VKI Technologies CAFFE MIO Operation & Service Manual Download Page 84 | Manualshive

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S E C T I O N 5 – R E P L A C I N G C O M P O N E N T S

CAFFÈ MIO – OPERATION AND SERVICE

Page 84 of 110

R e p l a c i n g M a j o r C o m p o n e n t s

5.

Re-install the front circuit board assembly onto the front door.

a)

Align the front circuit board into position on the front door – make certain that the foam
sponge spacer and all the screw holes align with the stand-offs on the front door.

b)

Install the 8 screws securing the front circuit board to the door. Hand-tighten the screws only –
do not over-tighten as this will strip the plastic standoffs, requiring a complete door shell
replacement.

c)

Install the 4 screws securing the LCD display board to the door. Hand-tighten the screws only
– do not over-tighten as this will strip the plastic standoffs, requiring a complete door shell
replacement.

6.

Re-install the front door onto the coffee maker.

a)

Align and slide the front door hinges down onto the machine cabinet hinges.

b)

Re-install the dispensing spout and hose assembly onto the front door by sliding it onto the
spout retaining bracket.

c)

Route the wiring harness through the round cutout in the metal door frame/support on the

inside of the front door.

NOTE:

From this point forward, all the wiring connections must be made with the wiring routed behind

the round cutout in the metal door frame/support. No door wiring should be visible after all the

connections are made (with the exception of the wiring harness going into the round cutout).

Front Circuit

Board

LCD

Display

Install

Install

Install

Install

Install

Install

Install

Install

Install

Install

Install

Install

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Summary of Contents for CAFFE MIO

Page 1: ...VKI Publication N016487 Operation Service Manual February 2012 ...

Page 2: ...CAFFÈ MIO OPERATION AND SERVICE Page 2 of 110 ...

Page 3: ...tments 25 Brew Chamber Tension Adjustment 25 Brew Chamber Installation 26 General Maintenance and Adjustments 26 Zuma Brewer Brew Chamber Tension Adjustment 27 Downloading Software Updates 29 SECTION 4 TROUBLESHOOTING 31 Indicator Messages 32 Troubleshooting 35 Coffee 35 Coffee Water 36 Chocolate 36 Fuses 37 Overflows 37 Water Tank 38 Zuma Brewer 39 SECTION 5 REPLACING COMPONENTS 39 Replacing Majo...

Page 4: ...RVICE Page 4 of 110 E q u i p m e n t O v e r v i e w Powder Dispenser Coffee Dispenser Dispenser Spouts Zuma Brewer Brewer Spout Grounds Container Hot Water Tank Water Tank Overflow Cup Coffee Packet Chute Cup Stand Sensor and Overflow Sensor Powder Whipper Assembly ...

Page 5: ...he decals onto the selection buttons Also note that there is only one button on the interior control panel This button allows access to the counters and to the SET UP mode NOTE An optional side mounted coin changer unit A510122 can also be installed on this unit Consult VKI Publication N016524 for more detailed information HIDDEN BUTTONS SCROLL UP AND INCREASE BUTTON SCROLL DOWN AND DECREASE BUTTO...

Page 6: ... 5 in 90 cm Width 22 5 in 57 cm Depth 24 in 61 cm WE I G H T Shipping 85 lbs 39 kg Operational 102 lbs 46 kg CA P A C I T Y Coffee Hopper 1 5 lbs 680 g Powder Hopper 2 lbs 908 g Hot Water Tank 1 9 gallons 7 3 liters BR E W E R 12 oz Zuma Paperless Brewing Temperature approximately 199 F 93 C FU S E S 5 amp Protects valves motors and electronics 15 amp Protects heater circuit only WARNING This equi...

Page 7: ...pensed as long as the HOT WATER button is pressed It will not be dispensed by the cup There is only one button on the inner board panel This button is used to access the set up mode and to return to the main menu after a setting has been changed The access code to enter the SET UP is SET UP ACCESS CODE COFFEE PACKET CHOCOLATE COFFEE To exit a sub menu and get back to the main menu press the SET UP...

Page 8: ...wing areas service cord brewer spout cup tray 5 Remove the cup tray shipped inside the coffee maker and install it onto the front door WARNING DO NOT lift the coffee maker by placing your hand underneath the front door It is not designed to support the weight of the machine and serious personal injury and or damage to the unit may occur NOTE Prior to signing for the delivery check the shipping car...

Page 9: ...wo 3 8 x 1 4 fittings and screw each into the filter head 4 Mount the water filter at an easily accessible place for servicing such as a Under the sink against the back or side wall b On the back of a utility cabinet c On the back of the coffee maker d Any location generally within 20 feet of the machine NOTE The shut off valve must be easily accessible by the customer who must be informed of its ...

Page 10: ...nd Maintenance manual included with every FLOJET Bottled Water Dispensing System I n s t a l l i n g t h e S c a l e h a m m e r The Scalehammer is very easy to install it takes a few minutes and does not require plumbing or any interruption to the water system All that is required is about 18 inches 45cm of exposed pipe on which to install the unit An adjacent power outlet is required for the plu...

Page 11: ...wo coats of tape For best results each antenna coil must be wound in very tight turns snuggly fitted against each other using up the entire antenna and held secure 4 Insert the power supply plug into the power supply jack on the side of the Scalehammer then plug the power supply into a standard electrical outlet When on the green power indicator will light up and when the water will be energized t...

Page 12: ...wo screws to secure the cup holder in position C o n d i m e n t S t a n d I n s t a l l a t i o n 1 Install two screws into the threaded clinch nuts on the top left wall of the coffee maker 2 Place the condiment stand onto the two screws making certain the screws enter the key hole shaped slots of the condiment stand 3 Slide the condiment stand downwards onto the two screws 4 Tighten the two scre...

Page 13: ...ine lid open 3 Lift and remove the coffee and chocolate dispenser lids 4 Pour fresh ground coffee into the coffee dispenser left side 5 Pour chocolate powder into the chocolate dispenser right side 6 Re install the coffee and chocolate dispenser lids 7 Close the machine lid 8 Close the front door Machine Lid Water Tank Access Panel Ingredient Dispensers ...

Page 14: ...eat the same procedure for the STRONG beverage 10 With the front door open place a cup on the cup stand on the door as chocolate is dispensed through the door spout 11 Press the HOT CHOCOLATE button on the selection panel 12 Press START to begin the cycle 13 Visually verify the operation of the chocolate dispenser whipper system including the tubing and chocolate water valve 14 Verify the quantity...

Page 15: ...u may want to replace the existing graphics in the equipment The procedure for replacing the publicity graphics on the Caffè Mio door is outlined below 1 Open the front door of the Caffè Mio 2 Lift the publicity graphics spring plate and remove the existing graphics sheet 3 Slide the new graphics sheet under the spring plate and align it so that it can be viewed through the front window 4 Gently r...

Page 16: ...T UP MENU EMPTY WATER TANK PRESS PRODUCT This feature opens the water valve and allows the water tank to drain to the valve level The inlet valve will be disabled during this cycle This will simplify valve replacement Press the COFFEE button to access this menu To drain the water tank press the COFFEE and HOT WATER buttons simultaneously and keep them pressed release the buttons to stop the cycle ...

Page 17: ...t or cup size by pressing the corresponding button on the front selection panel If LED is on the corresponding button is enabled and if LED is off the corresponding button is disabled To return to the main menu press SET UP mode button SET UP SET TOP PAUSE 1 Press the COFFEE button to enter this menu 2 Select a cup size 3 Increase or decrease top pause timing by using the hidden scroll buttons To ...

Page 18: ... or decrease the product timing using the hidden scroll buttons To test the water quantity to be dispensed press the HOT WATER button To return to the main menu press SET UP mode button SET UP SET PROD POWDER 1 Press the COFFEE button to enter this menu 2 Select POWDER or POWDER COFFEE MIX 3 Select a CUP size 4 Increase or decrease the powder timing using the hidden scroll buttons To test the powd...

Page 19: ...chocolate dispenser lids 3 Pour fresh ground coffee into the coffee dispenser left side 4 Pour chocolate powder into the chocolate dispenser right side 5 Re install the coffee and chocolate dispenser lids 6 Close the machine lid Clean Drip Tray 1 Pull the drip tray straight out 2 Empty the contents of the tray into a sink 3 Separate the grill from the tray 4 Rinse the grill under warm running wate...

Page 20: ...n of the brewer rinse cycle 2 Pour a packet of VKI Filterfresh approved brewer cleaner into the brew chamber 3 Press the SET UP button on the interior panel 4 Using the hidden scroll buttons scroll to the RINSE CYCLE menu 5 To start the automated brewer rinse cycle press the COFFEE button on the front selection panel 6 The piston will now move to the top of the brewer cylinder and water will be di...

Page 21: ...0 Place a large cup on the cup stand 11 Press the COFFEE button on the front selection panel and press the START button to brew a cup of coffee 12 Verify that the brewer and the wiper are working properly Clean Brewer Spout 1 Remove the brewer spout 2 Rinse the brewer spout under warm running water 3 Re install the brewer spout Chocolate Rinse Cycle 1 Open the front door and place a heat resistant...

Page 22: ... 12 Re connect the outlet elbow to the whipper chamber and secure it in place with a plastic clamp 13 Re install the whipper bowl on to the chamber and re connect the chocolate hose to the whipper bowl 14 Re install the whipper vacuum funnel onto the whipper bowl making sure to place the notched side over the vacuum hose coupling 15 Rotate the chocolate dispenser spout so that it is pointing downw...

Page 23: ...ed Replace the water filter cartridge if required Follow the manufacturer s instructions for replacing the cartridge 2 Inspect the water filter for any leaks around the filter head 3 Inspect the tubing and fittings for leaks on the inlet and outlet of the filter head Inspect Fascia and Selection Buttons 1 Inspect the fascia on the selection panel for damage and adhesion issues 2 If the fascia is d...

Page 24: ...panel once more to exit the SET UP mode Reading Counters 1 Press the button on the interior control panel 2 Using the hidden scroll buttons scroll UP until the display reads TOTAL SELECTION PRESS PRODUCT 3 This counter displays the number of cups brewed for the selection that corresponds to the LED s that are illuminated on the selection panel To get a counter reading press the buttons that would ...

Page 25: ...ing the T bar should be avoided and should only be done as a last resort If the brewer tension is still too loose after installing two full shims remove the two shims and only once they are removed should you turn the T bar one rotation clockwise If the wiper is hitting the coffee paddy as it moves towards the left this indicates that the brew chamber is not rising high enough Either something is ...

Page 26: ... top of the brew chamber not the release latch and pull it slightly If it is not properly locked in place you will be able to pull it out Failure to lock the brew chamber in place will result in the chamber moving forwards and then coming down on top of the plastic cylinder lip in front of the filter screen This can damage the brew chamber cylinder the arms and bearings and or the vertical rod hou...

Page 27: ... filter screen Perfect Tension Side View The wiper is gently touching the surface of the cylinder filter screen A slight deformation is seen on the wiper Perfect Tension Front View Slight bend on the wiper All coffee grounds will be removed from the surface of the filter screen Too Tight Side View The wiper is stretched and extremely deformed The brewer is under extreme pressure Too Tight Front Vi...

Page 28: ...int and the sound of the brewer motor may change to indicate that there is a larger load on it Permanent damage to the wiper may also result Figure 6 As the wiper moves across the top of the cylinder and filter screen there will be a very pronounced bend on it When it passes over the right most edge of the brewer cylinder and the pressure gets released from the wiper coffee grounds will be flung t...

Page 29: ...o program as many Caffè Mio coffee makers as needed The following procedures are required to download software updates from the Data Link device to the Caffè Mio Equipment required VKI Data Link Downloader p n A210214 sold separately Auxiliary Downloading Harness p n M310262 sold separately EPROM with Software Upgrade 1 Insert the EPROM containing the updated software into the VKI Data Link Downlo...

Page 30: ... Remove the front board access panel on the inside of the front door a Loosen the access panel screw b Lift and pull out the access panel c Connect one end of the auxiliary harness to the rear board Data Link connector and the other end to the Data Link downloader d Disconnect the phone jack cable from front board Front Board Access Panel Loosen Disconnect Front Circuit Board ...

Page 31: ...nit g Press the START button on the Data Link to begin the downloading operation Please note that the new factory settings must be downloaded as well h Once the download is complete re install the front board access panel on the inside of the front door WARNING Do not interrupt this procedure once it is in progress as data being transferred may become corrupted creating problems with the operation...

Page 32: ...o exit COIN CHANGER NOT INSTALLED The system is set to COIN mode but a coin changer is not installed Install a coin changer Switch to FREE mode DEFECTIVE COIN CHANGER SENSOR A sensor in the coin changer is defective Replace the coin changer EMPTY OR INSTALL CUP TRAY The cup tray may not be installed or it may be full of liquid Install the cup tray If the cup stand is full of liquid empty and clean...

Page 33: ... been corrupted Using the Data Link Downloader re install the software into the rear board EXACT CHANGE Equipment requires exact change to operate Insert exact change or add some coins to the coin changer tubes POUR PACKET CONTENTS The packet system has been activated Pour packet contents into the packet system and activate brew cycle PLEASE CHECK BREWER A problem exists with the brewer motor that...

Page 34: ...OBE The electronic temperature probe is not working properly Replace the electronic temperature probe in the water tank RINSE CYCLE CHOCO OR COFFEE The RINSE CYCLE has been activated Press CHOCOLATE to activate whipper rinse or press COFFEE to activate brewer rinse Press SET UP to exit the rinse cycle SELECTION NOT AVAILABLE Product selected may be disabled Check the ENABLE SWITCHES menu to see if...

Page 35: ... coupled properly with the motor remove dispenser and re install it making certain it is coupled with the motor Short Cup Dispensed Water setting may be too low increase the water setting Water tank may not be filling quickly enough verify main water pressure hoses and inlet valve Water filter may be clogged replace water filter If a self piercing saddle valve was used to tap into the water supply...

Page 36: ... the water tank is filling properly and quickly Inlet valve may not be working properly replace valve P N E310309S Water filter may be clogged replace water filter Chocolate Too Weak Ingredient dispenser may be empty refill the dispenser with chocolate Chocolate setting may be too low increase the chocolate setting Water temperature setting may be too low increase the temperature Ingredient dispen...

Page 37: ...e defective replace heater relay P N M018R08 Check the wiring inside the fuse box and on the 15 amp fuse holder P N E110114 repair or replace any damaged components Overflows Cup Tray Overflow The cup tray may be full of liquid clean and dry the catch The HOT WATER valve may be leaking repair or replace the valve P N M029082 The CHOCOLATE valve may be leaking repair or replace the valve P N M02908...

Page 38: ...ck the following o Water level probes may require cleaning o Water level probe harness may be defective replace the probe harness o Inlet valve may be leaking replace inlet valve P N E310018 If water tank is boiling over check the following o Water temperature setting may be too high reduce temperature setting o Temperature probe may be defective replace the probe P N M210220 o Components inside w...

Page 39: ...n seal on piston may be worn replace Teflon seal P N K110174 Leaking Verify that the brewer hose is properly positioned on the diffuser Brew chamber may not be closing properly adjust the brew chamber tension Brew chamber may be cracked replace brew chamber P N M044065 Brewer cylinder may be cracked replace cylinder P N M044071 Noisy Operation If the brewer was just cleaned with brewer cleaner mak...

Page 40: ... o r C o m p o n e n t s Outlet Valve s 1 Turn off the water supply to the machine 2 Switch off the power to the machine 3 Remove the waste bin 4 Drain the water tank to a level below the valves a Remove the clip from top of the drain plug b Gently push the drain plug upwards to open it Push plug upwards Remove locking clip ...

Page 41: ...a heat resistant and leak proof container d Carefully open the large clamp and drain water into the container e Once emptied close the large clamp on the drain hose f Pull down the drain plug and insert the top clip to lock it closed CAUTION Water coming out of the drain hose may be extremely hot Use caution when draining the water tank Drain Hose Hose Clamp Insert locking clip Pull fitting downwa...

Page 42: ... Loosen but do not remove the two screws securing the valve cover to the right wall of the machine b Remove the screw securing the left side of the cover c Pull the valve cover straight out clearing the loosened screws on the right wall 6 Disconnect the wires from the valve that needs to be removed Loosen Loosen Remove Valve Cover Chocolate Valve Hot Water Valve Coffee Valve ...

Page 43: ...let is for chocolate the center for hot water and the lower for coffee water 9 Re connect the valve wires a Coffee valve wires are numbered 3 and 1 8 Hot water valve wires are numbered 2 and 1 7 Chocolate valve wires are numbered 4 and 1 6 The green ground wires also need to be reconnected CAUTION A small quantity of water will drip out when a valve is removed and this water may be extremely hot U...

Page 44: ...the coffee hose brown to the brewer 12 Turn on the water supply to the machine 13 Switch ON the power to the machine 14 Allow the water tank to fill and check for leaks 15 Verify the operation of each valve a Test brew a cup of coffee and a cup of hot chocolate b Dispenser a cup of hot water 16 Switch the machine power OFF 17 Replace the valve cover a Slide the right side over the two loosened scr...

Page 45: ...he SET UP button on the interior panel a The display now reads TO OPEN BREWER PRESS PRODUCT 3 Press the COFFEE button on the front selection panel a The brewer motor will now cycle and stop with the brew chamber in the open position 4 Remove the brewer spout 5 Remove the brew chamber 6 Using a Zuma filter screen extractor tool hold turn handle section so tip section faces upward Set Up Button Inte...

Page 46: ...will dislodge the filter screen which can then be removed 10 Align the new filter screen in recession on the top of the brewer cylinder The round protrusion on the screen must be at the rear to properly align with the cylinder 11 Push the screen down into the top of the cylinder until it snaps in place at which point it should be flush with the top of the cylinder 12 Re install the brew chamber an...

Page 47: ... chamber in the open position 3 Release the brewer lock pin a Lower the lock pin by pulling it down all the way b Turn the pin to the left until it is directly below the flange and release 4 Remove the old brewer from the brewer bracket a Disconnect the coffee hose from the top of the brewer b Gently grasp the brewer with one hand on the top and the other hand on the bottom c Move the brewer to th...

Page 48: ... brewer with the flange at the rear of the brewer bracket e Push the brewer into place to engage the brewer drive pin with the slot in the motor coupling If it does not align move the brewer crank arm slightly until you feel the brewer engaging with the motor coupling f Once engaged move the brewer slightly to the left until it is behind the left support 6 Engage the lock pin a Release the lock pi...

Page 49: ...j o r C o m p o n e n t s 7 Connect the coffee hose to the top of the brewer 8 Press the COFFEE button on the front selection panel b The brewer motor will now cycle and stop in the home starting position 9 Press the SET UP button on the interior panel to exit the set up mode Brewer Coffee Hose Set Up Button Interior Panel ...

Page 50: ... brewer a See Replacing the Brewer section for more details 2 Remove the brewer bracket a Loosen but do not remove the three screws from the left side of the brewer bracket b Lift the bracket clear of the screws and pull it away from the wall c Disconnect the two brewer harnesses and the ground wire from the rear board Loosen Loosen Loosen Brewer Bracket Rear Circuit Board Brewer Harness Brewer Ha...

Page 51: ...wo lower screws securing the motor to the bracket 5 Remove the brewer motor assembly from the brewer bracket 6 Disconnect the power wires 8 and 9 from the brewer motor 7 Remove the switch plate assembly from the old brewer motor a Remove the three screws that secure the switch plate to the motor Loosen Remove Remove Loosen Brewer Bracket Brewer Motor Remove Screw Remove Screw Remove Screw Power Wi...

Page 52: ...brewer bracket using four screws the stack of the brewer motor should be towards the right side b Tighten all four screws 9 Re connect the power wires to the brewer motor a Wires 8 and 9 10 Install the switch plate assembly onto the new brewer motor a Secure the switch plate to the motor with three screws Install Install Brewer Bracket Brewer Motor Stack Install Install Wire 8 Switch Plate Brewer ...

Page 53: ...e ground wire to the rear board 12 Re install the brewer bracket assembly onto the left wall of the machine a Make sure the bracket goes over the three loosened screws b Tighten the screws to secure the bracket to the wall 13 Replace the brewer a See Replacing the Brewer section for more details Rear Circuit Board Brewer Harness Brewer Harness Ground Wire Tighten Tighten Tighten Brewer Bracket ...

Page 54: ...pen the machine lid 3 Remove the water tank access panel on top of the machine a Remove the screw securing the access panel to the top of the machine b Slowly lift the front of the water tank access panel and disconnect the ground wire connected inside the panel c Lift the access panel open and pull it forward to release it at the rear Machine Lid Water Tank Access Panel Ingredient Dispensers Remo...

Page 55: ...p clip on the drain fitting and push the drain plug upwards 5 Remove the brewer a See Replacing the Brewer section for more details 6 Disconnect the inlet hose a Remove the hose clamp securing the inlet hose to the inlet fitting b Pull the inlet hose off the inlet fitting CAUTION Water coming out of the water tank may be extremely hot Use caution when draining the water tank or when removing the o...

Page 56: ...f the machine b Remove the screw securing the left side of the cover c Pull the valve cover straight out clearing the loosened screws on the right wall 8 Remove the hoses from all three outlet valves a After removing the coffee hose connect it to the brewer to prevent misplacing it 9 Disconnect the power and ground wires from each of the outlet valves Loosen Loosen Remove Valve Cover Hot Water Hos...

Page 57: ...t the temperature probe harness from the rear board 11 Disconnect the wires from the tank lid 12 Carefully pull the old water tank up and out the top of the machine 13 With the valves pointing towards the front of the machine lower the new water tank assembly down through the top of the machine until it sits on the support 4 3 5 2 11 2 14 1 2 Temp Probe Harness ...

Page 58: ...erature probe harness to the rear circuit board a Route the harness down the front of the water tank and connect it to the rear circuit board 15 Connect the wires identified in the table and photo below WIRE CONNECTED TO 11 2 Heater element 14 Thermal cut off switch 1 2 Level probe long 4 3 Level probe long 5 2 Level probe short Temp Probe Harness 4 3 5 2 11 2 14 1 2 ...

Page 59: ...re the drain plug is also down and locked 17 Connect the respective hoses to all three outlet valves a Remove the coffee hose from the brewer and connect it to the coffee valve 18 Connect the power and ground wires to each of the outlet valves WIRES CONNECTED TO 2 and 1 7 13 5 is ground Hot Water Valve 3 and 1 8 13 6 is ground Chocolate Valve 4 and 1 6 13 4 is ground Coffee Valve Hot Water Hose Ch...

Page 60: ... s 19 Install the brewer a Refer to the Replacing the Brewer instructions in this manual 20 Connect the coffee hose to the brewer 21 Replace the valve cover a Slide the right side over the two loosened screws b Secure the left side with another screw c Tighten the two screws on the right side Tighten Tighten Install Valve Cover Brewer Coffee Hose ...

Page 61: ...a Slide the rear of the access panel into the area around the rear of the tank The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel b Connect the ground wire 13 3 to the grounding tab on the inside front of the access panel c Lower the front of the access panel closed and secure it closed with a screw Connect Ground Screw ...

Page 62: ... machine a Open the front door and the machine lid b Remove the screw securing the access panel to the top of the machine c Slowly lift the front of the water tank access panel and disconnect the ground wire connected inside the panel d Lift the access panel open and pull it forward to release it at the rear WARNING To avoid severe burns make absolutely certain that the heater element is not hot b...

Page 63: ... t s 2 Disconnect the wires from the tank lid 3 Remove the old lid assembly a Press the lock latch on the lid to free it b Lift the assembly up and out of the water tank 4 Lower the new lid assembly into the water tank a Slide the back of the lid into the tank first and push the front down until the latch engages Lock Latch 4 3 5 2 11 2 14 1 2 ...

Page 64: ...Slide the rear of the access panel into the area around the rear of the tank The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel b Connect the ground wire 13 3 to the grounding tab on the inside front of the access panel WIRE CONNECTED TO 11 2 Heater element 14 Thermal cut off switch 1 2 Level probe long 4 3 Level probe long 5 2 L...

Page 65: ...R E P L A C I N G C O M P O N E N T S CAFFÈ MIO OPERATION AND SERVICE Page 65 of 110 R e p l a c i n g M a j o r C o m p o n e n t s c Lower the front of the access panel closed and secure it closed with a screw Screw ...

Page 66: ...ater Tank Lid instructions in this manual 2 Remove the wires from the heater element terminals 3 Detach the thermal cut off switch from the heater element a Remove the clamp securing the thermal cut off switch to the element 4 Remove the two 11 16 brass nuts securing the heater element to the lid WARNING To avoid severe burns make absolutely certain that the heater element is not hot before procee...

Page 67: ...e thermal cut off switch onto the element and secure it with the clamp a The bulb of the thermal cut off switch must be installed about one third of the way down onto the heater element b The winding of the thermal cut off switch must be below the water line when the tank is full 9 Replace the lid assembly a Refer to the Replacing the Water Tank Lid instructions in this manual 10 Connect the power...

Page 68: ...rs 2 Disconnect the temperature probe from the WATER TEMP connector on the rear board 3 Lift the machine lid open 4 Remove the water tank access panel a Remove the screw securing the front of the cover to the top of the machine b Lift the front of the cover and disconnect the ground wire from the cover 5 Pull the temperature probe out of the grommet on the tank top Temp Probe Harness Temperature P...

Page 69: ...wiring out the top of the machine a Any tie wraps securing the temperature probe wiring to the main water tank wiring harness will need to be cut 7 Install the new probe into the grommet on the water tank top 8 Drop the temperature probe connector harness down the front of the water tank valve area and route it to the rear board Temperature Probe Push into Grommet Grommet Temp Probe Wiring ...

Page 70: ... the water tank access panel a Slide the rear of the access panel into the area around the rear of the tank The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel b Connect the ground wire 13 3 to the grounding tab on the inside front of the access panel c Lower the front of the access panel closed and secure it closed with a screw T...

Page 71: ...ear of the spill plate securing it to the top of the machine b Remove the lids on both of the dispensers c Slide the spill plate up and over the dispensers to remove it 4 Rotate both ingredient dispenser spouts upwards 5 Remove the screw securing the front of each dispenser to the dispenser base 6 Lift the front of the dispenser and pull it forward to unlock the dispenser 7 Lift the dispenser out ...

Page 72: ...t the rear of the dispenser with the drive pin on the dispenser motor 9 Slide the rear of the dispenser support into the cutout on the base and push the dispenser back to couple it with the motor The pin at the bottom of the dispenser will go into the notch on the base to help guide the dispenser into position Support Cutout Coupler Drive Pin Ingredient Dispenser Dispenser Motor Support Cutout Not...

Page 73: ...spill plate foam side down over the dispensers onto the top of the machine and secure it in place using the two screws 12 Install the dispenser covers onto the dispensers 13 Rotate the spouts down into their proper positions 14 Close the inner door and front door 15 Test brew a couple of cups of coffee or chocolate to verify dispenser operation Install Install Spill Plate Install Screw Install Scr...

Page 74: ...o the Replacing the Brewer Bracket instructions in this manual 4 Remove the spill plate that surrounds the two dispensers a Remove the screws at the front and rear of the spill plate securing it to the top of the machine b Remove the lids on both of the dispensers c Slide the spill plate up and over the dispensers to remove it 5 Rotate both ingredient dispenser spouts upwards 6 Remove the screw se...

Page 75: ...rs out of the top of the machine 9 Disconnect the power wires from the dispenser motor that needs to be replaced 10 While holding onto the motor from the underside of the ingredient dispenser base remove the two screws securing the motor to the base The motor will then be freed from the base and can be removed Dispenser Base Remove Remove Dispenser Motor Chocolate Dispenser Motor Coffee Dispenser ...

Page 76: ...te from the dispenser motor by removing the two screws that secure it 12 Install the support plate onto the new dispenser motor with two screws 13 While holding onto the motor from the underside of the ingredient dispenser base install the two screws that secure the motor to the base Support Plate Remove Remove Dispenser Motor Dispenser Base Install Install Dispenser Motor ...

Page 77: ...he power wires to the ingredient motor s 15 To install the dispenser lower in into position from the top of the machine and align the coupler at the rear of the dispenser with the drive pin on the dispenser motor Chocolate Dispenser Motor Coffee Dispenser Motor Wire 6 Wire 1 3 Wire 3 Wire 12 2 Support Cutout Coupler Drive Pin Ingredient Dispenser Dispenser Motor ...

Page 78: ... the dispenser support into the cutout on the base and push the dispenser back to couple it with the motor The pin at the bottom of the dispenser will go into the notch on the base to help guide the dispenser into position 17 Screw the front of the dispenser to the dispenser base Support Cutout Notch Guide Pin Dispenser Base Ingredient Dispenser Support Install Install ...

Page 79: ... down over the dispensers onto the top of the machine and secure it in place using the two screws 19 Install the dispenser covers onto the dispensers 20 Rotate the spouts down into their proper positions 21 Close the inner door and front door 22 Test brew a couple of cups of coffee or chocolate to verify dispenser operation Spill Plate Install Screw Install Screw Replace Lid Replace Lid ...

Page 80: ...rd 1 With the machine power OFF remove the drip tray assembly from the front door 2 Remove the front door a Remove the inner door by lifting it up and off the door hinges b Remove the front circuit board cover by loosening the mounting screw and lifting the cover up and pulling the bottom towards you Lift off the Hinges Inner Door Front Door Loosen Front Board Cover ...

Page 81: ...isconnect the phone type cable from the bottom of the front board and disconnect the ground wire from the inside wall of the door d Loosen the screws and remove the drip tray and overflow detection bracket at the inside bottom of the front door Disconnect Front Circuit Board Disconnect Loosen Loosen Overflow Detection Probes Drip Tray Detection Switch ...

Page 82: ...ound cutout in the metal door frame support on the inside of the front door h Remove the dispensing spout and hose assembly from the front door by lifting the spout off the retaining bracket i Remove the front door by lifting it up and off the door hinges 3 Lay the front door flat down on a table with the button side down NOTE The front door must remain flat on a table until all the modifications ...

Page 83: ...ing the LCD display to the front door c Carefully lift the circuit board assembly up and out of the door Front Circuit Board View inside door with front circuit board removed NOTE When the front circuit board is removed the selection switch caps and a sponge foam spacer will be exposed These switch caps and the foam spacer must be present on the door when the front circuit board is re installed Fr...

Page 84: ...nly do not over tighten as this will strip the plastic standoffs requiring a complete door shell replacement 6 Re install the front door onto the coffee maker a Align and slide the front door hinges down onto the machine cabinet hinges b Re install the dispensing spout and hose assembly onto the front door by sliding it onto the spout retaining bracket c Route the wiring harness through the round ...

Page 85: ...circuit board and connect the green ground wire to the ground tab on the inside wall of the door e Pick up the drip tray detection and overflow bracket that was set aside earlier f Connect the two small blue wires to the two overflow detection probes and connect the 3 position connector to the drip tray detection switch Overflow Detection Probes Drip Tray Detection Switch Connect Connect Connect F...

Page 86: ... in their proper position h Once certain that all the wiring connections have been made re install the front board cover making sure it the mounting screw passes through the key hole slot on the cover Tighten the screw to secure the cover in place 7 Re install the inner door by aligning and sliding the inner door hinges onto the machine cabinet hinges note that these are the same hinges used for t...

Page 87: ...joggle on the rear wall of the machine and slide it to the left to clear the rear of the water tank area 8 Remove the old rear circuit board from the machine 9 Position the left side of the new rear circuit board against the left wall of the machine and lift it as high as it can go it should come into contact with the bottom of the fuse box 10 Slide the circuit board towards the right until the sc...

Page 88: ...this manual 16 Replace the waste bin 17 Switch the machine power ON and allow the unit to fill and heat 18 Test the equipment to make certain everything is working properly a Refer to the Testing Equipment Operation section of this manual Install Screw Rear Circuit Board Fuse Box Connect Connect Connect Cconnect Connect Connect Connect Connect Connect Water Tank Area NOTE It may be necessary to re...

Page 89: ...R e p l a c i n g M a j o r C o m p o n e n t s Whipper Motor 1 Rotate the chocolate dispenser spout so that it is pointing upwards 2 Lift the whipper vacuum funnel off the whipper bowl 3 Lift the whipper bowl off the whipper chamber and disconnect the water hose from the whipper bowl Lift Off Lift Off ...

Page 90: ...e p l a c i n g M a j o r C o m p o n e n t s 4 Open the plastic clamp securing the whipper chamber outlet elbow to the whipper chamber and pull off the outlet elbow 5 Turn the whipper chamber clockwise about 1 8th of a turn and pull it straight out to remove it from the whipper base Pull Down Open Clamp ...

Page 91: ...pper base support bracket a Loosen the four screws securing the bracket b Lift the bracket up until it clear the screws and pull it out 7 Pull the whipper blade straight out to remove if from the whipper motor shaft 8 Remove the two screws securing the whipper base to the metal support and remove the base Remove Remove Pull Straight Out Loosen Loosen Loosen Loosen ...

Page 92: ...e 92 of 110 R e p l a c i n g M a j o r C o m p o n e n t s 9 From the rear side of the metal support plate disconnect the power wires to the whipper motor 10 Remove the two hex nuts securing the whipper motor to the support plate and remove the old motor Remove Remove Disconnect Disconnect ...

Page 93: ... Page 93 of 110 R e p l a c i n g M a j o r C o m p o n e n t s 11 Install the new motor onto the support plate and secure it in place with two hex nuts 12 Connect the two power wires coming from the transformer yellow and blue wires to the whipper motor Connect Connect Install Install ...

Page 94: ...n all of the parts that were removed earlier under warm running water prior to replacing them 15 Install the whipper base onto the metal support and secure it in place with the two screws 16 Re install the whipper blade a The whipper blade and whipper motor shaft have a D type fit The line at the rear or the blade must line up with the flat spot on the motor shaft These two areas must be aligned t...

Page 95: ...age 95 of 110 R e p l a c i n g M a j o r C o m p o n e n t s 17 Re install the whipper chamber by placing it onto the base a turning it counter clockwise to lock it in position 18 Re connect the outlet elbow to the whipper chamber and secure it in place with a plastic clamp Push Up Clamp ...

Page 96: ...the chocolate hose to the whipper bowl 20 Re install the whipper vacuum funnel onto the whipper bowl making sure to slide the notched side over the vacuum coupling 21 Rotate the chocolate dispenser spout so that it is pointing downwards onto the whipper bowl 22 Close the inner door and front door 23 Power ON the machine and test the system by making several cups of hot chocolate Vacuum Coupling Sl...

Page 97: ...ve at the back of the machine 5 Disconnect the two wires that go to the inlet valve 6 Disconnect the inlet hose from the hot water tank a Remove the clamp securing the hose to the inlet fitting at the bottom of the water tank b Pull firmly on the hose to remove it 7 Remove the screws that secure the old inlet valve to the back of the machine a These screws are located on the outside of the rear wa...

Page 98: ... 10 Secure the inlet valve hose using a hose clamp to the inlet at the bottom of the water tank 11 Make sure that the drain plug on the bottom of the tank a closed pulled down and locked with the locking clip Also make certain the large clamp at the end of the drain hose is closed 12 Connect a fitting to the inlet valve at the back of the machine and connect a water source to the fitting 13 Turn o...

Page 99: ...acket a Refer to the Replacing the Brewer Bracket instructions in this manual 5 Disconnect the wiring coming out of the fuse box a Disconnect the ground wire from the terminal on the left wall of the machine b Disconnect the wires connected to the door harness and water tank harness 3 total c Disconnect the wire connected to the heater relay WARNING To prevent electrical shock always disconnect th...

Page 100: ...mbly down and lift it at the rear to free it b Pull the fuse box assembly including the service cord out of the machine 8 Install the new fuse box assembly a Pass the service cord through the cut out at the rear of the machine from the inside to the outside b Insert the bottom of the fuse box assembly into the cut out at the rear of the machine and tilt the front of the fuse box up c Secure the fu...

Page 101: ...ire 2 to white wire 10 2 of the door harness d Connect the blue wire 3 3 to blue wire 12 3 of the door harness e Connect the blue wire 3 2 to blue wire 11 of the water tank harness 10 Install the brewer bracket a Refer to the Replacing the Brewer Bracket instructions in this manual 11 Install the brewer a Refer to the Replacing the Brewer instructions in this manual 12 Install the waste bin and cl...

Page 102: ...flow cup 3 Lift and remove the old overflow cup from its support 4 Connect the two inline wiring connections to the new overflow cup 5 Re seat the overflow cup onto the overflow cup support 6 Switch the machine power ON 7 Pour a small quantity of water into the overflow cup about half full and make certain the Tank Overflow error is displayed on the LCD 8 Once verified empty the overflow cup and p...

Page 103: ...heater relay is located on the right side wall behind the brewer assembly 5 Remove the two screws securing the old heater relay to the wall 6 Install the new heater relay and secure it with two screws 7 Reconnect the wiring to the heater relay a Connect wire 1 4 to pin 1 of the relay b Connect wire 7 to pin 2 of the relay c Connect wire 11 to pin 3 of the relay d Connect wire 14 to pin 4 of the re...

Page 104: ... the machine a Open the front door and the machine lid b Remove the screw securing the access panel to the top of the machine c Slowly lift the front of the water tank access panel and disconnect the ground wire connected inside the panel d Lift the access panel open and pull it forward to release it at the rear WARNING To avoid severe burns make absolutely certain that the heater element is not h...

Page 105: ...N AND SERVICE Page 105 of 110 R e p l a c i n g M a j o r C o m p o n e n t s 2 Disconnect the wires from the tank lid 3 Remove the old lid assembly a Press the lock latch on the lid to free it b Lift the assembly up and out of the water tank Lock Latch 4 3 5 2 11 2 14 1 2 ...

Page 106: ...itch a Disconnect the wire from the thermal cut off switch to the heater element b Loosen the clamp securing the thermal cut off switch to the heater element c Remove the two screws and hex nuts securing the thermal cut off switch to the tank lid d Remove the old thermal cut off switch by pulling it out the top of the tank lid Remove Remove Loosen Clamp Thermal Cut Off Disconnect ...

Page 107: ...o sets of screws and hex nuts The screws pass through the bottom of the lid to the top Secure the screws with the hex nuts c Secure the bulb of the thermal cut off switch to the heater element using a metal clamp i The bulb of the thermal cut off switch must be installed about one third of the way down onto the heater element and the winding of the thermal cut off switch must be below the water li...

Page 108: ...he lid assembly into the water tank a Slide the back of the lid into the tank top first and push the front down until the latch engages with the tank top 7 Connect the wires identified in the table and photo below WIRE CONNECTED TO 11 2 Heater element 14 Thermal cut off switch 1 2 Level probe long 4 3 Level probe long 5 2 Level probe short 4 3 5 2 11 2 14 1 2 ...

Page 109: ...a Slide the rear of the access panel into the area around the rear of the tank The metal top of the machine behind the tank has to slide into the notches on the sides at the rear of the access panel b Connect the ground wire 13 3 to the grounding tab on the inside front of the access panel c Lower the front of the access panel closed and secure it closed with a screw Connect Ground Screw ...

Page 110: ...S E C T I O N 5 R E P L A C I N G C O M P O N E N T S CAFFÈ MIO OPERATION AND SERVICE Page 110 of 110 ...

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