en Service Manual Coffee Machine

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.

5

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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5

67

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9

10

11

12 13

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15

3

16

17

18

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

20

21

22 232426

27

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

1

2

3

4

5

6

7

8

9

9

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

1

2

3

4

5

67

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)


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!


- 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 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


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:


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:


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).


Replacing steam pipe

Tools:

- Torx screwdriver T10- Torque wrench

Procedure:


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).



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



11.Remove clamp (45).

12.Replace connection (91) and fit newseal (90).

13.Assemble in reverse sequence.

Replacing ceramic valve



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:


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).


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

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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.


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.


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).



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).


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


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


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


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


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


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


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


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

Documents

en Service Manual Coffee Machine