Kalerm KLM1602 Service Manual Download

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KLM1602

Service Manual

Intelligent Fresh Ground Coffee Machine

KLM1602-SM-EN V002

Summary of Contents for KLM1602

Page 1: ...KLM1602 Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 SM EN V002 ...

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Page 3: ...English KLM1602 Service Manual Intelligent Fresh Ground Coffee Machine ...

Page 4: ... 2 3 1 Overview of water circuit 2 3 2 Water circuit for making coffee 2 3 3 Water circuit for making hot water 4 1 Tools preparation 4 2 General disassembly 4 2 1 Disassemble exterior parts 4 2 2 Disassemble power cord 4 2 3 Disassemble brew unit 4 2 4 Disassemble valve support group 4 2 5 Disassemble flowmeter 4 2 6 Disassemble grinder group 4 2 7 Disassemble control panel group 4 2 8 Disassembl...

Page 5: ... Precautions for maintenance and installation Precautions for assembling 4 3 1 Brew unit group 4 3 2 Grinder group 4 3 3 Control panel group 5 1 Function test and test standards 5 2 Coffee machine maintenance 5 2 1 Coffee machine decalcifying 5 2 2 Rinse the brew unit 5 2 3 Wipe the coffee machine ...

Page 6: ...indicated on the adaptor or leads or the maximum power indicated on the adaptor This appliance should only be used for what it has been designed Any other use is considered improper and consequently dangerous The manufacturer cannot be held responsible for any damages caused due to an erroneous or irrational use The technician must remind the user about the safety standards to ensure correct opera...

Page 7: ...ric shock and threat to life Non compliance with the operation may cause coffee machine damaged or personal injury Non compliance with the operation may cause scalded or burned This symbol if prompted please carefully read information with it This symbol if prompted represents recycle ...

Page 8: ...4 5 6 7 11 12 Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 Drip tray decoration cover Top cover Cup support Front cover right Drip tray cover Drip tray Bean container lid Water tank cover Water tank ornament cover Water tank Front cover left Export decorative cover ...

Page 9: ...18 19 20 15 Structure 7 14 16 17 13 16 17 Bean container Grinder adjustment knob Ground coffee container lid 13 14 15 Hot water export Coffee export Back cover Logo Right side section 18 19 20 ...

Page 10: ...7 28 29 30 21 22 Left side section Power line 21 22 Power switch Americano button Espresso button Coffee button Double cup Coffee strength button Setting button Screen Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 Structure ...

Page 11: ... 4 Thermoblock Solenoid valve 2W Geared motor Dispenser valve 2W Support PCBA Pump Drainage valve Line pencil connector Transformer Base Brew unit Drip tray microswitch Reed sensor Flowmeter Valve support Control panel Grinder group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Structure ...

Page 12: ...nd Coffee Machine KLM1602 Structure 2 3 1 Overview of water circuit 2 3 Water circuit Water tank Sieve Flowmeter Pump Pressure maintaining valve Coffee thermoblock 1 2 3 4 5 6 Dispenser valve 2W Drainage valve Brew unit Solenoid valve 2W Beverage export 7 8 9 10 11 ...

Page 13: ... 7 8 9 10 2 3 2 Water circuit for making coffee Structure Water tank Sieve Flowmeter Pump Pressure maintaining valve Coffee thermoblock 1 2 3 4 5 6 Dispenser valve 2W Drainage valve Brew unit Beverage export 7 8 9 10 ...

Page 14: ...ter circuit for making water Structure Water tank Sieve Flowmeter Pump Pressure maintaining valve Coffee thermoblock 1 2 3 4 5 6 Solenoid valve 2W Beverage export 7 8 Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 15: ...HMI Flowmeter Drip tray microswitch Reed sensor LED light Thermoblock NTC Feedback device Solenoid valve 2W Stepper motor 14 15 16 17 18 19 20 21 22 23 24 25 Drive motor Transformer Thermoblock fused cord Solenoid valve fused cord Pump Filter Terminal Power line Grinder motor Microswitch Communication cable Power PCBA 2 4 Schematic circuit diagram ...

Page 16: ...moblock Pump Solenoid valve 2W Grinder motor Drive motor Dispenser valve motor 220V 1200W 230V 50HZ 48W ULKA EP4 230V 50Hz 9 12VA DC 220V DC 24V DC 24V Capacities Water tank Coffee grounds container Coffee bean container Coffee powder volume for brew unit 1 8L 15 Pieces 250g MIN 5g MAX 14g Various data Dimensions length width height Cable Length Net weight 450 302 370 mm approx 1 5 m approx 11 5kg...

Page 17: ... out the drip tray after the coffee machine reset and the screen appears HEATING 5 Put the coffee groud container on the drip tray and insert them into the coffee machine again NO continue to 3 2 1 4 Drip tray group components damaged YES replace the components Replace or repair the damaged components according to the drip tray explosive view 8810102001 3 2 1 4 3 2 2 1 3 2 2 2 Export blocked the d...

Page 18: ...t or repair power switch connector NO continue to 3 3 1 6 1 Disassemble control panel according to 4 2 7 2 Disassemble control panel repair connection line according to 4 3 3 Disassemble right side section according to 4 2 1 Disassemble back cover according to 4 2 1 YES connct or repair the transformer connector NO continue to 3 3 1 7 YES replace the fuse inside the line pencil connector NO contin...

Page 19: ...RAY on screen YES clean rest coffee powder NO continue to 3 3 3 2 YES take out coffee grounds container reinstall drip tray NO continue to 3 3 3 3 Lots of coffee powder left on the base Brew unit does not reset The following should be repaired by disassembling or changing proper parts YES replace coffee grounds container frame item 79000113 NO continue to 3 3 3 4 YES replace microswitch item 73000...

Page 20: ...p NO continue to 3 3 5 4 Drainage valve group damaged 1 Dismantle brew unit according to 4 2 3 2 Replace or repair damaged components according to brew unit explosive view 8810101016 YES replace contropistone seal item 73000065 NO continue to 3 3 5 5 Contropistone seal damaged YES replace brew unit coffee brewing unit item 881010032 NO continue to 3 3 5 6 YES replace brew unit seal item 73000035 B...

Page 21: ... panel according to 4 2 7 2 Disassemble control panel components according to 4 3 3 3 Replace or repair damaged components according to control panel explosive view 8810102001 The button on HMI damaged YES replace and repair HMI item 78000055 NO continue to 3 4 3 4 HMI damaged YES replace and repair HMI item 78000055 The following should be repaired or replaced by dismatling the machine Use coffee...

Page 22: ...p between conical burr and upper burr lessens or no gap Water into grinder group Use coffee beans to make coffee FILL BEAN displays on the screen after grinding grinder unit works If conical burr and upper burr is stucked by foreign object there will be different regular noise when the conical buur and upper burr does not work 1 Disassemble grinder group according to 4 2 6 2 Disassemble grinder gr...

Page 23: ...exactly Refer to 3 5 3 5 YES replace damaged solenoid valve 1 Disassemble solenoid valve group according to 4 2 9 2 Replace or repair damaged components according to soleniod valve explosive view 8810102009 Coffee temperatur e is too low below 70 C YES preheat coffee cup or increase the temperature of environment NO continue to 3 5 4 2 The temperature of the cup is too low The temperature of the w...

Page 24: ...ive view 8810101006 1 Disassemble brew unit according to 4 2 3 2 Replace or repair damaged components according to brew unit explosive view 8810101016 YES replace contropistone seal item 73000065 NO continue to 3 5 6 7 Contropistone seal damaged coffee sprays from the gap between coffee brewing box and contropistone YES replace coffee brewing group item 8810101023 NO continue to 3 5 6 8 Brew unit ...

Page 25: ...lume is too little the volume of Espresso is lessthan25ml Coffee volume is too much the volume of Espresso is more than 100ml Coffee is too soft no crema on the top Refer to 3 5 4 Refer to 3 5 5 Refer to 3 5 6 Refer to 3 5 7 Refer to 3 5 8 3 6 2 1 3 6 2 2 3 6 8 Use coffee powder to make coffee The following should be repaired by dismatling the machine Coffee machine needs descale deposit makes pip...

Page 26: ... damaged magne nt does not work Program or PCBA damaged Refer to3 5 4 1 Disassemble water inlet valve group according to 4 2 4 2 Replace or repair damaged components according to water inlet valve group explosive view 8810101011 According to drip tray group explosive view 8810101017 According to frame explosive view 8810101021 Disassemble appearance components according to 4 2 1 Disassemble PCBA r...

Page 27: ...repair PCBA item 78000056 PCBA damaged System testing Malfunction YES Restart the machine NO continue to 3 12 2 2 Replace damaged components according to explosive view 8810102006 YES replace NTC item 73000221 NO continue to 3 12 2 3 YES connect or replace connection line item 73000221 Thermoblock NTC damaged NTC connection line does not work Refer to 3 12 2 1 Disassemble PCBA replace and repair a...

Page 28: ...continue to 3 12 5 3 HMI damaged Refer to 3 12 5 1 Disassemble PCBA replace and repair according to 4 2 11 YES replace or repair PCBA item 78000056 PCBA damaged Press any button to fill unit accomplished YES press any button to fill unit Water circuit lack of water ERROR 7 communic ation mistakes between PCBA and HMI UNIT EMPTY PRESSURE HIGH protective program during making coffee Information remi...

Page 29: ... 2 3 2 Replace or repair damaged components according to brew unit explosive view 8810101016 1 Disassemble geared motor group according to 4 2 14 2 Replace or repair damaged components according to geared motor group explosive view 8810101014 YES replace or repair brew unit parts NO continue to 3 16 4 4 YES replace or repair transmission group parts Brew unit parts damaged Transmission group parts...

Page 30: ...n a piece of paper in the position of microswitch as the picture shows and touch microswitch if the screen does not display INSTALL TRAY any more drip tray components damaged replace components if the screen still display NSTALL TRAY internal line fault disassemble and repair the machine 3 2 1 3 Drip tray terminal function Use a wire to connet the terminal on drip tray as the picture shows and ins...

Page 31: ... damaged machine can not be started on 3 2 1 4 Press button Operation all the function buttons on the control panel to judge if the press buttons are all right and confirm issues and causes according to check list 3 1 3 2 2 2 Check driving motor fuse of PCBA If fuse damaged driving motor will not work and machine can not be started on ...

Page 32: ... off state When touch microswitch contactor it is on state 3 2 3 Leakage Take off drip tray layer board as the picture shows fill drip tray microswitch with paper and press rinse button Check leakage of brew unit Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 33: ...31 Troubleshooting Check leakage of connectors ...

Page 34: ... 1 Tools preparation Torx screwdriver T6 T10 T15 T20 T25 Slotted type screwdriver 3mm series Needle nose pliers Electronic scale Temperature tester Multimeter Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 35: ... 2 Take out bean container lid group 4 2 1 Disassemble exterior parts 4 2 1 1 Take out movable parts 3 Take out water tank group 1 Rotate the Logo support according to the direction of the arrow 2 Dismantle 2 screws from the bottom of the Logo support 4 2 1 2 Disassemble back cover ...

Page 36: ...e Machine KLM1602 1 Disassemble the 2 screws from the bottom 2 Take out front cover right and front cover left separately according to the direction of the arrow 4 2 1 3 Disassemble front cover right and front cover left 1 Take out right side section according to the direction of the arrow 4 2 1 4 Disassemble right cover ...

Page 37: ... Loose top cover and hook of the frame 4 2 1 6 Disassemble top cover 3 Take out top cover according to the direction of the arrow 1 Disassemble 4 screws from the coffee bean container and take the coffee bean container out 4 2 1 5 Disassemble coffee bean container group Repair ...

Page 38: ... Refer to 4 2 1 Disassemble the exterior parts of the machine 4 2 1 7 Disassemble left cover 2 Disassemble 2 screws from the cable rack 3 Disassemble 1 screw from support loose 3 screws inside the line pencil connector and take out the power cord Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 Repair ...

Page 39: ...he machine 2 Disassemble 3 screws and take out frame support 3 Pull out silicon pipe from brew unit 4 Disassemble 3 screws from brew unit 5 Pull the brewing unit outward and rotate the gear clockwise to the position as the picture shows 6 Disassemble 1 screw from backside and take out brew unit Repair ...

Page 40: ...t according to the direction of the arrow and pull out silicon pipe Note There are 4 hooks between valve support and base 2 4 2 5 Disassemble flowmeter 1 Refer to 4 2 1 Disassemble exterior parts 2 Pull out the flowmeter terminal and pull out the flowmeter according to the arrow direction 3 Pull out the silicone pipe at two sides of the flowmeter and take out flowmeter 2 3 1 1 ...

Page 41: ...of the machine 1 4 5 1 2 4 2 6 Disassemble grinder group 1 Refer to 4 2 1 1 4 2 1 6 disassemble top cover 2 Disassemble 3 screws 3 Pull out grinder motor terminal from PCBA and take out grinder group Repair 4 2 8 Disassemble control panel group 1 Refer to 4 2 1 disassemble exterior parts 5 Remove 1pcs screw and remove the switch pull out the tuo terminals ...

Page 42: ...er disassemble 1pcs screw 8 Remove the front control panel from the main support pull out the silicone pipe 4 2 8 Disassemble drainage valve group 1 Refer to4 2 1 disassemble exterior parts 2 Refer to4 2 3 disassemble brew unit group 3 Remove the spring clip pull out the connector 4 Pull out dispenser valve terminal on PCBA and take it out from the cable rack ...

Page 43: ...is a sealing element left at the bottom after taking out drainage valve group 4 2 9 Disassemble solenoid valve group 1 Refer to 4 2 1 1 4 2 1 4 disassemble right side section 2 Pull out 3pcs terminals on soleniod valve 3 Disassemble 2 screws 4 Pull out the silicone pipe and spring clip remove the solenoid valve ...

Page 44: ... 1 Disassemble exterior parts of the machine 1 Pull out the flowmeter and pull out the silicone pip 2 Pull out the silicone pipe 4 Pull out pump terminal on PCBA and take it out from the cable rack 5 Take all cables out from the cable rack pull out 3pcs screws remove the cable rack 6 Pull out the spring clip and teflon pipe remove the pump ...

Page 45: ...rews on PCBA and take out PCBA 1 Refer to 4 2 1 1 4 2 1 4 disassemble right side section 4 2 11 Disassemble PCBA 4 2 12 Disassemble dispenser valve 2W group 1 Refer to4 2 1 1 4 2 1 4 disassemble right side section 2 Pull out 2pcs spring clips and take out dispenser valve 2W ...

Page 46: ...up 2 Loose screw on the line pencil connector pull out the terminal on filter 3 Pull out all the terminals on PCBA and take it off cable rack 4 Pull out the terminal on soleniod valve 5 Pull out the spring clip and teflon pipe 6 Pull out the spring clip and teflon pipe 7 Disassemble 2pcs screws 1 Refer to 4 2 1 disassemble exterior parts ...

Page 47: ... the support and take out thermoblock 4 2 14 Disassemble drive motor group 1 Refer to 4 2 1 1 4 2 1 4 disassemble right side section 2 Pull out the terminals on PCBA and take it off cable rack 3 Disassemble 2pcs screws remove the drive motor group ...

Page 48: ...rrow direction 2 Disassemble the wiper notice the hooks showed by the arrow 4 3 1 Brew unit group 1 2 3 Disassemble the 4 screws from the left and right cover 3 3 4 Disassemble 4 hooks from the top cover of the brew unit take out top cover of brew unit 4 1 1 1 1 Note deeper slot side should be installed to the front position of the brew unit It should match the wiper 1 46 ...

Page 49: ...cover 6 Take out connect part and reset base 5 6 7 Take out left and right pull plate and pull plate sleeve 8 Rotate the gear 7 8 9 Take out the contropistone 9 10 Take out the connector pay attention to the direction of the spring 10 2 1 1 47 Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 50: ...11 12 Disassemble release link and take out piston 12 13 Disassemble the screw from contropistone and take out filter screen 13 14 Disassemble seal from contropistone 14 Note The bigger opening of the piston should face to the release link 1 1 1 1 2 Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 48 ...

Page 51: ...ment sector 2 Rotate the upper burr group anticlockwise 4 3 3 Grinder group Repair 3 Disassemble the three hooks from the motor support for grinder and take out the grinder adjustment ring 4 Disassemble 1 middle screw 5 Take out the line pencil and conical burr group 6 Take out 1 screw from the coffee powder hopper ...

Page 52: ...out 3 screws from the gear box 9 Take out the 3 hooks from the gearbox and then take out the coffee 10 Disassemble steel ball support and 34 pcs steel ball 11 Take out the epicyclic gear group B 12 Take out filler piece and the epicyclic gear group A Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 53: ...one tube top tube for coffee bottom pipe for water 51 Repair 13 Disassemble the 2 screws inside the gearbox and take out the grinder motor 4 3 4 Control panel group 1 Pull out the terminal 2 Disassemble 2pcs screws 3 Remove the coffee outlet group ...

Page 54: ...pcs hooks 6 Remove the decorative cover panel and the power button 7 Disassemble 2pcs hooks on both sides 8 Remove the HMI pull out 3pcs terminals 9 Disassemble 2pcs hooks on both sides and remove the switch support Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 55: ...10 1 2 11 1 12 13 53 Repair 10 Remove the HMI group disassemble 5pcs screws pull out LCD terminal 11 Remove the HMI 12 Disassemble 2pcs hooks on both sides 13 Remove the LCD screen ...

Page 56: ...iameter 1 1 Install the piston and release link into the coffee brewing unit oil MI setral 61B coating position should be as the picture shows 1 1 1 Valve support group Brew unit 1 2 Install the coffee brewing unit into the brew unit frame and install reset base and connect part 2 1 ...

Page 57: ...en 3 4 5 Assemble the connector ball and spring into contropistone Pay attention to the arrow direction 6 Assemble the already installed contropistone into the brew unit frame Note The direction of the contropistone should be the same as the picture showed 5 6 Repair 7 Rotate the gear onto the brew unit frame install the sleeve pipe the small head of sleeve pipe should be inward 7 Service Manual I...

Page 58: ... 61B coating position for left and right pull plate should be as the picture shows 8 8 9 Install the brew unit top cover 9 1 1 1 Note Pay attention to the direction of the brew unit top cover the deeper groove should be in front 10 Lock the left side and right side cover screws 10 10 1 1 57 Repair ...

Page 59: ...pare to the bigger groove Screw tightly 9 Install the line pencil into the grinder motor red line correspond to the red mark 8 9 1 Note The installation direction for the grinder antivibration pads and 3 antivibration bushes 10 Insert the already installed grinder motor in the grinder support and lock screws 11 Install the coffee powder hopper on the coffee powder container and lock the screw 10 1...

Page 60: ...he coffee powder container pillar 16 17 1 Repair 12 Install 3 spring sleeves into the hole of the support lower grinder 13 Install the screw pin worm drive and conical burr to support lower grindor 12 13 14 Put 3 conical burr protective steel balls and spring into support lower grinder 15 Put the felt ring into the already installed coffee powder container 14 15 61 ...

Page 61: ...tor support for grinder and adjust the gap between the conical burr and upper burr 21 Install the grinder adjustment sensor to grinder adjustment ring The position should be as the picture shows 22 The already installed grinder group should be tested when the whole machine is installed The thickness of the powder should be adjusted properly 20 21 Repair Service Manual Intelligent Fresh Ground Coff...

Page 62: ...ss the button to select Descaling 6 Press the button to select OK press the P button twice in a row to enter the descaling cleaning Function test and maintenance methods 5 Function test and maintenance methods 5 1 Function test and test standards 5 2 Coffee machine maintenance 5 2 1 Coffee machine decalcifying Use Kalerm decalcifier only It may damage machine if use other decalcifier The whole pro...

Page 63: ...and clean water tank Add fresh pure water again and install the water tank 9 After the second cleaning coffee machine starts preheating 10 After preheating the third cleaning starts 11 The screen shows READY cleaning is completed then you can make coffee Daily descale comparison table Water hardless level Descale cycle around2 4weeks around4 6weeks around once per 2 months around once per 3 months...

Page 64: ...prompts to clean brew unit cleaning brew unit process it needs to open the power cover add cleaning tablets 6 After cleaning coffee machine enter the Ready state 5 2 2 Rinse the brew unit Use Kalerm cleaning agent only It may damage machine if use other cleaning agent The whole process costs about 10 minutes 5 2 3 Wipe the coffee machine Power off and pull out plug before clean the inside machine ...

Page 65: ...of the drip tray 1 Clean drip tray 3 Clean coffee bean container and the hopper Use dry rag or tissue clean rest oil inside bean container Do not use water to wash bean container 4 Clean hopper Use dry rag clean the channel of hopper Do not use water to wash hopper channel Service Manual Intelligent Fresh Ground Coffee Machine KLM1602 ...

Page 66: ...e methods 5 Clean the internal machine Clean base 6 Clean coffee machine Use dry and soft rag to clean the appearance of the coffee machine Clean brew unit coffee brewing box position 1 and contropistone position 3 and position 2 is the back side ...

Page 67: ...arbox 1 1 2 Install 3 epicyclic gear A and 3 epicyclic gear pin A into epicyclic gear support A and coat with oil MI setral 61B 3 Install 3 epicyclic gear B and 3 epicyclic gear pin A into epicyclic gear support B and coat with oil MI setral 61B 2 3 Grinder group 1 4 Put the already installed epicyclic gear frame A into the gearbox put 1 filler piece onto epicyclic gear frame A 5 Put the already i...

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Page 78: ...Suzhou Industrial Park Kalerm Electric Appliances Co Ltd www kalerm com 86 4006 800 866 Add 100 Sumu Rd SIP Suzhou 215021 Jiangsu China T e l 86 512 68180758 Fax 86 512 68181050 ...

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