Thermal cut-off switch Level probe - long Level probe - long Level probe - short 6. Replace the water tank access panel. a) Slide the rear of the access panel into the area around the rear of the tank.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s c) Lower the front of the access panel closed and secure it closed with a screw.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Heater Element WARNING: To avoid severe burns, make absolutely certain that the heater element is not hot before proceeding! 1. With machine power OFF, remove the water tank lid. a) Refer to the "Replacing the Water Tank Lid" instructions in this manual. 2. Remove the wires from the heater element terminals. 3. Detach the thermal cut-off switch from the heater element.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 5. Remove the old heater element from the lid. 6. Position the new heater element into the tank lid. a) The "curve" at the bottom of the heater element should point towards the rear of the tank. 7. Secure the heater element to the tank lid with the two 11/16" brass nuts. Install Install 8. Replace thermal cut-off switch onto the element and secure it with the clamp.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Temperature Probe 1. Switch the machine power OFF, and open the front and inner doors. 2. Disconnect the temperature probe from the “ WATER TEMP” connector on the rear board. Temp. Probe Har ness 3. Lift the machine lid open. 4. Remove the water tank access panel. a) Remove the screw securing the front of the cover to the top of the machine.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 6. Carefully pull the temperature probe’s wiring out the top of the machine. a) Any tie-wraps securing the temperature probe wiring to the main water tank wiring harness will need to be cut. 7. Install the new probe into the grommet on the water tank top. Temperature Probe Push into Grommet Grommet 8.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 9. Connect the temperature probe to the “ WATER TEMP” connector of the rear board. Temp. Probe Har ness 10. Replace the water tank access panel. a) Slide the rear of the access panel into the area around the rear of the tank. The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Ingredient Dispenser 1. Open the front door and the inner door. 2. Lift the machine lid open. 3. Remove the spill plate that surrounds the two dispensers. a) Remove the screws at the front and rear of the spill plate securing it to the top of the machine. b) Remove the lids on both of the dispensers. c) Slide the spill plate up and over the dispensers to remove it.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 8. To install the new dispenser, lower in into position from the top of the machine and align the coupler at the rear of the dispenser with the drive pin on the dispenser motor. Dispenser Motor Drive Pin Support Cutout Coupler Ingredient Dispenser 9. Slide the rear of the dispenser support into the cutout on the base, and push the dispenser back to couple it with the motor.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 10. Screw the front of the dispenser to the dispenser base. Install Install 11. Re-install the spill plate (foam side down) over the dispensers onto the top of the machine and secure it in place using the two screws. Install Screw Replace Lid Replace Lid Spill Plate Install Screw 12. Install the dispenser covers onto the dispensers. 13. Rotate the spouts down into their proper positions. 14.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Ingredient Dispenser Motor 1. With machine power OFF, open the front door and open the machine lid. 2. Remove the brewer. a) Refer to the "Replacing the Brewer" instructions in this manual. 3. Remove the brewer bracket. a) Refer to the "Replacing the Brewer Bracket" instructions in this manual. 4. Remove the spill plate that surrounds the two dispensers.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 7. Lift the front of each dispenser and pull it forward to unlock the dispenser. 8. Lift the dispensers out of the top of the machine. 9. Disconnect the power wires from the dispenser motor that needs to be replaced. Coffee Dispense r Motor Chocolate Dispense r Motor Disconnect Disconnect Disconnect Disconnect 10.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 11. Remove the support plate from the dispenser motor by removing the two screws that secure it. Remove Remove Support Plate Dispense r Motor 12. Install the support plate onto the new dispenser motor with two screws. 13. While holding onto the motor from the underside of the ingredient dispenser base, install the two screws that secure the motor to the base.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 14. Reconnect the power wires to the ingredient motor(s). Coffee Dispense r Motor Chocolate Dispense r Motor Wire #6 Wire #1-3 Wire #3 Wire #12-2 15. To install the dispenser, lower in into position from the top of the machine and align the coupler at the rear of the dispenser with the drive pin on the dispenser motor.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 16. Slide the rear of the dispenser support into the cutout on the base, and push the dispenser back to couple it with the motor. The pin at the bottom of the dispenser will go into the notch on the base to help guide the dispenser into position. Ingredient Dispenser Guide Pin Support Support Cutout Notch Dispenser Base 17. Screw the front of the dispenser to the dispenser base.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 18. Re-install the spill plate (foam side down) over the dispensers onto the top of the machine and secure it in place using the two screws. Install Screw Replace Lid Replace Lid Spill Plate Install Screw 19. Install the dispenser covers onto the dispensers. 20. Rotate the spouts down into their proper positions. 21. Close the inner door and front door. 22.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Front Circuit Board 1. With the machine power OFF, remove the drip tray assembly from the front door. 2. Remove the front door. a) Remove the inner door by lifting it up and off the door hinges. Lift off the Hinges Inner Door Front Door b) Remove the front circuit board cover by loosening the mounting screw and lifting the cover up and pulling the bottom towards you.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s c) Disconnect the phone type cable from the bottom of the front board, and disconnect the ground wire from the inside wall of the door. Disconnect Front Circuit Board Disconnect d) Loosen the screws and remove the drip tray and overflow detection bracket at the inside bottom of the front door.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s e) Disconnect the wiring from the two overflow detection probes and from the 3-position connector from the drip tray detection switch. Disconnect Drip Tray Detection Switc h Disconnect Overflow Detection Probes f) Set aside the drip tray detection and overflow bracket – it will be required later.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 4. Remove the front circuit board assembly from the front door. Remove Remove Remove Remove Remove Remove LCD Display Front Circuit Board Remove Remove Remove Remove Remove Remove a) Remove the 8 screws securing the front circuit board to the front door. b) Remove the 4 screws securing the LCD display to the front door. c) Carefully lift the circuit board assembly up and out of the door.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 5. Re-install the front circuit board assembly onto the front door. a) Align the front circuit board into position on the front door – make certain that the foam sponge spacer and all the screw holes align with the stand-offs on the front door. b) Install the 8 screws securing the front circuit board to the door.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s d) Connect the phone-type cable to the connector on the bottom of the front circuit board and connect the green ground wire to the ground tab on the inside wall of the door. Connect Front Circuit Board Connect e) Pick up the drip tray detection and overflow bracket that was set aside earlier.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s g) Install the drip tray detection and overflow bracket onto the slots at the inside bottom of the front door, and tighten the screws to secure the bracket in place. Make certain the probes and switch arm are placed in their proper position.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Rear Circuit Board 1. With machine power OFF, open the front and inner doors. 2. Remove the waste bin. 3. Remove the brewer. a) Refer to the "Replacing the Brewer" instructions in this manual. 4. Remove the brewer bracket. a) Refer to the "Replacing the Brewer Bracket" instructions in this manual. 5. Disconnect all of the wiring connections and ground connections to the rear circuit board.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 13. Connect all of the wiring connections and ground connections (green wires) to the rear circuit board. Connect Fuse Box Install Scre w Connect Connect Wate r Ta nk Area Rear Circuit Board Connect Connect Cconne ct Connect Connect Connect 14. Install the brewer bracket. a) Refer to the "Replacing the Brewer Bracket" instructions in this manual. 15. Install the brewer.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Whipper Motor 1. Rotate the chocolate dispenser spout so that it is pointing upwards. 2. Lift the whipper vacuum funnel off the whipper bowl. Lift Off 3. Lift the whipper bowl off the whipper chamber and disconnect the water hose from the whipper bowl.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 4. Open the plastic clamp securing the whipper chamber outlet elbow to the whipper chamber and pull off the outlet elbow. Pull Down Open Clamp 5. Turn the whipper chamber clockwise about 1/8th of a turn, and pull it straight out to remove it from the whipper base.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 6. Remove the whipper base support bracket. a) Loosen the four screws securing the bracket. b) Lift the bracket up until it clear the screws and pull it out. Loosen Loosen Loosen Loosen 7. Pull the whipper blade straight out to remove if from the whipper motor shaft. Pull Straight Out 8. Remove the two screws securing the whipper base to the metal support and remove the base.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 9. From the rear side of the metal support plate, disconnect the power wires to the whipper motor. Disconnect Disconnect 10. Remove the two hex nuts securing the whipper motor to the support plate, and remove the old motor.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 11. Install the new motor onto the support plate and secure it in place with two hex nuts. Install Install 12. Connect the two power wires coming from the transformer (yellow and blue wires) to the whipper motor.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 13. Install the whipper base support bracket. c) Lower the bracket onto the four loose screws. d) Tighten the screws to secure the bracket in place. Tighten Tighten Tighten Tighten 14. Clean all of the parts that were removed earlier under warm running water prior to replacing them. 15. Install the whipper base onto the metal support and secure it in place with the two screws. Install Install 16.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 17. Re-install the whipper chamber by placing it onto the base a turning it counter-clockwise to lock it in position. 18. Re-connect the outlet elbow to the whipper chamber and secure it in place with a plastic clamp.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 19. Re-install the whipper bowl on to of the chamber and re-connect the chocolate hose to the whipper bowl. Push Down 20. Re-install the whipper vacuum funnel onto the whipper bowl, making sure to slide the notched side over the vacuum coupling. Slide Down Vacuum Coupling 21. Rotate the chocolate dispenser spout so that it is pointing downwards onto the whipper bowl. 22. Close the inner door and front door.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Inlet Valve 1. Switch the coffee maker "OFF". 2. Shut off the water supply. 3. Drain the water tank completely. 4. Remove the fitting from the inlet valve at the back of the machine. 5. Disconnect the two wires that go to the inlet valve. Wate r Ta nk Disconnect Wires Inlet Valve 6. Disconnect the inlet hose from the hot water tank.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 8. Place the new inlet valve into position and secure it with the two screws. a) These screws are located on the outside of the rear wall of the machine. 9. Connect wires #6 and #1-2 onto the inlet valve. Wate r Ta nk Connect Wires Inlet Valve 10. Secure the inlet valve hose (using a hose clamp) to the inlet at the bottom of the water tank. Drain Plug Down Install Clamp Inlet Hose 11.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Fuse Box Assembly WARNING: To prevent electrical shock, always disconnect the service cord from the wall outlet when working on the fuse box. Even with the main power switch in the OFF position, parts of the fuse box will remain live. 1. With machine power OFF, disconnect the service cord from the wall outlet. 2. Open the front door, the inner door, and remove the waste bin. 3. Remove the brewer.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 6. Remove the two screws securing the fuse box assembly to the rear wall of the machine. Remove Remove Fuse Box 7. Remove the old fuse box assembly. a) Tilt the front of the fuse box assembly down, and lift it at the rear to free it. b) Pull the fuse box assembly (including the service cord) out of the machine. 8. Install the new fuse box assembly.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 9. Connect the wiring coming out of the fuse box. a) Connect the green ground wire #5 to the ground terminal on the left wall of the machine. b) Connect the heavy duty white wire #11 to the terminal on the heater relay. c) Connect the white wire #2 to white wire #10-2 of the door harness. d) Connect the blue wire #3-3 to blue wire #12-3 of the door harness.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Overflow Cup Assembly 1. With machine power OFF, open the front door and inner door. 2. Disconnect the two inline wiring connections to the overflow cup. Overflow Cup Wiring Connections 3. Lift and remove the old overflow cup from its support. 4. Connect the two inline wiring connections to the new overflow cup. 5. Re-seat the overflow cup onto the overflow cup support. 6. Switch the machine power ON. 7.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Heater Relay 1. Switch the coffee maker "OFF". 2. Remove the brewer. 3. Remove the brewer bracket. 4. Disconnect the four wires from the heater relay. a) The heater relay is located on the right side wall behind the brewer assembly. Remove Screw Heater Relay Remove Screw 5. Remove the two screws securing the old heater relay to the wall. 6. Install the new heater relay and secure it with two screws. 7.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s Thermal Cut-Off Switch WARNING: To avoid severe burns, make absolutely certain that the heater element is not hot before proceeding! 1. With machine power OFF, remove the water tank access panel on top of the machine. a) Open the front door and the machine lid. b) Remove the screw securing the access panel to the top of the machine.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 2. Disconnect the wires from the tank lid. #1-2 #4-3 #5-2 #11-2 #14 3. Remove the old lid assembly. a) Press the lock latch on the lid to free it. Lock Latch b) Lift the assembly up and out of the water tank.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 4. Remove the thermal cut-off switch. a) Disconnect the wire from the thermal cut-off switch to the heater element. b) Loosen the clamp securing the thermal cut-off switch to the heater element. Disconnect Loosen Clamp The rmal Cut-Off c) Remove the two screws and hex nuts securing the thermal cut-off switch to the tank lid.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 5. Install the new thermal cut-off switch. a) Pass the bulb and winding of the new thermal cut-off switch through the opening on the tank lid. b) Secure the top of the thermal cut-off switch to the tank lid using two sets of screws and hex nuts. The screws pass through the bottom of the lid, to the top. Secure the screws with the hex nuts.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 6. Lower the lid assembly into the water tank. a) Slide the back of the lid into the tank top first, and push the front down until the latch engages with the tank top. 7. Connect the wires identified in the table and photo below.
S E CT I ON 5 – REP LA C I NG C O M P O N E NT S R e pl a ci n g Ma j o r C om p o nen t s 8. Replace the water tank access panel. a) Slide the rear of the access panel into the area around the rear of the tank. The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel. b) Connect the ground wire (#13-3) to the grounding tab on the inside front of the access panel.
S E CT I ON 5 CAFFÈ MIO – OPERATION AND SERVICE – REP LA C I NG C O M P O N E NT S Page 110 of 110
