en service manual coffee machine
TRANSCRIPT
1
en Service Manual Coffee Machine
EF 748EF 749
01.2004 DOG
2
Contents
Main Components ........................................................ 5Overview ....................................................................................... 5Jaw ................................................................................................ 6Overview of rating plates .............................................................. 7Water circuit .................................................................................. 8Technical Data ............................................................................... 9
Operation .................................................................... 10Preparation.................................................................................. 10Making coffee ............................................................................... 11Preparing hot water ..................................................................... 11Frothing aids ............................................................................... 12Heating with steam ..................................................................... 12Frothing ....................................................................................... 12LED status diagram .................................................................... 13
Troubleshooting ......................................................... 14Checking the machine - receipt (1) ............................................ 14Checking the machine - receipt (2) ............................................ 15Coffee temperature too low ........................................................ 16Coffee temperature too high ...................................................... 16No function.................................................................................. 16No outflow ................................................................................... 17No steam function or too little steam ......................................... 18No capsule ejection .................................................................... 18Jaw does not close ..................................................................... 18Water on the jaw ......................................................................... 18Water on side of machine or below machine............................. 19Pump noisy ................................................................................. 19Not enough froth when frothing milk ......................................... 19
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Contents
Repair .......................................................................... 20General disassembly (stage 1) ................................................... 20General disassembly (stage 2) ................................................... 21Replacing thermoblock .............................................................. 22Replacing NTC ............................................................................ 22Replacing pump .......................................................................... 23Replacing fine-wire fuse ............................................................. 24Replacing control board ............................................................. 25Replacing main switch or steam switch .................................... 26Replacing LED ............................................................................ 26Replacing steam pipe ................................................................. 26Replacing jaw.............................................................................. 27Complete jaw disassembly......................................................... 28Complete jaw disassembly......................................................... 29Replacing heating PTC ............................................................... 30Replacing pyramid plate ............................................................. 31Replacing capsule cage ............................................................. 31Electronic mainboard, wiring diagram ....................................... 32
Maintenance................................................................ 33Descaling .................................................................................... 33Measuring rate of flow ................................................................ 35Checking for leaks and pump pressure (1) ................................ 36Checking for leaks and pump pressure (2) ................................ 37Checking extraction chamber for leaks ..................................... 38Measuring coffee temperature ................................................... 39Measuring closing force ............................................................. 40Checking reed contact ................................................................ 41Daily maintenance and final cleaning ........................................ 42
Spare parts ................................................................. 43
4
Preface
The purpose of this Service Manual is to provide the service personnel with all necessaryinformation with regards to correct handling, maintenance and repair of the coffee machineEF 748 and EF 749.This manual should be used by the technicians as a valuable aid to guarantee the permanentreadiness for use of the machine. In order to take full advantage of all the functions, it isabsolutely necessary to follow the instructions in this manual.
Please keep this manual together with the corresponding service documentation. This wayyou are assured to have the necessary information.
For fast access to information directly from the PC or MAC monitor, this manual is alsoavailable on CD-ROM. The required utility (Adobe Acrobat), also on this CD-ROM, runs on PCand MAC computers. At the Internet address www.adobe.com you can obtain the utility AdobeAcrobat for additional platforms, free of charge.
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Main Components
Overview
1 Switch On/ Off2 Switch steam3 Upper part Jaw4 Lower part Jaw5 LED6 Electronic mainboard7 Steam pipe8 Frothing aid9 Floater10 Drip tray11 Drip grid12 Closing handle13 Jaw stick coffee / hot water14 Water tank15 Water tank connector16 Condensation room17 Thermoblock18 Pump19 Container for used capsules
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2
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10
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12 13
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15
3
16
17
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19
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Main Components
Jaw
20 Support for brewing unit21 Capsule cage22 Closing handle23 Jaw stick coffee, hot water/ steam24 Blades25 Cover26 Heating PTC (until Sept. 2003 only)27 Coffee capsule28 Ejector29 Pyramid plate (PPP, plastic)30 Pyramid plate support31 Brewing unit with ceramic valve and
reed contact board32 Capsule cage connection
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21
22 232426
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28
29
30
31
3225
7
Overview of rating platesDepending on the brand, the rating plate maybe of varying design.
The rating plates carry the followinginformation:
Turmix
Date codeDDMMY
KrupsFNA141 = type
1M = factory0 = internal number
08081 = Date codeDDMMY
Jura636 = type
A = colour code1 = Appliance
modification status
König03170 = Item numberwith colour code
Date code DDMMY
MagimixM200 = type code
Item number with colourand country coding
Date code DDMMYY
Saeco
Date code WWYY
Main Components
8
Main Components
Water circuit
1 Water tank2 Water tank valve3 Pump4 Thermoblock5 Ceramic valve6 Coffee outlet7 Steam pipe and frothing aid8 Condensation room9 Drip tray
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2
3
4
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6
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9
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Mains EUR: 230V / 50 HzUSA /CAN:120 V / 60 Hz
JAP: 110 V / 50-60 Hz
Cable length ~1,5 m
Approvals SEV, CENELEC, - conformUL, CUL, MITI
Pump pressure:- max. permissible 17,5 bar ±1,5 bar- during coffee preparation 9 - 13 bar
(depending on brand of coffee)
Flow performance100 - 240 ml/min. at 12 bar
Weight of machine 4,8 kg(without water)
CapacitiesWater tank 1.2 lDrip tray 0.45 lCapsule container 10-12 pcs.
Main Components
Dimensions in mm
Technical Data
Pre-heating time approx. ca. 45 s
Safety temperature (thermal cut-off) 184° C
Power consumption(at all voltages and frequencies):
Heating 1�200 WPump 60 WHeating PTC 15 W
Ratings:
Preheating 15.5 Wh1 small cup (45ml) 5.5 Wh1 large cup (110ml) 9 WhStand-by mode (24 hours) 575 Wh
10
Operation
1 Switch on machine2 Position pot underneath3 LED flashes green4 Fill with water5 Flush JAW
Preparation
12 3
4
5
11
Preparing hot water1 Position cup underneath steam pipe2 LED illuminates green3 Place jaw stick in the rear position, hot
water flows into the cup4 Once the cup contains the required
amount, return the jaw stick to themiddle position
1 Open jaw2 Insert capsule3 Close jaw4 Position cup5 LED must be green6 Place jaw stick in the front position,
coffee flows into the cup7 Once the cup contains the required
amount, return the jaw stick to themiddle position
8 Briefly open jaw and eject capsule intothe capsule container
Making coffee
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2
3
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1 2
3
4
Operation
12
Operation
Heating with steam
1 Slide down frothing pipe (only frothingaid A and B)
2 Press steam switch3 LED flashes orange, wait until LED
illuminates orange4 Immerse frothing pipe approx. 1cm
deep in the liquid5 Place jaw stick in the rear position until
the required temperature is reached6 Return jaw stick to the middle position
Frothing
There are three different types of frothing aid.A) EF 749B) EF 748 Turmix and NespressoC) EF 748 Krups
Frothing aids
1 Slide down frothing pipe (only frothingaid A and B)
2 Press steam switch3 LED flashes orange, wait until LED
illuminates orange4 Immerse frothing pipe approx. 1cm
deep in the milk5 Place jaw stick in the rear position until
the required foam is produced6 Return jaw stick to the middle position
1
2
34
5
6
A B C
13
Operating sequenceSwitch on main switchJaw stick forward or backJaw stick in middleOperate steam switchJaw stick backJaw stick in middle
Operation
LED status diagram
Steampreparation H
eatin
g up
Rea
dy
Cof
fee
/ hot
wat
erpr
epar
atio
n
Hea
ting
up
Rea
dy
Hea
ting
up
Stea
m re
ady
Stea
m p
repa
ratio
n
Coo
ling
LED-status1 LED flashes green slowly
2 LED illuminates green
3 LED flashes orange slowly
4 LED illuminates orange
5 LED flashes green quickly
1 2 2 2 3 4 4 51
A
The LED status diagram shows thebehaviour of the LED depending ontemperature and function.
Coffee andhot waterpreparation
NoteAfter the preparation of coffee or hotwater, the green LED may flashrapidly for a short time due to over-temperature.
!ABCDEF
!
DCB E F
3
14
� Check appliance for visible damage
� Check mechanical elements
� Switch on
� Fill water tank
� Coffee preparation without capsule
� Hot water preparation
- Parts of housing broken or damaged?- Mains cable damaged?- Has the customer opened the machine?
- Does the jaw stick engage?- Does the closing handle work?- Is the ejector mechanism in working order?
- LED flashes during heating up- How long does the machine need for
heating up (typical time approx. 45s)?
- Water tank leaks?
- Does the reed contact work?- Does the pump work?- Does hot water escape?
- Does the reed contact work?- Does hot water escape?
Troubleshooting
The receipt check enables you to rapidlylocate faults on the machine and to initiateappropriate repair action.
Keep to the order given in the table.
Repair any faults found and repeat therepair routine to the end.
Checking the machine - receipt (1)
15
� Steam preparation
� De-scale
� Flow rate
� Check for leaks
� Temperature measurement
� Clean
- Does the steam switch work correctly?LED must flash orange slowly duringheating up and then illuminate continuously.
- Does steam escape?
- See page 33
- See page 34
- See page 35 to 37
- See page 38
- See page 41
- See page 39
- See page 40
Troubleshooting
Checking the machine - receipt (2)
� Measure closing force
� Check reed contact
16
Troubleshooting
Complaint:
Coffee temperature too low
Cause?
� Jaw not preheated?
� Machine scaled (low outflow)?
� Faulty NTC temperature sensor?
� Faulty resistor in the thermoblock?
� Faulty heating PTC?
� Faulty NTC temperature sensor orelectronic mainboard?
� Machine not connected to mains?
� Intermittent contact in cables?
� Faulty fine-wire fuse?
� Faulty main switch?
� Faulty NTC temperature sensor?
Remedy!
- Preheat jaw, allow 2 large cups of water toflow through without capsule
- De-scale machine (see page 33)
- Replace NTC (see page 22)
- Replace thermoblock (see page 22)
- Replace heating PTC (see page 30)
- Replace NTC temperature sensor (seepage 22)
- Replace electronic mainboard (see page 25)
- Check mains voltage and plug into mains
- Replace cable
- Replace - determine reason for fault (seepage 24)
- Replace main switch (see page 26)
- Replace NTC temperature sensor (seepage 22)
Coffee temperature too high
No function
17
Troubleshooting
Complaint:
No outflow
Cause?
� Water tank empty?
� Water tank fitted incorrectly?
� Top of brewing unit is clogged?
� Pyramid plate is clogged?
� Machine is scaled?
� Pump connected incorrectly, or faulty?
� Electronic mainboard fault?
Remedy!
- Fill
- Insert correctly
- Clean, de-scale or replace (see page 27and 31)
- Replace (see page 31)
- De-scale (see page 33)
- Check pump connections- Replace pump (see page 23)
- Replace electronic mainboard (see page 25)
18
Troubleshooting
No steam function or too little steam
Cause?
� Steam and hot water pipe scaled?
� Steam and hot water pipe clogged?
� Steam switch faulty?
� Pump connected incorrectly?
� Reed contact faulty?
� Electronic mainboard faulty?
� Capsule ejector faulty?
� Capsule cage dirty or damaged?
� Pyramid plate dirty?
� Jaw poorly closed?
� Brewing unit leaks at the top?
� Not possible to close the jaw?
Remedy!
- De-scale machine (see page 33)
- Clean pipe
- Replace steam switch (see page 26)
- Check electrical connections on pump (seepage 23)
- Check reed contact (see page 40)- Replace reed contact (see page 29)
- Replace electronic mainboard (see page 25)
- Replace ejector (see page 31)
- Clean or replace capsule cage (see page 31)
- Clean or replace (see page 31)
- Close jaw correctly
- Replace hose, seal or valve (see page 29)
- Screw capsule cage on fully
No capsule ejection
Water on the jawWater runs out from the side of the jaw
Jaw does not close
19
Not enough froth when frothing milk
Cause?
� Thermoblock leaking?
� High pressure connections leaking?
� Silicon hoses torn?
� Valve on the water tank leaking?
� Internal manifold sleeve leaking?
� Water tank empty?
� Water tank not inserted correctly?
� Steam nozzle dirty or scaled?
� Frothing aid not correctly assembled?
� Milk not at fridge temperature?
� The temperature of the pot is too high?
� Heating element is scaled (temperatureloss)?
Remedy!
- Tighten connections on the thermoblock orreplace (see page 22)
- Replace seals or (and) hoses- Check for leaks (see page 35)
- Replace silicone hoses
- Replace water tank
- Replace internal manifold sleeve
- Fill
- Insert correctly
- Clean or de-scale (see page 33)
- Assemble correctly
- Only use milk at fridge temperature
- Use chrome-steel pot at fridge temperature
- De-scale machine (see page 33)
Complaint:
Pump noisy
Troubleshooting
Water on side of machine or belowmachine
20
General disassembly (stage 1)
Repair
Tools:
- Special screwdriver (oval)
General information:The screws are labelled with letters (A, B andC) in the figures.These refer to the tightening torques for thescrews.A = 0,5 to 0,9 NmB = 0,8 to 1,4 NmC = 1,3 to 1,8 Nm
A and B can be tightened by hand (A =tighten lightly, B = tighten firmly).For tightening screws labelled C it is im-perative that a torque wrench is used.
Procedure:
1. Remove water tank, drip tray, andcapsule container.
2. Place machine on the disassembly jig(item no. 28087).
3. Remove screws (13) on the undersideand rear of the side pieces.
4. Remove side pieces (2 and 3).
Unplug from the mains beforedisassembling machine -appliance must be isolated!
Item no. 28087
21
Tools
- Torx screwdriver T10, T15- Special screwdriver (oval)
Procedure
1. General disassembly stage 1.
2. Remove 3 bolts (13) on the cover at therear (9) on the underside.
3. Open jaw and remove screws (111) onthe cover.
4. Unscrew ball (80) on the jaw stick.
5. Remove screws (83) and closing lever(84).
6. Move cover (81) a little to the side andremove.
7. Remove 2 bolts (12) on the cover at therear on the top.
8. Remove cover at the rear (9).
General disassembly (stage 2)
Repair
22
Replacing thermoblock
Tools / aids:
- Torx screwdriver T10, T15- Flat nose pliers- Open-ended spanner 8/10mm AF- Pot to collect water- Torque wrench
Procedure:
1. General disassembly stage 1 and 2 (seepage 20 and 21).
2. Remove bolt (47) on the thermoblock (66).
3. Remove all electrical connectors.
4. Remove fine-wire fuse clip (43).
5. Remove NTC temperature sensor (64).
ATTENTION: Keep a pot at hand forcollecting the water left in thethermoblock.
6. Remove water connections on thethermoblock.
7. Replace thermoblock (66).
8. Assemble in reverse sequence. Only tightenNTC temperature sensor lightly until thespring washer is flat. Tighten bolt (46) totorque C using torque wrench.
Repair
Replacing NTC
Tools:
- Open-ended spanner 10mm AF
Procedure:
1. Remove connector on the logic board
2. Undo NTC temperature sensor (64)replace
3. Assemble in reverse sequence. Onlytighten NTC temperature sensor lightlyuntil the spring washer is flat.
23
Replacing pump
Tools / aids:
- Torx screwdriver T10- Open-ended spanner 14mm AF- Long-nose pliers- Pot to collect water
Procedure:
1. General disassembly stage 1 (see page20).
2. Remove all electrical connections
3. Remove steam switch (30, 63) on theunderside of the appliance to make iteasier to disassemble the pump (see page25).
4. Remove clamp (45) and hose (65).
ATTENTION: Keep a pot at hand forcollecting the water left in the pump.
5. Remove angled hose (57).
6. Release pump first from bottom rubberstrap, then from the top rubber strap (54).
Repair
7. Remove seal (51) and angle (37).
8. Replace pump (61).
9. Insert seal (51) and tighten cornerconnector (37).
10.Turn corner connector to the correctposition using open-ended spanner onpump projection.
11.Remaining assembly in reverse sequence.
ATTENTION!Check cable connection! If the
cables are reversed, it is not possible togenerate any steam.
Red cable
24
Repair
Replacing fine-wire fuse
Tools:
- Torx screwdriver T15- Long-nose pliers- Torque wrench
Procedure:
1. General disassembly stage 1 and 2 (seepage 20 and 21).
2. Remove all connections with red cable.
3. Undo clamp (43).
4. Replace fault fine-wire fuse (998).
5. Assemble in reverse sequence. Tightenbolt (46) to torque C using torque wrench.
25
Procedure:
1. General disassembly stage 1 (see page20).
2. Place earthing strap around the wrist andconnect to the earthing cable on the un-plugged machine! In this way a potentialdifference is avoided.
3. Remove connections from the board.
4. Undo 2 screws (12) and remove thecontrol board.
5. Replace control board (59).
6. Assemble in reverse sequence (see wiringdiagram, p.32)
Replacing control board
Tools:
- Torx screwdriver T10- Long-nose pliers
The service engineer must beearthed using an earthingstrap!
Repair
26
Repair
Tools:
- Torx screwdriver T10- Long-nose pliers
Procedure:
1. General disassembly stage 1 (see page 20).
2. Remove screws (12) on underside ofappliance.
3. Remove connections
4. Replace main switch (62) or steam switch(63).
5. Assemble in reverse sequence.
Replacing main switch or steamswitch
Replacing LED
Tools:
- Torx screwdriver T10
Procedure:
1. General disassembly stage 1 (see page 20).
2. Remove connector in the electronicmainboard.
3. Remove screws (12) and cover (33).
4. Remove screw (48) on the LED board.
5. Replace LED board (58).
6. Assemble in reverse sequence.
Replacing steam pipe
Tools:
- Torx screwdriver T10- Torque wrench
Procedure:
1. General disassembly stage 1 (see page 20).
2. Remove screws (12).
3. Remove cover (32).
4. Remove steam pipe (40) and replace.
5. Assemble in reverse sequence. Tightenbolt (12) to torque C using torque wrench.
27
Replacing jaw
Tools:- Torx screwdriver T10, T15- Cross-headed screwdriver- Long-nose pliers
Procedure:1. General disassembly stage 1 (see page 20).
2. Open jaw and remove screws (111) on thecover.
3. Unscrew ball (80) on the jaw stick (134).
4. Remove screws (83) and closing lever(84).
5. Move cover (81) a little to the side andremove.
6. Disassemble hoses (85, 65) on theceramic valve and remove grounding wire(115) on the support.
7. Pull off hose (132) on the expansionhousing.
8. Unplug heating PTC (110) and reedcontact (86) on the control board.
9. Remove screws (131) on the supportmodule (126).
10. Remove complete jaw and replace.
Repair
- Procedure on disassembly of the jaw when fitted.
28
Repair
Complete jaw disassembly
Tools:
- Hammer (plastic head)- Drift No. 4- Torx screwdriver T10- Torque wrench
Procedure:
1. General disassembly stage 1.
2. Disassemble jaw as per page 27.
3. Remove capsule cage (see page 31)
4. Remove cover (112).
5. Remove springs (98).
6. Remove shafts (108 +127).
7. Remove side closing lever (120), lockinglever (119) and shaft (113).
8. Remove screws on the control board.
9. Remove swivelling plate (97) with ejectorlever (94) and spring bearing (99).
- Procedure for complete disassembly of the jaw
29
Repair
Complete jaw disassembly
Replacing reed contact
Perform points 1 to 9 (see page 28).
10.Remove screws (87).
11.Remove screws (96) and bearing (109).
12.Remove reed contact (86) and replace.
Attention!The cover on the ceramic valve mustnot be removed.
13.Assemble in reverse sequence.
Replacing connection to capsule cage
Perform points 1 to 9 (see page 28).
10.Remove screws (96) and bearing (109).
11.Remove clamp (45).
12.Replace connection (91) and fit newseal (90).
13.Assemble in reverse sequence.
Replacing ceramic valve
Perform points 1 to 9 (see page 28).
10.Remove screws (96) and bearing (109).
11.Remove clamp (45) on the ceramic valve.
12.Remove connection (91) and hose (88).
13.Remove screws (87) on the ceramic valve.
14.Replace complete ceramic valve (incl.reed contact, 86).
15.Assemble in reverse sequence. Fit newseal (90) and tighten screws (87) to torqueC using torque wrench.
30
Repair
Replacing heating PTC
Tools / aids:
- Torx screwdriver T10
Only pertains to machinesproduced until sept. 2003.
Procedure:
1. General disassembly stage 1 and 2 (seepage 20 and 21).
2. Disassemble cover (112).
3. Remove connections on the electronicmainboard.
4. Pull out cable.
5. Remove screws (96) and PTC clamp(107).
6. Replace heating PTC (110).
7. Assemble in reverse sequence.
31
Replacing pyramid plate
Repair
Refer to modification sheetno. 2003-01.
Procedure:
1. Remove ejector (122).
2. Remove pyramid plate (123) withreceptacle (138).
3. Fit new pyramid plate with receptacle.Ensure that the pyramid plate is insertedin the correct position.
4. Fit ejector.
Replacing capsule cage
Tools / aids:
- Assembly tool (106)
Procedure:
1. Rotate capsule cage (137) from the cagebracket using the assembly tool (106).
2. Fit new capsule cage.
32
Electronic mainboard, wiring diagram
1) Reed contact
2) NTC temperature sensor
3) Board fastening
4) LED board
5) Steam switch (violet)
6) Steam switch (violet)
7) Pump (black)
8) Thermoblock (white)
9) Mains cable (blue)
10) Heating PTC (white)
11) Heating PTC (blue)
12) Fine-wire fuse and thermoblock (red)
Repair
1
2
3
4
5
6
7
8
9
10
11
12
3
33
Descaling
Maintenance
Never use vinegar.Decalcifier is aggressive to thesurface of the casing.
Preparation
1. Eject capsule, close jaw and place jawstick to middle position.
2. Remove steam nozzle and frothing pipeand put them into a pot (min. 0.6 l capacity).
3. Remove drip grid and place pot on driptray.
Read safety instructions on sideof descaling sachet.
4. Fill water tank with 0.1 l descaling fluidand 0.5 l water.
5. Switch on machine.
6. Wait till green indicator lights up.
Descaling
7. Place jaw stick in hot water position.
8. Let entire descaling solution pass throughsteam pipe.
9. Place jaw stick to middle position.
10. Fill water tank again with descalingsolution from pot.
2
1
Item no. 24361
3
4
9
8
6
7
10
34
11. Place pot with steam nozzle and frothingpipe on drip tray.
12. Place jaw stick in coffee position and letpass the entire descaling solution throughcoffee outlet.
13. Place jaw stick to middle position.
Rinsing
14. Empty pot. Rinse steam nozzle andfrothing pipe.
15. Flush water tank thoroughly and fill it withfresh water.
16. Place pot on drip tray.
17. Place jaw stick in hot water position. Lethalf a tank of water run through steam pipe.
18. Place jaw stick in coffee position and letremaining water run through coffee outlet.
19. Place jaw stick to middle position.
20. Switch machine off � decalcification iscompleted.
21. Mount steam nozzle and frothing pipe.
22. Insert drip grid.
23. Clean machine.
Descaling
Maintenance
11
1213
14 15
1719 18
22
162123
35
Maintenance
Measuring rate of flow
30 s
1. Remove ejector
2. Remove pyramid plate support
3. Fit pressure gauge
4. Close jaw
5. Position measuring beaker underneath
6. Switch on machine
7. Open valve fully
8. Place jaw stick in the front position
9. Close valve until 12 bar are indicated
10. Perform measurement for approx.30 sec.
11. There must be at least 60-120ml in themeasuring beaker
If the manometer indicates largefluctuations during the
measurement (12 +/- 4 bar), this is anindication that the pump is faulty.
Keep a watch for leaks!
The manometer must beobserved continuously and the
pressure regulated using the valve ifnecessary. With increasing temperaturethe pressure also increases, if necessaryreadjust the pressure to 12 bar.
10
1
2
3
4
5
7
8
9
12 bar
60...120 ml
36
1) Preparation of the machine
1. General disassembly stage 1 (seepage 20).
2. Open jaw and remove screws (111) onthe cover.
3. Unscrew ball (80) on the jaw stick(134).
4. Remove screws (83) and closing lever(84).
5. Move cover (81) a little to the side andremove.
6. Refit closing lever.
7. Fit pressure gauge.
8. Close jaw.
9. Position pot underneath.
Checking for leaks and pump pressure (1)
Maintenance
111 (A)
13484
83
81
37
Checking for leaks and pump pressure (2)
Maintenance
System: no leak leak
The residual pressure must bereleased after the test byopening the valve!The pump is permitted to be inoperation for max. 50 sec.without an outlet.
The following components are checked forleaks:- Capsule cage- Connections- Thermoblock- Pump
2) Check
1. Perform points 1 to 9 on page 35.
2. Jaw stick to the front (the valve on thepressure gauge must be opened).
3. Switch on machine.
4. Leave water to run out for approx. 10 s.
5. Fully close valve. The pressure willrise rapidly initially and stabilisebetween 16-19 bar (pump pressurecheck). The pressure will rise slowlydue to the temperature increase.
6. Visual and acoustic check on allpressurised connections. The pumpmust not be in operation for longerthan 50 s.
7. Switch off machine using the On-Offswitch (jaw stick remains in the frontposition).
8. The needle on the display must notdrop below 12bar in 60 s.
9. Open valve, open jaw (pressuregauge empties).
38
Maintenance
Checking extraction chamber for leaks
1. Switch on machine.
2. Remove ejector.
3. Remove pyramid plate support.
4. Insert special pyramid plate support.
5. Insert capsule and close jaw.
6. Jaw stick to the front.
7. Check outflow. The coffee should flow outevenly and without splashing to the side.
8. If the jet is not correct, replace capsulecage.
Preparation of the special pyramid platesupportSaw off the lower part of the pyramid platesupport such that the inner cone is notdamaged.
2
3
4
56
7
39
Maintenance
Measuring coffee temperature1. Switch on machine.
2. After warming up, leave 150ml of water toflow through to heat the jaw.
3. Insert capsule (Cosi is the most suitable).
4. Close jaw.
5. Position a pot underneath.
6. Place jaw stick in front position.
7. Measure the temperature approx.5 - 10 mm below the outlet opening.
8. Temperature should be approx.86 °C ± 3 °C (187 °F ± 5.4 °F).
40
Maintenance
Measuring closing force1. Switch on machine
2. After warming up, leave 150ml of water toflow through to heat up the jaw.
3. Insert capsule.
4. Attach spring balance to the middle of theclosing lever.
5. Press down closing lever with the aid ofthe spring balance until the closing leveris closed. Ensure that the spring actionof closing is not taken into account.
6. Read off value. Repeat measurementseveral times as necessary.
Closing force for new appliance: 25N +/-5N
If the closing force is less than 10N,replace capsule cage, pyramid plate andsupport.
Art. Nr. 80005
Art. Nr. 4.004
Ordering information:
Spring balance (80005) and compressionforce measuring tool (4.004) can be orderedfrom the following address:
PESOLA AGRebmattli 19CH-6340 BaarSwitzerland
Tel. +41 (0) 41 769 60 40Fax +41 (0) 41 769 60 42e-mail [email protected]
www.pesola.chwww.pesola.com
41
Maintenance
Checking reed contact
1. Press the test button on the reed contacttester - both LEDs must illuminate. Ifnecessary, replace battery.
2. General disassembly stage 1 (see page20, only remove the side piece coveringelectronic components).
3. Remove connection from reed contact tothe electronic mainboard and connect tothe reed contact tester.
4. Place the jaw stick at the front. The�coffee� LED illuminates, otherwise thereed contact is faulty.
5. Place the jaw stick at the rear: The�steam� LED illuminates, otherwise thereed contact is faulty.
During the test the machinemust be switched off andunplugged from the mains!
1
3
4
5
42
Daily maintenance and final cleaning
1. Clean water tank and fill with fresh water
2. Empty drip tray and clean
3. Empty capsule container
4. Flush jaw (min. 150 ml)
Maintenance
1
2
3
4
43
Spare parts
Pos. EFR item Description
001 0025391 Support black
002A Side piece 748 right black
003A Side piece 748 left black
002B Side piece 748 right yellow
003B Side piece 748 left yellow
002C Side piece 748 right blue
003C Side piece 748 left blue
002D Side piece 749 right silver
003D Side piece 749 left silver
002E Side piece 749 right white
003E Side piece 749 left white
002F Side piece 749 right red
003F Side piece 749 left red
004A 0025394 Drip tray 748 black
004B 0026377 Drip tray 749 black
005 0025395 Capsule container black
006A 0025396 Cover 748
006B 0026378 Cover 749 black
007 0025427 Water tank cover black
008A 0027295 Float yellow
008B 0027120 Moulded plug black
009 0025404 Cover rear black
010 0026373 Centring ring water tank black
44
Spare parts
Pos. EFR item Description
011 0023908 Valve flange 420 black to water tank
012 0016052 Cross panhead screw KST/PT 3.0x12 zinc plated blue Torx-10
013 0024863 Cross panhead screw locking washer zinc plated blue ovalKST/Remf.3.0x12
014 0010585 Locking washer 770 Inox
015 0010586 Grid 770 rust-free
016A 0025446 Drip plate 748
016B 0026374 Drip plate 749
017 0011933 IInternal manifold sleeve (M3) 22.22/15.87x4.76 black
018 0015890 Elastic stop 15.9 x 4.75mm black SJ-6115
019 0025463 Water tank transp. compl. welded/assembled
020 0025451 Base plate
45
Spare parts
Pos. EFR item Description
030 0025417 Switch panel black
031 0025409 Receptacle steam pipe black
032 0025419 Panel steam pipe black
033 0025418 Panel LED black
035 0027429 Expansion housing cpl. welded, bare
036 0006517 Cap top D=16x10.6mm for heater cartridge
037 0005466 Connection angle black 770 (pump)
038 0001053 Strain relief transparent screwed
039 0001442 Sheet bracket 946 EX100/964
040 0025751 Steam pipe long, chrome-plated
041A 0001349 Steam nozzle 925 Ms chrome-plated M6x0.5 for screw fitting
041B 0012050 Protective rubber Turmix Nespresso
042A 0011970 Frothing aid Turmix Nespresso
042B 0002630 Frothing aid Krups 72mm compl. incl. brass pipe, body, cap
042C 0014622 Frothing aid 749 AE compl. with grill AE Ks nozzle, pipe, O-ring
043 0021542 Fine-wire fuse TB2001 0.5x10.0x21.0mm
044 0005245 Lock washer M5 zinc-plated blue
045 0005470 Clamp 770 pressure hose
046 0019799 Screw GF/Tapt.M4.0x 8 zinc plated panhead with lock ring Torx-20
047 0018121 Screw GF/Tapt.M4.0x40 zinc plated blue panhead Torx-20 waxed
048 0020151 Screw sheet 2.9x 9.5 zinc-plate black panhead Torx-10 point
049 0025452 Support TB2001
050 0008242 Washer 04.3x12.0x1.5 zinc plated blue M4
46
Spare parts
Pos. EFR item Description
051 0024374 O-ring 003.40x1.90 silicone 70 Shore red, 2-comp. silicon
052 0001565 O-ring 005,28x1.78 EPDM 70 Shore black
053 0010629 O-ring 005.70x1.90 EPDM 70 Shore black
054 0025450 Pump supports AE grey 60 Shore 3 fastening holes 6.5mm
055 0009212 Hose silicon 05.0x2.00x090 75 Shore, transparent
056 0012440 Hose silicon 08.0x1.75x260 55 Shore white, cut
057 0005454 Angle hose 770 silicon
058 0025298 El.LED 748
059 0025299 El. control board 748 230-240V 50-60Hz
060A 0025449 Mains cable black HO5VVF-3G075 1,50 S1: Cebec S2: 140/90/40
060B 0025554 Mains cable black H05VVF-3G075 1.50 S1:GB S2:140/90/40
060C 0025555 Mains cable black H05VVF-3G075 1.50m S1: SEV/ S2: 140/90/40
061 0018526 Pump CP4/SP(CP2) 230V/50Hz without thermost./without strap/with th. recept.
062 0004561 Switch B111C1121000 16A/250V black, making 0/I white
063 0025447 Switch B1A4C112K000 16A/250 black whitemarking steam symbol
064 0015448 Temperature sensor with wires 230mm
065 0027345 Hose PFA D4.0/2.50x280mmwith 1 clamping ring/1 Sertokl� ring/2 tubular rivets assembled
066 0026677 Replacement thermobl.2001 230V compl. with Serto fittingand flange connector
47
Spare parts
Pos. EFR item Description
080 0024394 Ball handle black for jaw stick
081A 0027886 Cover 748 silver painted symbols black
081B 0025401 Cover 749 black symbols silver
081C 0027884 Cover 748 yellow symbols black
081D 0027885 Cover 748 blue symbols black
082 0025432 Panel valve lever Inox
083 0024537 Cross cyl. head screw KST/PT 4.0x 8 Inox Torx-15
084 0025293 Closing lever chrome-plated cast zinc
085 0025278 Hose FEP D4.0/2.50x220mm with 2 clamping ringswith tubular rivets assembled
086 0024397 El. reed contact board
087 0022504 Screw KST/PT 3.5x16 zinc-plated blue panhead Torx-10
088 0025280 Hose FEP D4.0/2.50x 35mm
089 0024314 Support ring black profile seal
090 0024379 Seal black for capsule cage connection
091 0024301 Connection to capsule cage black
093 0005255 Washer 03.2x09.0x0.8 zinc-plated blue M3 DIN 9021/ISO 7093
094A 0024296 Ejector lever black first version
094B 0028218 Ejector lever 748/2 black
095 0027339 Spring (torsion spring) Inox D=1.0x12.0;Nt4.25
096 0020740 Cross panhead screw GF/Tapt.M3.0x 8 Torx-10, waxedzinc-plated blue
097 0024288 Swivelling plate Inox to brewing unit
098 0024377 Spring for brewing unit D=0.70x6.0x29.4mm Inox
099 0024304 Spring bearing plain
102 0024387 O-ring 010.00x2.00 black
104 0024317 Plate Inox
105 0024318 Banjo bolt Inox
106 0024361 Assembly tool black for capsule cage
107 0024307 PTC clamp until Sept. 2003 only
48
Pos. EFR item Description
108 0024298 Shaft for module support rear, Inox hardened
109 0024302 Bearing capsule cage aluminium
110 0024396 Heating PTC type 83/112/20/17,5 32-I, for brewing unit 748
111 0018904 Cross panhead screw KST/PT 3.0x16 zinc plated blue Torx-10
112 0024360 Cover swivelling piece black
113 0024300 Shaft for closing lever steel hardened
115 0025455 Si wire EU yellow-gr.480mm 0.75 1xFHL4.8- Ni/1xRKS4.3-Ni
116 0010997 Panhead screw M4.0x 8 zinc-plated black Torx-15
117 0024390 Connecting piece black for closing lever
118 0024388 Recessed disc size 6, for shafts / with slot, type KL, dacrometised
119 0024395 Closing lever plate Inox
120 0024291 Sealing plate Inox
121 0024295 Shaft sealing system for brewing unit Inox hardened
122 0024311 Ejector black
123 0036692 Plate pyramide Polymer black PPP
124A 0025676 Outlet compl. welded for brewing unit, black first version
124B 0029385 Outlet 748/2 compl. welding black
125 0011020 Seal black (OCS) for outlet
126A 0024312 Support module, black first version
126B 0028220 Support 748/2 module, black Brewing unit
127 0024299 Shaft for module support steel hardened
128 0024297 Supporting plate Inox
129 0025678 Cover spring
130 0025398 Panel brewing head black
131 0019504 Cross panhead screw KST/PT 3.0x20 zinc-plate blue Torx-10
132 0025287 Hose silicon 05.0x2.00x200 70 Shore black, cut
133 0026392 Hose silicon 08.0x1.75x190 55 Shore white, cut
Spare parts
49
135 0026650 Replacement ceramic valve pre-assembled
Pos. EFR item Description
136 0026797 Replacement support ring with seal fitted
137 0026651 Replacement capsule cage fitted
138A 0026799 Replacement outlet with seal fitted first version
138B 0037590 Spare-Outlet 737 compl. with gasket assemb.
139 0026798 Replacement brewing unit without support assembled
140 0026801 Replacement brewing unit with support assembled
998A 0025461 EF wire EU 216°C (1xG4) brown 130/120/120/250mm
998B 0025456 Si wire EU black 310mm 0.75 1xFHL4.8- Ni/1xFLH6.3-Ni
998C 0025460 Si wire EU violet 260mm 0.75 1xFHL4.8-Ni/1xFHW4.8-Sn
Spare parts
50
998D 0001219 Si wire EU white 130mm 0.75 2xFHL4.8-Ni
Pos. EFR item Pesola item Description
0027917 Pressure gauge
0027918 Reed contact tester
0028087 Machine assembly/disassembly
0024361 Assembly tool
0004872 Special (oval) screwdriver with Bit
0004878 Bit oval for screwdriver
80005 Spring balance 5kg. Pesola AG, Switzerland
4.004 Spring balance accessory(compression force measuring tool) Pesola AG, Switzerland
Spare parts
0027917
0027918
00280870024361
80005
4.004 0004872
0004878