Bosch tca60f9 Repair Instruction Download Page 86

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58300000111195_ARA_en_f.doc – 02.06.09

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7.4 Service

diagnosis

7.4.1 Hardware

requirements

To operate the system without errors, the following minimum
requirements must be satisfied:

Hardware requirements

PC 486 or higher

VGA

MS DOS 6.0 or higher

Windows 95 / 98 / NT / 2000

At least 5MB disc space

on HD

3.5” disk drive

At least 2 serial interfaces

USB interface

Parallel interface

Printer

7.4.2 Service

diagnosis

kit (Mat.-no. 34 0995)

A service diagnosis kit is required to support diagnosis of the
appliances by PC. This kit includes the following components:

(A)

Scanner (is switched between PC and test object)

(B)

Connecting cable between scanner and test object

(C)

CD with diagnostic software

(D)

Connecting cable between PC and scanner

(E)

Start installation disk

(F)

Power supply unit for scanner (In: 230 V/50 Hz,

Out: 9 VAC/300 mA 2.7 VA)

Summary of Contents for tca60f9

Page 1: ... 6 Brewing unit 27 4 7 Gear unit 33 4 8 Ceramic valve 2 way valve 37 4 9 Hot water steam nozzle 39 4 10 Coffee outlet 40 4 11 Drip tray 42 4 12 Water filter 44 5 FUNCTIONS 45 5 1 The perfect espresso 45 5 2 Operating principle 45 5 3 Warming the cups 45 5 4 Diaphragm regulator with blow off valve 46 5 5 Reduction angle with blow off valve alternative 46 5 6 Temperature 47 5 7 Overview of the symbo...

Page 2: ...0000111195_ARA_en_f doc 02 06 09 Seite 2 von 102 8 TECHNICAL SPECIFICATIONS 99 8 1 Rating plate 99 8 2 Power 100 8 3 Temperatures 100 8 4 Dimensions and weight 101 8 5 Filling amounts 101 8 6 Components 102 ...

Page 3: ...airs are complete perform a test in accordance with VDE 0701 or the corresponding national regulations Following each repair conduct a leak and performance test 1 2 Repair instructions Caution NEVER attempt repairs by randomly replacing components ALWAYS proceed systematically and comply with the technical documentation for the appliance Components become hot during operation Before commencing rep...

Page 4: ...urface e g heating plate and never use it close to an open flame 2 2 Scope of delivery All appliances are supplied with the Welcome pack starter kit 2 2 1 Welcome pack The Welcome pack starter kit contains the parts required to start up the appliance 2 Detergent tablets Test strip for determining the local water hardness 2 Descaler tablets for 1 descaling process Scoop and screw in aid for water f...

Page 5: ...e bean container with fresh coffee beans Preferably use espresso beans or bean mixtures for fully automatic machines Set mains switch at the back of the appliance to I Set function selector to coffee brewing process Press Standby button The appliance conducts a self test heats up and rinses Heating up to standby temperature Moving the brewing unit to the upper end position Pump starts 50 ml of wat...

Page 6: ...tton 3 2 2 Standby button The Stand by button switches on and starts the appliance or switches it from brewing mode to stand by When the standby button has been pressed the appliance heats up and is then rinsed The illuminated ring around the button flashes during this process During the coffee brewing process the standby button is assigned a Stop function Press this button to end the current brew...

Page 7: ...m pipe Steam can be drawn after the appliance has heated up to steam temperature After steam has been drawn coffee can be brewed again immediately 3 2 4 Coffee dispensing button Press the coffee dispensing button to start the coffee brewing process During the brewing process the green illuminated ring flashes If the coffee dispensing button is pressed again the coffee brewing process ends early Th...

Page 8: ...coffees and 2 XXL coffees are not the same as the double filling quantity for corresponding single cups Therefore aromatic coffee can still be brewed even when there is the maximum amount of liquid selected 3 2 6 Coffee strength selector The amount of coffee to be ground can be changed by rotating the coffee strength selector This setting affects the aroma and flavour the caffeine and acid content...

Page 9: ...can still be brewed To start the cleaning cycle press the clean button for approx 3 sec Use cleaning tablets Mat no 31 0575 3 2 8 Descaling button When the red illuminated ring lights up around the descaling button calc the appliance must be descaled Coffee can still be brewed To start the descaling cycle press the calc button for approx 3 sec Use liquid descaling agent Mat no 31 0451 ...

Page 10: ...amount of ground coffee can cause malfunctions especially by using dark roasted coffee beans with high oil rate Risk of damage Adjust the grinding unit only while the grinding unit is running Otherwise the appliance may be damaged Open right cover of the appliance Press the coffee dispensing button to start a brewing cycle While the grinding unit is running turn the knob to select the degree of gr...

Page 11: ...ght be empty and must still be filled up with ground coffee Therefore press the coffee dispensing button again to make sure that there is enough ground coffee filled in the brewing unit 3 3 2 Using preground coffee WARNING Risk of damage Do not add whole coffee beans or instant coffee Add a maximum two scoops of pre ground coffee A second type of coffee can be used Pre ground coffee can be filled ...

Page 12: ...ctly If external water softeners are used in the domestic water system or if filtered water is used select water hardness 1 Water hardness 4 is preset Determine the water hardness with the enclosed test strip or ask your local water supplier Test strip for determining the water hardness mat no 05 6317 Hardness 1 Descale alarm after 220 litres Hardness 2 Descale alarm after 100 litres Hardness 3 De...

Page 13: ... Press calc descaling button until the illuminated rings for the desired water hardness light up If the illuminated ring around the cafe button flashes the filter can be set Press cafe button once The selected water hardness is saved Note The appliance now switches on automatically As soon as the illuminated rings around the stand by and cafe buttons as well as the coffee cup sign in the display a...

Page 14: ...lter system message is displayed immediately replace or remove used water filters If no new water filter is inserted adjust the water hardness To activate the filter and ensure correct function the inserted filter must be rinsed Observe the following points 3 4 2 1 Inserting the water filter The appliance must be in stand by mode Place a vessel with a capacity of at least 500 ml under the hot wate...

Page 15: ...veyed into the collecting vessel approx 2 minutes The water may be a little cloudy do not drink it If the turn on coffee system message is displayed turn function selector back to brew coffee The appliance is ready for use again 3 4 2 3 Removing the water filter Switch the appliance to stand by mode Using the screwing aid unscrew the water filter in an anti clockwise direction Simultaneously hold ...

Page 16: ...side of the appliance with a damp cloth Remove water tank rinse out and fill with fresh water Pull drip tray forwards and remove Empty drip tray 1 and dregs drawer 2 and clean with mild detergent solution Only degs drawer 2 can be cleaned in the dishwasher Thoroughly clean drawer contacts 3 on all sides and dry Note Coffee or water residue between the drawer contacts may result in error messages E...

Page 17: ...e with vinegar or vinegar based substances Do not interrupt the descaling programme Never drink the liquid 3 6 1 Descaling alarm The correct setting of the water hardness is important for the descaling indicator Test strip for determining the water hardness mat no 05 6317 Hardness 1 220 litres Hardness 2 100 litres Hardness 3 70 litres Hardness 4 40 litres If water hardness 1 is set the request to...

Page 18: ...y and re insert drip tray and dregs drawer 2 This display is indicated irrespective of the actual filling of the trays and ensures that the descaling cycle is not interrupted 3 Fill water tank up to the mark 0 5 l with warm water and add descaling agent or Fill water tank with 0 5 l of ready mixed descaling solution If using descaling tablets add two tablets Observe the dissolving time of the tabl...

Page 19: ...is completely drained Wait for the next display approx 10 minutes 8 Pull drip tray out of the appliance empty and re insert 9 Remove water tank rinse out fill with fresh water and re insert Empty collecting vessel and place back under the steam nozzle 10 Rotate function selector to draw hot water The appliance is rinsed auto matically Water approx 150 ml is conveyed in intervals into the collectin...

Page 20: ...tically The descaling process is complete The illuminated ring around the calc descaling button goes out The appliance is ready for use again If the descaling process is termi nated prematurely the descaling alarm is not cancelled 3 6 2 4 The descaling programme does not start The descaling programme starts only if the FILTER programming is not active Take the filter out of the water tank and set ...

Page 21: ...hragm controller pressure controller 3 Mains transformer 4 Flowmeter 5 Pump 6 Watertank valve support 7 Gear unit 8 Power electronics module 9 Control electronics module 10 Heating element 11 Service plug Note From production date FD8701 on Implementation of a second thermal fuse on heater Drip tray monitoring by an additional microswitch ...

Page 22: ...t the flowmeter must be operated in a horizontal position 4 2 1 Design and function Water is pumped in from the water tank and flows through the flowmeter Water is supplied via the connection pipe in the lower section of the housing D Water is discharged via the connection pipe in the upper section of the housing A The two halves of the housing are sealed with a silicone seal B The fan impeller C ...

Page 23: ...ing via the Hall IC Wrong connection of voltage signal and earth destroys the flowmeter Prevent inductive faults via the cable Do not lay the cable together with supply cables to consumers 4 3 Heater and NTC sensor 4 3 1 Heater Instantaneous water heater In the instantaneous water heater the water for coffee production or hot water steam purchase is heated up Therefore the water is pumped in a sta...

Page 24: ...58300000111195_ARA_en_f doc 02 06 09 Seite 24 von 102 4 3 2 Characteristic of NTC sensor Temperature R min R nom R max 25 C 9 78k 10 00K 10 22k 95 C 0 77k 0 78k 0 80k 140 C 0 232k 0 234k 0 237k ...

Page 25: ...re masks are programmed remove the older versions The appliance software on the control module cannot be updated for the service 4 4 1 Overview of software mask version Version Change Mask 2 Switch off time changed from 4 to 3 hours CSI 01 Mask 3 According to tank sensor coffee quantity from 100ml to 200ml can be drawn Temperature from value 1 High to value 2 Maximum CSI 02 Mask 5 Position detecti...

Page 26: ...wing unit 4 5 1 Door lock The service door behind the brewing unit is installed is locked with a bar Open the door by rotating the locking knob in a clockwise direction To ensure that the door is not opened without authorisation e g with a coin the locking knob features an additional crosspiece A Open the service door with a screwdriver PB 169 6 M4 ...

Page 27: ...ma formation the crema valve which is situated above the brewing head opens when the pressure reaches 4 5 bar At the end of the brewing process the used coffee dregs are emptied into the dregs drawer via the discharge chute D 4 6 1 1 Variable brewing chamber The brewing unit consists primarily of the brewing chamber A into which the ground coffee 7 g 14 g is metered and the spring mounted brewing ...

Page 28: ...ely ground coffee can be poured in via the powder slot 4 6 2 2 Compression The grinding unit stops The gears control the brewing unit to the upper end position In doing so the ground coffee is compressed in the brewing chamber C The pressure applied to the ground coffee causes the spring mounted brewing head D to move up The more powder there is in the brewing chamber the higher the brewing head i...

Page 29: ...avours and formation of the crema If the pressure inside the brewing chamber increases above 4 5 bar the crema valve E opens and the coffee can flow to the coffee outlet F 4 6 2 4 Emptying When the programmed amount of water is reached the pump stops The pressure in the brewing chamber drops and the coffee dregs are compressed into a solid cake The drainage valve opens pressure and residual water ...

Page 30: ...mediately before the pressure pump switches on and can therefore detect whether and how much ground coffee has been metered This value can be compared with the nominal value for the aroma setting Differences are adjusted by changing the running times of the grinding unit 4 6 3 1 Switching states If there is a minimum amount of coffee 7 g the brewing head does not move The switch is not actuated No...

Page 31: ...unit B Long discharge chute new reinforced brewing unit 4 6 4 1 Stripping off clip To improve functional safety a stripping off clip B was fitted to the brewing unit A This stripping off clip is attached to the discharge chute on the brewing chamber and moves closely past the brewing head C during each brewing cycle Coffee dregs which stick to the brewing head are therefore removed mechanically Fa...

Page 32: ...e and did not fall into the brewing chamber could become jammed near the control lever of the brewing unit This resulted in a blockage of the brewing unit and error messages The additionally attached rib A prevents cleaning tablets from sticking in this location and causing damage Note The control lever is a component of the brewing unit and is not available separately All current replacement brew...

Page 33: ...e brewing unit via a cam B connected to the drive shaft Note From production date FD8701 on the drip tray is monitored by an additional microswitch in the appliance If the drip tray is pulled out the microswitch opens and interrupts the power supply to the gear motor via the power module 4 7 2 Rear housing On the rear housing section of the gear unit the drainage valve B is attached to the expansi...

Page 34: ...rainage position S1 ON S2 OFF The brewing unit is in the grinding position and can be filled Switch S1 is activated by switch cam A Switch S2 remains open S1 OFF S2 ON The transmission turns clockwise until switch S2 is closed by switch cam A and switch S1 is open The brewing unit is in the brew position The transmission motor stops Water can be supplied and coffee can be brewed S1 ON S2 ON Once t...

Page 35: ...ears are in the home position the drainage valve is open The cam E of the actuator must then be in the illustrated position Warning Malfunction The position of the actuator and therefore the cam E is not specified permanently on the drive shaft The actuator may be in the wrong position The function sequence may malfunction When installing the gears ensure that actuator is in the correct position a...

Page 36: ...e drainage valve control line and closes it Water can flow from inlet A through drainage valve B to outlet C 4 7 4 3 Drainage position Once the brewing process is complete the water pump switches off The transmission motor turns the input shaft with tripping device D back through about 8 and opens the drainage valve The pressure is relieved and the water can drain into the expansion chamber and th...

Page 37: ...against each other convey the hot water or the steam to the hose connections for the drainage valve or the steam pipe A Heating inlet C To the drainage valve brewing unit D To the steam pipe drawing hot water and steam 4 8 1 Switch matrix The microswitches S1 and S2 control the heater and pump via the logic board The microswitches are actuated by rotating the cam 4 8 1 1 Switch positions Steam S1 ...

Page 38: ...ceramic wheel releases the water or steam passage The corresponding openings in the lower wheel are connected to each other via indentations in the upper wheel A Inlet B Outlet to the steam pipe C Outlet to the drainage valve brewing module Drawing steam Drawing coffee Drawing hot water ...

Page 39: ...gh steam pipe A and the connected steam nozzle thereby creating underpressure inside the steam nozzle This underpressure is balanced out by fresh air flowing in through opening B on the nozzle holder and C on the tip of the nozzle If the nozzle is immersed in cold milk to above side opening C and steam is dispensed fresh air flows in through opening B on the nozzle holder At the same time milk is ...

Page 40: ...ts dissolved in the coffee can froth up inside the coffee outlet D and form the crema The coffee is distributed evenly from the overflow to the left and right and then flows out through the outlet nozzles E into the cup Note To ensure that the coffee flows out evenly from the left and right it is essential that the machine is level Soiling and deposits affect the coffee outlet Therefore regularly ...

Page 41: ...production date FD8606 A newly introduced jug 1 in conjunction with changes to the distributor 2 and to the distributor cover 3 ensure a more even outlet with lower right left tolerances The coffee outlet is available only as a complete pre assembled spare part with or without chrome plated outlet sleeves and replaces the previous coffee outlet ...

Page 42: ...erted into the water The electrical resistance between the tray contacts drops EMPTY TRAYS is displayed If the EMPTY TRAYS display does not go out despite the trays having been emptied there may be residual water or moisture between the contacts transfer resistance caused by damp ground coffee Carefully clean trays in the area of the contacts with a soap solution and then dry Note From production ...

Page 43: ... the appliance is opened 4 11 2 1 Function Drip tray is missing Detection springs 1 and 2 are not jumpered by the tray contact I The circuit is interrupted Drip tray inserted Detection springs 1 and 2 are jumpered by the tray contact I The circuit is closed Drip tray is full of water The tray contacts I and II are inserted into the water The electrical resistance between the tray contacts drops Th...

Page 44: ...te and conveyed out through the centre of the water tank valve Up flow principle 4 12 2 Filter specifications The filter capacity at 27 dH is approx 50 litres 400 brews or 2 months The filter filling consists of approx 100 ml ion exchange resin and silvered activated carbon in the ratio 4 1 Filter diameter 27 42 mm Filter length 175 mm Filling volume 95 100 ml Filter effect Carbon hardness Chlorin...

Page 45: ...wing module moves into the upper end position When this position has been reached the water pump begins conveying water Water is drawn out of the tank via the flowmeter The water flow causes the fan impeller to rotate in the flowmeter causing electrical pulses to be generated The running time of the pump is specified by the number of the pulses The pump conveys the water through the heater at a pr...

Page 46: ...into the drip tray via hoses Note From production date FD8307 on a reinforced brewing unit has been implemented so the blow off valve is no longer necessary 5 5 Reduction angle with blow off valve alternative The water is drawn out of the water tank via the hose connection A The water flows through the flow meter B and rotates the fan impeller inside This causes electronic impulses to be generated...

Page 47: ...actory A Switch on press Standby button B Press the coffee dispensing button or draw hot water C Stop drawing coffee hot water D Turn function selector to steam heating up process begins E Draw steam F Turn function selector to cafe cooling down process begins After coffee has been drawn the appliance may be briefly disabled from reheating As soon as steam has been drawn coffee can be brewed again...

Page 48: ...unless coffee was drawn as the last product the temperature on the thermal block is below 130 C 5 7 2 Filling the system Symbol is lit The water line system in the appliance is empty lit flashes Remark System must be refilled with water Remedial action Press the coffee dispensing button System is filled minimum amount Note If the message does not go out check the water flow If water runs into the ...

Page 49: ...A_en_f doc 02 06 09 Seite 49 von 102 5 7 3 Appliance is being cleaned Symbol is lit The appliance is being cleaned lit flashes 5 7 4 Appliance is being descaled Symbol is lit The appliance is being descaled lit flashes ...

Page 50: ...ound coffee flashes Remedial action Leave the appliance to cool down or cool it manually by drawing hot water 5 7 6 Filling with ground coffee cover closed Coffee scoop flashes Coffee cup is lit The ground coffee duct flap was opened the ground coffee slot can be filled with ground coffee lit lit Remark Before coffee can be brewed the ground coffee duct flap must be closed ...

Page 51: ...button The grinding unit does not start in this function Note If the cup is not actuated within 90 sec the system is automatically drained to prevent overfilling The system is drained and rinsed 5 7 8 Drawing coffee with preground coffee Both symbols are lit Preground coffee is being drawn lit flashes Remark If the coffee dispensing button is pressed again the brewing of pre ground coffee can be i...

Page 52: ...ash The bean container is empty lit lit Remedial action Fill the bean container and restart coffee production by pressing the coffee dispensing button 5 7 10 Coffee brewing in standby Symbol is lit Indicates that the appliance is in normal operating mode Coffee or hot water can be drawn lit lit ...

Page 53: ...g coffee Symbol is lit Coffee is being drawn lit flashes Remark If the coffee dispensing button is pressed again the drawing of coffee can be interrupted at any time 5 7 12 Appliance is heating up Symbol flashes Appliance is heating up flashes Remark Approx 70 seconds ...

Page 54: ...4 von 102 5 7 13 Drawing steam Symbol is lit Steam is being drawn lit flashes 5 7 14 Appliance heats up to steam temperature Symbol flashes Heater heats up from coffee temperature to steam temperature lit flashes Remark Duration approx 15 seconds ...

Page 55: ...r and float mag netic switch A residual water level between 80 ml and 180 ml in the tank is possible The amount of residual water in the tank depends on the product which was last brewed espresso coffee 5 7 16 Empty the trays Symbol is lit Drip tray or coffee dregs tray is full OR the switch contacts on the drip tray are dirty lit Remedial action Remove drip tray or coffee dregs tray empty and re ...

Page 56: ...rectly inserted The appliance cannot detect the coffee dregs tray lit Remedial action Insert trays correctly Note Heater OFF 5 7 18 Turn on coffee Symbol is lit For reasons of function the function selector must be set to the coffee position lit Remedial action Rotate function selector to the coffee position ...

Page 57: ...uld be cooled down by drawing hot water lit lit Remark Required before starting the cleaning or descaling programme Remedial action Set function selector to draw hot water 5 7 20 Door not closed No brewing unit Symbol is lit Service door is not closed OR Brewing unit is not or in correctly installed lit Remedial action Close service door Re install and lock brewing unit ...

Page 58: ...tion without filter Change settings on the appliance accordingly Note Descaling and cleaning programmes are disabled while this display is lit 5 7 22 Error 1 Upper symbol is lit lower row flashes Error 1 NTC temperature sensor is out side the measurement range flashes Appliance too cold 5 C or NTC defective short circuit The message is indicated when the appliance has been switched on and initiali...

Page 59: ...wing unit cannot move properly Error 8 Initialisation of the brewing unit has failed flashes The brewing unit cannot be moved into the upper end position This may be due to several causes e g Incorrect operation the brewing unit was filled with too much pregorund coffee or with whole coffee beans via the ground coffee slot Incorrect operation cleaning tablet was inserted too early and blocked the ...

Page 60: ...customers During a service the brewing unit can be released and taken out of the appliance 6 1 1 1 Opening the service door The service door behind the brewing unit is permanently installed is locked with a bar Open the door by rotating the locking knob in a clockwise direction To ensure that the door is not opened without authorisation e g with a coin the locking knob features an additional cross...

Page 61: ...t is accessible The brewing unit is secured in the appliance with three locks Removing the brewing unit A Remove 3 rubber caps with a flat screwdriver B Loosen 3 locks by rotating them with a flat screwdriver C Pull out brewing unit of the appliance Symbols on the brewing unit indicate whether the lock is open or closed Lock closed Lock open ...

Page 62: ...amber is located completely underneath the filling funnel Inserting the brewing unit A Insert brewing unit into the appliance B Fix two locks by rotating them clockwise with a flat screwdriver C Fix lock by rotating it counter clockwise with a flat screwdriver D Insert three rubber caps into the notches Symbols on the brewing unit indicate whether the lock is open or closed Lock closed Lock open ...

Page 63: ...e brewing head B the O ring for the water inlet C and the coupling for the input shaft D must be thinly greased with food safe special lubricating grease PARALIQ GTE 703 Mat no 31 0574 Note After replacing the O ring for the coffee outlet A or for the water inlet C they must be thinly greased with food safe special lubricating grease PARALIQ GTE 703 Mat no 31 0574 ...

Page 64: ...k A from the appliance 2 Remove the aroma protection cover B from the bean container 3 Open and remove the ground coffee flap C To do this open the flap and pull it up 4 Loosen 8 Torx T10 screws D on back panel E of appliance Note When removing the back panel take care of the supply cable to the mains switch 5 Remove back panel E to rear 6 Remove upper section of housing to rear and up 7 Remove ho...

Page 65: ...use is in perfect condition and is correctly installed 6 3 1 Checking an installed thermal fuse The following points must be checked Position and attachment of the Teflon hose must be firmly anchored Position of the thermal fuse centred under installation bracket Quality of the cable connections Bend correct Installation bracket is firmly attached 6 3 2 Component The thermal fuse is supplied as a ...

Page 66: ...rmal fuse to be replaced This must be done with a suitable pair of flat nose pliers In doing so comply with the following points Bend must be at least 5 mm from the housing of the thermal fuse Teflon hose and thermal fuse must not be damaged Connections may be bent 1 x only 6 Position thermal fuse on the mounting surface of the heater ensuring that the installation bracket is in the centre of the ...

Page 67: ...open the coffee outlet insert a flat tipped screwdriver into the catch on the underside of the outlet slide 1 loosen the catch 2 and remove the front housing section of the outlet slide 3 6 4 2 Loosening the coffee distributor First remove the silicone hose A Remove the coffee distributor B after detaching the catches C ...

Page 68: ...s press For subsequent removal Press the outlet slide all the way down 1 Insert a flat tipped screwdriver into the side openings in the metal bands A and prise the metal bands out of the guide pins by rotating the screwdriver 2 6 4 4 Removing the metal bands Using a flat tipped screwdriver press the metal band A downwards Remove the metal bands A and the braking magnets B ...

Page 69: ...02 06 09 Seite 69 von 102 6 4 5 Loosening the screw fittings When the metal bands have been removed the screw fittings are accessible A Attachment of the outlet slide 2x Torx T10 B Fastening screws for the front panel 3x Torx T10 ...

Page 70: ... message does not go out when the appliance is switched off and on again disconnect the appliance from the power supply and clean the upper brewing filter C in the brewing unit It is not necessary to remove the brewing unit for this process Pull out and remove the drip tray Insert a damp cloth into the drip tray duct from the front on the right pull upwards and clean the brewing filter by hands 6 ...

Page 71: ...essage In the worst case this may also cause the lever to jump out Therefore a fin A is also attached the control lever The control lever is a component of the brewing unit and is not available separately All current replacement brewing units feature this new lever 6 5 2 4 Cleaning process sticker Information sticker to avoid damage caused by adding the cleaning tablet at the wrong time is stuck t...

Page 72: ...ng for the cleaning tablet is reduced This is compensated for by the roun ding of the filling edge d on the ground coffee duct In the event of a service the modified components ground coffee duct and grinding unit funnel should both be replaced Module consisting of a ground coffee duct and grinding unit funnel is available under mat no 49 6369 6 5 2 6 Plug insulation on gearbox microswitch During ...

Page 73: ...fee duct flap and start a coffee brewing process Rotate function selector briefly to draw steam in order to increase the temperature Appliance calcified Descale Heater has heated up to steam temperature Coffee temperature too high NTC temperature sensor defective NTC temperature sensor not screwed on correctly Cool down heater by drawing hot water Replace NTC temperature sensor Tighten NTC tempera...

Page 74: ...r dirty or defective Place appliance on a level base Replace outlet distributor Hose system or drainage valve leaking During a brewing process check hose system and drainage valve for leaks when drawing several cups in succession Drainage valve leaking due to coffee dregs Run descaling programme Replace drainage valve Incorrect pulsing from flowmeter Check hose system between flowmeter and pump If...

Page 75: ...ty and clean bean container Use beans with lower fat content Noise of grinding unit is loud Foreign object in grinding unit e g grit may also occur with select coffees Replace grinding unit Grinding unit is not functioning Ground coffee has been selected Press coffee dispensing button again to start another brewing process Power module not actuated by the logic module Check actuation to do this pr...

Page 76: ...ion selector blocked calci fied Replace ceramic valve and descale Too little froth when frothing milk Frother dirty or calcified Dismantle frother clean carefully or descale poor froth consistency Frother assembled incorrectly Assemble correctly and ensure all parts are fitted securely without gaps froth collapses Milk is not at refrigerator temperature Use only cold milk which is at refrigerator ...

Page 77: ... tablet is blocking brewing unit From production date FD8701 on Microswitch for drip tray monitoring is not actuated Remove and clean brewing unit remove cleaning tablet If damaged replace brewing unit Wrong or defective drip tray inserted Power supply for gear motor is interrupted Brewing unit cannot be moved Replace drip tray Descaling programme does not start System too hot message on display C...

Page 78: ...l times Water running out during brew ing process Ceramic valve leaking Replace ceramic valve and following in stallation actuate 2 3 times Drip tray leaking Crack in drip tray Replace drip tray new material Hose system leaking Calcification increases pressure in the hose above 35 bar Replace hose descale Fabric hoses burst Hose has preliminary damage Drainage valve leaking Water running out durin...

Page 79: ...on and initialised If the ambient temperature is too low the message goes out when the appliance has warmed up to room temperature 7 2 1 2 Error 5 Upper symbol is lit Lower row flashes Error 5 Heater or thermal link is defective interrupted If this defect occurs while the appliance is operating in a warm state the message Unit is heating is displayed The message is indicated as long as the applian...

Page 80: ...eans via the ground coffee slot Incorrect operation cleaning tablet was inserted too early and blocked the brewing unit Wrong coffee settings too much too finely ground coffee Wrong grinding unit setting grinding too coarse amount too large If the message does not go out when the appliance is switched off and on again disconnect the appliance from the power supply and clean the upper filter in the...

Page 81: ...ctuates the magnetic switch The appliance is ready to use 3 If the water level drops to a level between 80 ml and 180 ml ADD WATER is displayed The amount of residual water in the tank depends on the product which was last brewed espresso coffee Brewing is not terminated due to lack of water 4 Silting or calcification in the water tank may cause the float to stick to the tank wall Despite the fill...

Page 82: ...during the brewing process ADD BEANS is displayed even though the bean container has been filled Grinding unit is not filled with ground coffee e g when switching on the appliance for the first time or following service press the coffee dispensing button to start another coffee brewing process Beans cannot flow into the grinding unit empty and clean bean container Use beans with lower fat content ...

Page 83: ...ety this retaining ring has since been used in series production as well 7 2 2 4 Empty trays Symbol is lit EMPTY TRAYS Dregs drawer or drip tray are full or tray contacts are dirty When the drip tray is full of water the tray contacts are inserted into the water The electrical resistance between the contacts drops EMPTY TRAYS is dis played Pull trays empty and re insert If the EMPTY TRAYS display ...

Page 84: ... 2 2 5 Trays missing Symbol flashes TRAYS MISSING Drip tray not or incorrectly inserted Insert drip tray all the way If the TRAYS MISSING display goes out even though the drip tray has not been inserted check that the tray contacts are positioned correctly ...

Page 85: ...nduct drawer test with original tray Insert test drawer appliance rinses independently Are illuminated rings on the standby and coffee dispensing buttons lit How long does the machine require to heat up rinse Standard time approx 70 sec 4 Fill water tank Water tank leaking 5 Coffee preparation without coffee Open and close ground coffee lid are messages indicated Press the coffee dispensing button...

Page 86: ...disk drive At least 2 serial interfaces USB interface Parallel interface Printer 7 4 2 Service diagnosis kit Mat no 34 0995 A service diagnosis kit is required to support diagnosis of the appliances by PC This kit includes the following components A Scanner is switched between PC and test object B Connecting cable between scanner and test object C CD with diagnostic software D Connecting cable bet...

Page 87: ...The scanner is connected to the PC and test object with the connecting cables included in the diagnostic kit The scanner is supplied with a 9 VAC operating voltage via the power supply unit 7 4 5 USB service diagnosis kit The scope of delivery is changed with the introduction of the new USB service diagnostic kit Mat no 34 0995 The power supply unit is no longer required because the scanner is sup...

Page 88: ...e cover A 7 4 7 Input diagnostic Data is read out Production statistical service customer data The difference on the counter since the last service is deleted The latest current factory settings are transferred from the PC to the machine The internal appliance faults are analysed service fault bits Then either a static diagnostic or a dynamic diagnostic is run similar to the final inspection durin...

Page 89: ...mple 00001000 Heating up not possible 7 4 9 Measured variables for service suggestions Brews since last intervention 1500 Fault rectified Brews since last intervention 1500 3500 Minor service Brews since last intervention 3500 Major service Total brews total rinses and Brews since last intervention 2 2500 Major service 7 4 10 Definition of minor major service 7 4 10 1 Minor service Descale applian...

Page 90: ...n of the heating cartridge Input service entry via input mask see service stamp Identical to the input diagnostic a report is also prepared here with the same processing options 7 4 14 Service stamp The service stamp is input via the following form 7 4 14 1 Group definition Specific fault groups are allocated to the working points When a working point has been selected its fault group is activated...

Page 91: ...he animation system stamp 3 1 4095 Invoice item stamp 3 1 255 7 4 15 Service data Special software is required to analyse the data from the service systems This software is executed at each start of the service system It combines all repaired appliances in one text file This file can be imported for further processing into Excel or Access The update solution FTP tool can send these files by e mail...

Page 92: ... VAC If there is no electrical meter available temporarily insert and operate another electrical device on the same socket No power supply Have electrical installation checked Power supply available see Point 2 2 Check voltage at mains input 220 240 VAC To do this open the appliance Using the Torx T10 screwdriver unscrew all rear panel screws and remove the rear panel Check voltage at the mains in...

Page 93: ...g CP4 2 x red 15 VDC 2 x white 9 VDC No voltage defective transformer No 15 VDC voltage defective transformer No 9 VDC voltage defective transformer Voltage available see Point 7 7 Check voltage at power module output to logic 5 VDC The output voltage is measured from the power module to the logic module control electronics on plug CP9 terminals 1 GND brown and 2 5V red No voltage defective power ...

Page 94: ...signal voltage can be measured on plug CM9 on terminals 1 GND brown and 5 5 VDC green The grinding unit must be actuated by a coffee brewing process No signal voltage Logic module or connecting cable defective Voltage available see Point 2 2 Check voltage on power module grinding unit output The voltage for the grinding unit is measured on plug CP5 on terminals 3 GND black and 2 230 VDC transparen...

Page 95: ...module pump output The voltage for the pump is measured on plug CP5 on terminal 1 phase and the neutral conductor terminal 4 The pump must be actuated by a coffee brewing process No voltage defective power module Voltage available see Point 3 3 Check voltage on thermostat input Before the voltage can be checked on the pump itself the thermostat must be tested for function The pump must not be over...

Page 96: ...ses No control voltage Logic module or connecting cable defective Voltage available see Point 2 2 Check voltage on power module heater output The voltage for the heater is measured on plug CP5 on terminal 5 neutral conductor blue and terminal 1 phase brown The heater must be actuated by drawing hot water The heater is actuated in pulses No voltage defective power module Voltage available see Point...

Page 97: ... left Logic module or connecting cable defective Voltage available see Point 2 2 Check voltage on power module brewing unit output To check the voltage at the power module brewing unit output 12 VDC open the appliance Using the Torx T10 screwdriver unscrew all rear panel screws and remove the rear panel Remove upper appliance cover to the rear Remove both side panels upwards The voltage for the dr...

Page 98: ...art coffee brewing process by pressing the coffee dispensing button 6 Wait until there are 20 ml of coffee in the measuring cup Then measure the coffee temperature approx 5 10 mm under the coffee outlet B in the middle of flow 1st coffee The coffee temperature should be approx 82 C 5 C 7 Empty the measuring cup A and place it under the coffee outlet again 8 Start coffee brewing process by pressing...

Page 99: ...ication designation C Customer service index Newly launched appliances are given the customer service index 01 The customer service index is increased to 02 03 etc if customer service makes changes to the appliance D Frequency E Production date according to BSH key For example FD8410 84 year minus 20 2004 10 month October F Serial number optional G Power H Type works designation I Field for approb...

Page 100: ...when equal amounts of ice water and salt are mixed He then defined 96 F as the temperature when the thermometer is held in the mouth or under the armpit of a living man in good health Celsius 0 C and 100 C are arbitrarily placed at the melting and boiling points of water and standard to the metric system Formula C F 32 0 5555 F 1 8 C 32 8 3 1 Coffee outlet 1st coffee NORMAL in the flow 82 C 5 2nd ...

Page 101: ...1 2 m 8 4 3 Weight of machine 7 5 kg 8 5 Filling amounts 8 5 1 Capacity Water tank 1 8 l Bean container Approx 250 g Drip tray 750 ml signal limit 8 5 2 Cup filling amounts 1 220 ml XXL COFFEE 2 160 ml LARGE COFFEE 3 125 ml COFFEE 4 80 ml SMALL COFFEE 5 40 ml ESPRESSO 6 20 ml SMALL ESPRESSO 7 40 ml 2 SMALL ESPRESSOS 8 80 ml 2 ESPRESSOS 9 160 ml 2 SMALL COFFEES 10 250 ml 2 COFFEES 11 300 ml 2 LARGE...

Page 102: ...C 3000 r p m no load 451 1 6 6 r p m 4 0 Nm from spindle Transformer Primarily power supply Secondary voltage 1 Secondary voltage 2 230 V AC 50Hz 9 0 V AC 15 0 V AC Heater Supply voltage Power 230 V AC 50Hz 1250 W Pump Supply voltage Power 230 V AC 50 Hz 65 W 15 17 bar static Pump thermostat Switching off limit 115 C Pressure valve Opening pressure 10 bar Grinding unit Supply voltage Speed motor S...

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Bosch tca60f9, Repair Instruction

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