en Service Manual Coffee Machine EF 748 EF 749 1 01.2004 DOG
Contents Main Components... 5 Overview... 5 Jaw... 6 Overview of rating plates... 7 Water circuit... 8 Technical Data... 9 Operation... 10 Preparation... 10 Making coffee... 11 Preparing hot water... 11 Frothing aids... 12 Heating with steam... 12 Frothing... 12 LED status diagram... 13 Troubleshooting... 14 Checking the machine - receipt (1)... 14 Checking the machine - receipt (2)... 15 Coffee temperature too low... 16 Coffee temperature too high... 16 No function... 16 No outflow... 17 No steam function or too little steam... 18 No capsule ejection... 18 Jaw does not close... 18 Water on the jaw... 18 Water on side of machine or below machine... 19 Pump noisy... 19 Not enough froth when frothing milk... 19 2
Contents Repair... 20 General disassembly (stage 1)... 20 General disassembly (stage 2)... 21 Replacing thermoblock... 22 Replacing NTC... 22 Replacing pump... 23 Replacing fine-wire fuse... 24 Replacing control board... 25 Replacing main switch or steam switch... 26 Replacing LED... 26 Replacing steam pipe... 26 Replacing jaw... 27 Complete jaw disassembly... 28 Complete jaw disassembly... 29 Replacing heating PTC... 30 Replacing pyramid plate... 31 Replacing capsule cage... 31 Electronic mainboard, wiring diagram... 32 Maintenance... 33 Descaling... 33 Measuring rate of flow... 35 Checking for leaks and pump pressure (1)... 36 Checking for leaks and pump pressure (2)... 37 Checking extraction chamber for leaks... 38 Measuring coffee temperature... 39 Measuring closing force... 40 Checking reed contact... 41 Daily maintenance and final cleaning... 42 Spare parts... 43 3
Preface The purpose of this Service Manual is to provide the service personnel with all necessary information with regards to correct handling, maintenance and repair of the coffee machine EF 748 and EF 749. This manual should be used by the technicians as a valuable aid to guarantee the permanent readiness for use of the machine. In order to take full advantage of all the functions, it is absolutely necessary to follow the instructions in this manual. Please keep this manual together with the corresponding service documentation. This way you are assured to have the necessary information. For fast access to information directly from the PC or MAC monitor, this manual is also available on CD-ROM. The required utility (Adobe Acrobat), also on this CD-ROM, runs on PC and MAC computers. At the Internet address www.adobe.com you can obtain the utility Adobe Acrobat for additional platforms, free of charge. 4
Main Components Overview 1 Switch On/ Off 2 Switch steam 3 Upper part Jaw 4 Lower part Jaw 5 LED 6 Electronic mainboard 7 Steam pipe 8 Frothing aid 9 Floater 10 Drip tray 11 Drip grid 12 Closing handle 13 Jaw stick coffee / hot water 14 Water tank 15 Water tank connector 16 Condensation room 17 Thermoblock 18 Pump 19 Container for used capsules 1 3 4 5 7 6 12 13 14 16 15 8 11 19 17 9 18 10 2 5
Main Components Jaw 20 Support for brewing unit 21 Capsule cage 22 Closing handle 23 Jaw stick coffee, hot water/ steam 24 Blades 25 Cover 26 Heating PTC (until Sept. 2003 only) 27 Coffee capsule 28 Ejector 29 Pyramid plate (PPP, plastic) 30 Pyramid plate support 31 Brewing unit with ceramic valve and reed contact board 32 Capsule cage connection 21 27 25 26 24 32 22 23 28 29 31 30 20 6
Main Components Overview of rating plates Depending on the brand, the rating plate may be of varying design. The rating plates carry the following information: Turmix Date code DDMMY König 03170 = Item number with colour code Date code DDMMY Krups FNA141 = type 1M = factory 0 = internal number 08081 = Date code DDMMY Magimix M200 = type code Item number with colour and country coding Date code DDMMYY Jura 636 = type A = colour code 1 = Appliance modification status Saeco Date code WWYY 7
Main Components Water circuit 1 Water tank 2 Water tank valve 3 Pump 4 Thermoblock 5 Ceramic valve 6 Coffee outlet 7 Steam pipe and frothing aid 8 Condensation room 9 Drip tray 5 1 8 6 2 7 3 9 4 8
Main Components Technical Data Mains EUR: 230V / 50 Hz USA /CAN:120 V / 60 Hz JAP: 110 V / 50-60 Hz Pre-heating time approx. Safety temperature (thermal cut-off) ca. 45 s 184 C Cable length ~1,5 m Approvals SEV, CENELEC, - conform UL, CUL, MITI Pump pressure: - max. permissible 17,5 bar ±1,5 bar - during coffee preparation 9-13 bar (depending on brand of coffee) Power consumption (at all voltages and frequencies): Heating Pump Heating 1 200 W 60 W PTC 15 W Dimensions in mm Flow performance 100-240 ml/min. at 12 bar Weight of machine 4,8 kg (without water) Capacities Water tank 1.2 l Drip tray 0.45 l Capsule container 10-12 pcs. Ratings: Preheating 15.5 Wh 1 small cup (45ml) 5.5 Wh 1 large cup (110ml) 9 Wh Stand-by mode (24 hours) 575 Wh 9
Operation Preparation 1 Switch on machine 2 Position pot underneath 3 LED flashes green 4 Fill with water 5 Flush JAW 1 2 3 5 4 10
Operation Making coffee 1 Open jaw 2 Insert capsule 3 Close jaw 4 Position cup 5 LED must be green 6 Place jaw stick in the front position, coffee flows into the cup 7 Once the cup contains the required amount, return the jaw stick to the middle position 8 Briefly open jaw and eject capsule into the capsule container 4 2 3 1 5 7 6 Preparing hot water 1 Position cup underneath steam pipe 2 LED illuminates green 3 Place jaw stick in the rear position, hot water flows into the cup 4 Once the cup contains the required amount, return the jaw stick to the middle position 3 4 1 2 11
Operation Heating with steam 1 Slide down frothing pipe (only frothing aid A and B) 2 Press steam switch 3 LED flashes orange, wait until LED illuminates orange 4 Immerse frothing pipe approx. 1cm deep in the liquid 5 Place jaw stick in the rear position until the required temperature is reached 6 Return jaw stick to the middle position Frothing 1 Slide down frothing pipe (only frothing aid A and B) 2 Press steam switch 3 LED flashes orange, wait until LED illuminates orange 4 Immerse frothing pipe approx. 1cm deep in the milk 5 Place jaw stick in the rear position until the required foam is produced 6 Return jaw stick to the middle position 4 1 3 5 6 2 Frothing aids There are three different types of frothing aid. A) EF 749 B) EF 748 Turmix and Nespresso C) EF 748 Krups A B C 12
Operation LED status diagram The LED status diagram shows the behaviour of the LED depending on temperature and function. LED-status 1 LED flashes green slowly 2 LED illuminates green 3 LED flashes orange slowly 4 LED illuminates orange 5 LED flashes green quickly Steam preparation Heating up Ready Coffee / hot water preparation Heating up Ready Heating up Steam ready Steam preparation Cooling Operating sequence A Switch on main switch B Jaw stick forward or back C Jaw stick in middle D Operate steam switch E Jaw stick back F Jaw stick in middle Coffee and hot water preparation 3 A! B C D E F Note! After the preparation of coffee or hot water, the green LED may flash rapidly for a short time due to overtemperature. 1 2 2 1 2 3 4 4 5 13
Troubleshooting Checking the machine - receipt (1) The receipt check enables you to rapidly locate faults on the machine and to initiate appropriate repair action. Keep to the order given in the table. Repair any faults found and repeat the repair routine to the end. Check appliance for visible damage Check mechanical elements - 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? Switch on - LED flashes during heating up - How long does the machine need for heating up (typical time approx. 45s)? Fill water tank - Water tank leaks? Coffee preparation without capsule - Does the reed contact work? - Does the pump work? - Does hot water escape? Hot water preparation - Does the reed contact work? - Does hot water escape? 14
Troubleshooting Checking the machine - receipt (2) Steam preparation - Does the steam switch work correctly? LED must flash orange slowly during heating up and then illuminate continuously. - Does steam escape? De-scale - See page 33 Flow rate - See page 34 Check for leaks - See page 35 to 37 Temperature measurement - See page 38 Clean - See page 41 Measure closing force - See page 39 Check reed contact - See page 40 15
Troubleshooting Complaint: Cause? Remedy! Coffee temperature too low Jaw not preheated? Machine scaled (low outflow)? Faulty NTC temperature sensor? Faulty resistor in the thermoblock? Faulty heating PTC? - Preheat jaw, allow 2 large cups of water to flow 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) Coffee temperature too high Faulty NTC temperature sensor or electronic mainboard? - Replace NTC temperature sensor (see page 22) - Replace electronic mainboard (see page 25) No function Machine not connected to mains? Intermittent contact in cables? Faulty fine-wire fuse? Faulty main switch? Faulty NTC temperature sensor? - Check mains voltage and plug into mains - Replace cable - Replace - determine reason for fault (see page 24) - Replace main switch (see page 26) - Replace NTC temperature sensor (see page 22) 16
Troubleshooting Complaint: Cause? Remedy! No outflow 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? - Fill - Insert correctly - Clean, de-scale or replace (see page 27 and 31) - Replace (see page 31) - De-scale (see page 33) - Check pump connections - Replace pump (see page 23) - Replace electronic mainboard (see page 25) 17
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? Remedy! - De-scale machine (see page 33) - Clean pipe - Replace steam switch (see page 26) - Check electrical connections on pump (see page 23) - Check reed contact (see page 40) - Replace reed contact (see page 29) - Replace electronic mainboard (see page 25) No capsule ejection Capsule ejector faulty? Capsule cage dirty or damaged? Pyramid plate dirty? - Replace ejector (see page 31) - Clean or replace capsule cage (see page 31) - Clean or replace (see page 31) Water on the jaw Water runs out from the side of the jaw Jaw poorly closed? Brewing unit leaks at the top? - Close jaw correctly - Replace hose, seal or valve (see page 29) Jaw does not close Not possible to close the jaw? - Screw capsule cage on fully 18
Troubleshooting Complaint: Cause? Remedy! Water on side of machine or below machine Thermoblock leaking? High pressure connections leaking? Silicon hoses torn? Valve on the water tank leaking? Internal manifold sleeve leaking? - Tighten connections on the thermoblock or replace (see page 22) - Replace seals or (and) hoses - Check for leaks (see page 35) - Replace silicone hoses - Replace water tank - Replace internal manifold sleeve Pump noisy Water tank empty? Water tank not inserted correctly? - Fill - Insert correctly Not enough froth when frothing milk 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 (temperature loss)? - 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) 19
Repair General disassembly (stage 1) Tools: - Special screwdriver (oval) General information: The screws are labelled with letters (A, B and C) in the figures. These refer to the tightening torques for the screws. A = 0,5 to 0,9 Nm B = 0,8 to 1,4 Nm C = 1,3 to 1,8 Nm Unplug from the mains before disassembling machine - appliance must be isolated! Item no. 28087 A and B can be tightened by hand (A = tighten lightly, B = tighten firmly). For tightening screws labelled C it is imperative that a torque wrench is used. Procedure: 1. Remove water tank, drip tray, and capsule container. 2. Place machine on the disassembly jig (item no. 28087). 3. Remove screws (13) on the underside and rear of the side pieces. 4. Remove side pieces (2 and 3). 20
Repair General disassembly (stage 2) Tools - Torx screwdriver T10, T15 - Special screwdriver (oval) Procedure 1. General disassembly stage 1. 2. Remove 3 bolts (13) on the cover at the rear (9) on the underside. 3. Open jaw and remove screws (111) on the 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 and remove. 7. Remove 2 bolts (12) on the cover at the rear on the top. 8. Remove cover at the rear (9). 21
Repair 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 (see page 20 and 21). 2. Remove bolt (47) on the thermoblock (66). 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. Only tighten NTC temperature sensor lightly until the spring washer is flat. 3. Remove all electrical connectors. 4. Remove fine-wire fuse clip (43). 5. Remove NTC temperature sensor (64). ATTENTION: Keep a pot at hand for collecting the water left in the thermoblock. 6. Remove water connections on the thermoblock. 7. Replace thermoblock (66). 8. Assemble in reverse sequence. Only tighten NTC temperature sensor lightly until the spring washer is flat. Tighten bolt (46) to torque C using torque wrench. 22
Repair 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 page 20). 2. Remove all electrical connections 3. Remove steam switch (30, 63) on the underside of the appliance to make it easier to disassemble the pump (see page 25). 4. Remove clamp (45) and hose (65). ATTENTION: Keep a pot at hand for collecting the water left in the pump. 5. Remove angled hose (57). 6. Release pump first from bottom rubber strap, then from the top rubber strap (54). 7. Remove seal (51) and angle (37). 8. Replace pump (61). 9. Insert seal (51) and tighten corner connector (37). 10.Turn corner connector to the correct position using open-ended spanner on pump projection. 11.Remaining assembly in reverse sequence. ATTENTION! Check cable connection! If the cables are reversed, it is not possible to generate any steam. Red cable 23
Repair Replacing fine-wire fuse Tools: - Torx screwdriver T15 - Long-nose pliers - Torque wrench Procedure: 1. General disassembly stage 1 and 2 (see page 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. Tighten bolt (46) to torque C using torque wrench. 24
Repair Replacing control board Tools: - Torx screwdriver T10 - Long-nose pliers The service engineer must be earthed using an earthing strap! Procedure: 1. General disassembly stage 1 (see page 20). 2. Place earthing strap around the wrist and connect to the earthing cable on the unplugged machine! In this way a potential difference is avoided. 3. Remove connections from the board. 4. Undo 2 screws (12) and remove the control board. 5. Replace control board (59). 6. Assemble in reverse sequence (see wiring diagram, p.32) 25
Repair Replacing main switch or steam switch Tools: - Torx screwdriver T10 - Long-nose pliers Procedure: 1. General disassembly stage 1 (see page 20). 2. Remove screws (12) on underside of appliance. 3. Remove connections 4. Replace main switch (62) or steam switch (63). 5. Assemble in reverse sequence. Replacing LED Tools: - Torx screwdriver T10 Procedure: 1. General disassembly stage 1 (see page 20). 2. Remove connector in the electronic mainboard. 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. Tighten bolt (12) to torque C using torque wrench. 26
Repair Replacing jaw - Procedure on disassembly of the jaw when fitted. 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 the 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 and remove. 6. Disassemble hoses (85, 65) on the ceramic valve and remove grounding wire (115) on the support. 7. Pull off hose (132) on the expansion housing. 8. Unplug heating PTC (110) and reed contact (86) on the control board. 9. Remove screws (131) on the support module (126). 10. Remove complete jaw and replace. 27
Repair Complete jaw disassembly - Procedure for complete disassembly of the jaw 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), locking lever (119) and shaft (113). 8. Remove screws on the control board. 9. Remove swivelling plate (97) with ejector lever (94) and spring bearing (99). 28
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 must not be removed. 13.Assemble in reverse sequence. Replacing connection to capsule cage 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 new seal (90) and tighten screws (87) to torque C using torque wrench. 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 new seal (90). 13.Assemble in reverse sequence. 29
Repair Replacing heating PTC Tools / aids: - Torx screwdriver T10 Procedure: Only pertains to machines produced until sept. 2003. 1. General disassembly stage 1 and 2 (see page 20 and 21). 2. Disassemble cover (112). 3. Remove connections on the electronic mainboard. 4. Pull out cable. 5. Remove screws (96) and PTC clamp (107). 6. Replace heating PTC (110). 7. Assemble in reverse sequence. 30
Repair Replacing pyramid plate Procedure: Refer to modification sheet no. 2003-01. 1. Remove ejector (122). 2. Remove pyramid plate (123) with receptacle (138). 3. Fit new pyramid plate with receptacle. Ensure that the pyramid plate is inserted in the correct position. Replacing capsule cage Tools / aids: - Assembly tool (106) Procedure: 1. Rotate capsule cage (137) from the cage bracket using the assembly tool (106). 2. Fit new capsule cage. 4. Fit ejector. 31
Repair 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) 1 2 3 4 3 5 7 9 11 6 8 10 12 32
Maintenance Descaling Preparation Never use vinegar. Decalcifier is aggressive to the surface of the casing. 1. Eject capsule, close jaw and place jaw stick to middle position. 2. Remove steam nozzle and frothing pipe and put them into a pot (min. 0.6 l capacity). 3. Remove drip grid and place pot on drip tray. Read safety instructions on side of descaling sachet. 1 Item no. 24361 2 3 4 4. Fill water tank with 0.1 l descaling fluid and 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 through steam pipe. 9. Place jaw stick to middle position. 10. Fill water tank again with descaling solution from pot. 7 6 9 33 8 10
Maintenance Descaling 11. Place pot with steam nozzle and frothing pipe on drip tray. 13 12 12. Place jaw stick in coffee position and let pass the entire descaling solution through coffee outlet. 13. Place jaw stick to middle position. Rinsing 14 15 14. Empty pot. Rinse steam nozzle and frothing pipe. 15. Flush water tank thoroughly and fill it with fresh water. 11 16. Place pot on drip tray. 17. Place jaw stick in hot water position. Let half a tank of water run through steam pipe. 18. Place jaw stick in coffee position and let remaining water run through coffee outlet. 17 19 18 19. Place jaw stick to middle position. 20. Switch machine off decalcification is completed. 22 21. Mount steam nozzle and frothing pipe. 22. Insert drip grid. 23. Clean machine. 16 23 21 34
Maintenance Measuring rate of flow 1. Remove ejector 2. Remove pyramid plate support 3. Fit pressure gauge 4. Close jaw 5. Position measuring beaker underneath 6. Switch on machine 1 4 8 7. Open valve fully 8. Place jaw stick in the front position 2 9. Close valve until 12 bar are indicated 10. Perform measurement for approx. 30 sec. 11. There must be at least 60-120ml in the measuring beaker If the manometer indicates large fluctuations during the measurement (12 +/- 4 bar), this is an indication that the pump is faulty. 12 bar 3 9 7 Keep a watch for leaks! The manometer must be observed continuously and the pressure regulated using the valve if necessary. With increasing temperature the pressure also increases, if necessary readjust the pressure to 12 bar. 5 60...120 ml 35 10 30 s
Maintenance Checking for leaks and pump pressure (1) 1) Preparation of the machine 1. General disassembly stage 1 (see page 20). 2. Open jaw and remove screws (111) on the 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 and remove. 6. Refit closing lever. 7. Fit pressure gauge. 8. Close jaw. 9. Position pot underneath. 111 (A) 84 83 81 134 36
Maintenance Checking for leaks and pump pressure (2) The following components are checked for leaks: - 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 the pressure gauge must be opened). 3. Switch on machine. 4. Leave water to run out for approx. 10 s. 5. Fully close valve. The pressure will rise rapidly initially and stabilise between 16-19 bar (pump pressure check). The pressure will rise slowly due to the temperature increase. 6. Visual and acoustic check on all pressurised connections. The pump must not be in operation for longer than 50 s. 7. Switch off machine using the On-Off switch (jaw stick remains in the front position). 8. The needle on the display must not drop below 12bar in 60 s. 9. Open valve, open jaw (pressure gauge empties). The residual pressure must be released after the test by opening the valve! The pump is permitted to be in operation for max. 50 sec. without an outlet. System: no leak leak 37
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. 2 5 6 6. Jaw stick to the front. 3 7. Check outflow. The coffee should flow out evenly and without splashing to the side. 8. If the jet is not correct, replace capsule cage. 4 Preparation of the special pyramid plate support Saw off the lower part of the pyramid plate support such that the inner cone is not damaged. 7 38
Maintenance Measuring coffee temperature 1. Switch on machine. 2. After warming up, leave 150ml of water to flow 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). 39
Maintenance Measuring closing force 1. Switch on machine 2. After warming up, leave 150ml of water to flow through to heat up the jaw. 3. Insert capsule. 4. Attach spring balance to the middle of the closing lever. 5. Press down closing lever with the aid of the spring balance until the closing lever is closed. Ensure that the spring action of closing is not taken into account. 6. Read off value. Repeat measurement several times as necessary. Closing force for new appliance: 25N +/-5N If the closing force is less than 10N, replace capsule cage, pyramid plate and support. Art. Nr. 80005 Art. Nr. 4.004 Ordering information: Spring balance (80005) and compression force measuring tool (4.004) can be ordered from the following address: PESOLA AG Rebmattli 19 CH-6340 Baar Switzerland Tel. +41 (0) 41 769 60 40 Fax +41 (0) 41 769 60 42 e-mail info@pesola.ch www.pesola.ch www.pesola.com 40
Maintenance Checking reed contact 1. Press the test button on the reed contact tester - both LEDs must illuminate. If necessary, replace battery. 2. General disassembly stage 1 (see page 20, only remove the side piece covering electronic components). 3. Remove connection from reed contact to the electronic mainboard and connect to the reed contact tester. 4. Place the jaw stick at the front. The coffee LED illuminates, otherwise the reed contact is faulty. 5. Place the jaw stick at the rear: The steam LED illuminates, otherwise the reed contact is faulty. During the test the machine must be switched off and unplugged from the mains! 1 3 5 4 41
Maintenance 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) 1 2 4 3 42
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 43
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 oval KST/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 44
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 45
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 white marking steam symbol 064 0015448 Temperature sensor with wires 230mm 065 0027345 Hose PFA D4.0/2.50x280mm with 1 clamping ring/1 Sertokl ring/2 tubular rivets assembled 066 0026677 Replacement thermobl.2001 230V compl. with Serto fitting and flange connector 46
Spare parts 47 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 rings with 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, waxed zinc-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
Spare parts 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 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 49
Spare parts 0028087 0027918 0027917 0024361 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 80005 0004878 4.004 0004872 50