Nescafe Dolce Gusto Piccolo XS Service Manual
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Nescafe Dolce Gusto Piccolo XS Service Manual

Nescafe Dolce Gusto Piccolo XS Service Manual

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SERVICE MANUAL
BEVER AGE CENTRE
PICCoLo XS
Version 1.0 EN
last modified - 01.05.2019

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Summary of Contents for Nescafe Dolce Gusto Piccolo XS

  • Page 1 SERVICE MANUAL BEVER AGE CENTRE PICCoLo XS Version 1.0 EN last modified - 01.05.2019...

  • Page 2: Table Of Contents

    CoNtENtS C o N T E N T S Main Components ............... 5 Design Variants ........................... 5 overview of External Parts ......................6 overview of Internal Parts ......................7 overview of Extraction Head Parts ..................... 8 Water Circuit ..........................9 Rating Plate ..........................
  • Page 3 CoNtENtS Wiring Diagram ................. 54 Final Tests.................. 55 test Equipment ......................... 55 Cleaning or Replacing the Needle Plate ..................56 Heating up time ........................58 Priming the Fluid System ......................58 Flow Rate and temperature ...................... 59 Moving Force of Selection Lever ....................61 Final Inspections ................
  • Page 4 P R E F A C E the purpose of this service manual is to provide the service personnel with all neces- Please keep this manual together sary information with regards to correct handling, maintenance and repair of the with the corresponding Piccolo XS beverage center.

  • Page 5: Main Components

    MAIN CoMPoNENtS > DESIGN VARIANtS M A I N C o M P o N E N T S Design Variants the Piccolo XS beverage centre comes in two different design variants. From a service technicians standpoint both of the housings, the shutter support and the valve shut- ter are different.

  • Page 6: Overview Of External Parts

    MAIN CoMPoNENtS > oVERVIEW oF EXtERNAL PARtS overview of External Parts the numbers are not consistent with the position numbers of the spare parts list. Fig. 1  1) Water tank body 8) Rinsing tool 2) Water tank lid 9) Capsule holder 3) Selection lever 10) Cleaning needle 4) Cold position...

  • Page 7: Overview Of Internal Parts

    MAIN CoMPoNENtS > oVERVIEW oF INtERNAL PARtS overview of Internal Parts the numbers are not consistent with the position numbers of the spare parts list. View from the back. Fig. 2  1) Hot water pressure hose 7) Main PCB 2) Cold water pressure hose 8) Pump outlet 3) thermoblock NtC 9) Indicator light guide...

  • Page 8: Overview Of Extraction Head Parts

    MAIN CoMPoNENtS > oVERVIEW oF EXtRACtIoN HEAD PARtS Overview of Extraction Head Parts the numbers are not consistent with the position numbers of the spare parts list. Fig. 3  1) Selection lever 7) Head chassis 2) Shutter support 8) Locking handle 3) Shutter 9) Rocker lever 4) Valve microswitch...

  • Page 9: Water Circuit

    MAIN CoMPoNENtS > WAtER CIRCuIt Water Circuit the numbers are not consistent with the position numbers of the spare parts list. 8,11 8,10 Fig. 4  1) Water tank 7) F-Connector 2) Water tank connector with valve 8) Needle plate 3) Pump 9) Capsule holder 4) thermoblock 10) Injector needle...

  • Page 10: Rating Plate

    MAIN CoMPoNENtS > RAtING PLAtE Rating Plate TYPE 9781 www.dolce-gusto.com 220-240V~ 50/60Hz 1340-1600W YYMDDWXXLXXXXPVPCCV MADE IN INDONESIA REF:MD9781 White-WWYY Fig. 5  the rating plate is located on the bottom, underneath the machine. Decoding the serial number Example of a direct markets rating TYPE XXXX plate.

  • Page 11: Technical Data

    MAIN CoMPoNENtS > tECHNICAL DAtA Technical Data Mains voltages Europe (Lt, EE, LV, Ru, No, SE, FI, DK, ES, It, CH, uK, DE, AuS, ZA) ....230 V, 50 Hz uS / CA ......................120 V, 60 Hz Mexico ....................127 V, 50 / 60 Hz Brazil ......................127 V, 60 Hz Chile ......................220 V, 50 Hz Argentina ......................220 V, 50 Hz...
  • Page 12 MAIN CoMPoNENtS > tECHNICAL DAtA Environmental conditions operating temperature range ........+5 °C – +45 °C (+41 °F – +113 °F) Storage temperature range ..........-20 °C – +70 °C (-4 °F – +158 °F) operating humidity range .......no condensation, 30 – 90 % relative humidity operating altitude ..................

  • Page 13: Operating

    oPERAtING > MACHINE StAtuS o P E R AT I N G Machine Status After switching on (i.e. inserting/removing the capsule holder), an automatic self-test is performed to check if the NtC is connected, NtC is short-circuited, Valve is in middle position. operating modes and detected failures are indicated by signals of the indicator light as listed in the following table: Operating mode...

  • Page 14: Preparing A Beverage

    oPERAtING > PREPARING A BEVERAGE Preparing a Beverage 1. Check if the water tank contains 4. Pull out the capsule holder. the enough fresh drinking water. Machine switches on automatically. 2. Adjust the drip tray position 5. the indicator light blinks red while depending on the chosen beverage.

  • Page 15: Descaling

    oPERAtING > DESCALING Descaling Caution! Only use descaling solution that is suitable for coffee machines – never use vinegar! • Carefully read the safety instructions on the descaler package. • Descaling solution is aggressive to the surface of the casing. Wipe off any splashes with a damp cloth immediately.
  • Page 16 oPERAtING > DESCALING 13. the indicator light switches to a 15. Empty and clean the container. steady green when descaling is 16. Rinse and clean the water tank finished. using a clean, food-safe brush and 14. For a better effect of the descaler, washing-up liquid as needed.
  • Page 17 oPERAtING > DESCALING STOP 26. Check visually when the water tank 28. Remove and empty the container. is empty. 29. open the locking handle. 27. Push the selection lever to the 30. Pull out the capsule holder and “StoP” position. remove the rinsing tool.

  • Page 18: Troubleshooting Checklist

    tRouBLESHootING CHECKLISt T R O U B L E S H O O T I N G C H E C K L I S T Symptom Observation Cause / Repair action Further action • Check presence of the magnet in the capsule holder or try with another capsule holder.
  • Page 19 tRouBLESHootING CHECKLISt Symptom Observation Cause / Repair action Further action • this issue can be related to a “blocked capsule”. If not, go to next Check the flow without capsule. repair action. • A clogged injector needle (limescale) is the most frequent reason for machine return.
  • Page 20 tRouBLESHootING CHECKLISt Symptom Observation Cause / Repair action Further action • the cause can be a defective batch of capsules It happened once with delamination of the top membrane. Make with one capsule or a trial with a capsule (ideally capsules that bring If no, go to next with capsules from pressure e.g.
  • Page 21 tRouBLESHootING CHECKLISt Symptom Observation Cause / Repair action Further action • the most likely root cause is a broken/open ther- mofuse of the thermoblock. test the continuity of the fuses and if they are indeed defective, If no, go to next exchange the power cord.
  • Page 22 tRouBLESHootING CHECKLISt Symptom Observation Cause / Repair action Further action • this is not a defect but a reminder for the cus- tomer to descale the machine. • try to prepare a beverage. Check the different Power button/indica- parameters (flow rate, volume, temperature, tor light is orange.
  • Page 23 tRouBLESHootING CHECKLISt Symptom Observation Cause / Repair action Further action • the thermoblock could be failing to reach the tar- get temperature if the flow rate is too high. If no, go to next temperature is • Check the flow rate with a capsule and replace repair action.
  • Page 24 tRouBLESHootING CHECKLISt Symptom Observation Cause / Repair action Further action • this might be due to an ongoing production fail- ure of a PCB component. Machine works with • open the machine and check its behaviour, If no, go to next burnt smell or smoke replace the PCB if needed.

  • Page 25: Repair

    REPAIR > GENERAL R E PA I R General this chapter contains special safety and assembly notes. Non-observance of the safety and assembly notes can lead to injuries and damages! • the disassembly / repair procedures are presented as step by step instructions. •...

  • Page 26: Tools And Repair Accessories

    REPAIR > tooLS AND REPAIR ACCESSoRIES Tools and Repair Accessories With the following tools, all described disassembly and repair work can be done: Tools and consumable material Applications torque screwdriver to apply correct screw torques → p. 27. A pin-torx screw tamper proof security torx bit t10 All fastening screws except thermoblock, head of a security...

  • Page 27: Screw Tightening Torques

    REPAIR > SCREW tIGHtENING toRquES Screw Tightening Torques The max. screw Screw connection / type Torque Position tightening torque indicated must not be exceeded. The torque values for plastic parts Housing fixing screw (1×) 4.5 ± 0.5 kgf cm 44.1 ± 4.9 Ncm are only applicable tX10 2.9 ×...
  • Page 28 REPAIR > SCREW tIGHtENING toRquES Screw connection / type Torque Position thermoblock NtC and fuse sheet fixing screws (2×) 4.5 ± 0.5 kgf cm 44.1 ± 4.9 Ncm Crosshead screw 3.9 ± 0.4 lbf-in dia. M3 × 6 thermoblock fixing screw (1×) 18.0 ±...

  • Page 29: General Disassembly

    REPAIR > GENERAL DISASSEMBLy General Disassembly Removable Parts Unplug the machine from the mains before disassembly - appliance must be isolated! Fig. 8  1. Switch the machine off by unplugging the power cord. 2. Remove and empty the water tank (10). 3.

  • Page 30: Remove Left And Right Housings

    REPAIR > GENERAL DISASSEMBLy Remove Left and Right Housings Fig. 9  Loosen one screw (tX10 with safety pin) on the back of the machine. Fig. 10  6. Lay the coffee machine on its side and loosen 2 latches (circled in red) from hous- ing left (1) with the help of a small flathead screwdriver.
  • Page 31 REPAIR > GENERAL DISASSEMBLy Fig. 11  7. Insert a screwdriver into the hole in frame base (24) to push the housing out- wards so the lower hook (circled in red) holding together the housings can be released. 8. At the same time, push another screwdriver into the gap between housing left (1) and frame base (24).
  • Page 32 REPAIR > GENERAL DISASSEMBLy Fig. 12  10. Keep pulling on housing left (1) with one hand. 11. use your free hand to simultaneously press in housing right (1b) at the red circled locations on the front and the back of the machine to release the corresponding latches.
  • Page 33 REPAIR > GENERAL DISASSEMBLy Releasing this last latch might require some force. Fig. 13  12. Swing up housing left (1) to release the last latch (circled in red) holding the hous- ings together. 13. Pull off and remove housing left (1). Version 1.0 EN Piccolo XS Service Manual...
  • Page 34 REPAIR > GENERAL DISASSEMBLy Fig. 14  14. Loosen 2 latches (circled in red, see detail) from housing right (1) on the bottom of the machine. 15. Pull off housing right (1) including the shutter assembly (4). Assembly Tip • Ensure that the shutter assembly (4) is completely snapped into housing right (1) before reassembling the housings.

  • Page 35: Remove Back Housing

    REPAIR > GENERAL DISASSEMBLy Remove Back Housing Fig. 15  Prerequisites • Housing left/right (1) are removed → p. 30. Procedure 1. turn the machine upside-down. 2. Loosen 2 latches with your thumbs and pull off back housing (21). Version 1.0 EN Piccolo XS Service Manual...

  • Page 36: Replace Pump

    REPAIR > REPLACE PuMP Replace Pump Fig. 16  Prerequisites • General disassembly → p. 29. Procedure 1. unplug the flat receptacle of the red wire from the pump (15). use flat nose pliers for easy removal. 2. unplug the flat receptacle of the white pump wire from the main PCB (14). This kind of flat receptacle has a special connector latching.
  • Page 37 REPAIR > REPLACE PuMP Fig. 17  3. Release the latch of the support beam on the front of the machine by inserting a screwdriver into the outer hole (A) and apply a push and lift force while pulling on the pump by hand at the same time. 4.
  • Page 38 REPAIR > REPLACE PuMP Fig. 18  5. Pull off the water outlet (23) and suspension spring (22) from the pump (15). 6. Check the condition of the pressure hoses (35) on the pump outlet and the pump outlet itself. 7. Discard a dirty, clogged or leaky outlet together with a defect pump (15). Piccolo XS Service Manual Version 1.0 EN...
  • Page 39 REPAIR > REPLACE PuMP the extension on the pump outlet is rotatable and has a square fork shaft for a fork wrench. Fig. 19  8. If the pressure hoses and the pump outlet are in good condition, they can be reused with the following procedure: •...
  • Page 40 REPAIR > REPLACE PuMP Make sure that the pieced together pressure hose does not touch the housings after installation to avoid noise emission. Fig. 20  9. If the pressure hoses and the pump outlet are in bad condition, they need to be replaced as well: •...

  • Page 41: Assembly Tips

    REPAIR > REPLACE PuMP Assembly Tips Fig. 21  • Check according to illustration: - orientation/Position of the hose clips. - orientation of the pump outlet. - Arrangement of pressure hoses. • Always use new hose clips for pressure hose assembly. •...

  • Page 42: Replace Water Outlet

    REPAIR > REPLACE WAtER outLEt Replace Water Outlet Fig. 22  Prerequisites • General disassembly → p. 29. • Execute step 1 to 3 of the procedure “Replace Pump“ → p. 36. Procedure 1. Pull off the water outlet (23) from the pump (15). 2.

  • Page 43: Replace Thermoblock Ntc

    REPAIR > REPLACE tHERMoBLoCK NtC Replace Thermoblock NTC Fig. 24  Prerequisites • General disassembly → p. 29. Procedure 1. unplug the thermoblock NtC (19) from the main PCB (14, see detail). 2. Loosen one screw (crosshead) on thermoblock (16). 3. Pull the thermoblock NtC (19) including spring (A) and washer (B) out of its socket.

  • Page 44: Replace Main Pcb

    REPAIR > REPLACE MAIN PCB Replace Main PCB Fig. 26  Prerequisites • General disassembly → p. 29. Procedure 1. unplug the flat receptacle of the black wire from the thermoblock (16). 2. unplug the flat receptacle of the red wire from the main PCB (14). 3.

  • Page 45: Assembly Tip

    REPAIR > REPLACE MAIN PCB Fig. 27  8. Swing the main PCB (14) out of its guides and pull it out on the left side. Assembly Tip Fig. 28  • use the guides (circled in red) to correctly place the main PCB (14) before fasten- ing the screw.

  • Page 46: Replace Thermoblock

    REPAIR > REPLACE tHERMoBLoCK Replace Thermoblock 20/A Fig. 29  Prerequisites • General disassembly → p. 29. • thermoblock NtC (19) is removed → p. 43. Procedure 1. unplug the flat receptacle of the black wire from the thermoblock (16). 2. unplug the flat receptacle of the red wire from the thermoblock (16). 3.
  • Page 47 REPAIR > REPLACE tHERMoBLoCK Fig. 30  6. Loosen 1 screw (tX30) inside the thermoblock (16). 7. Pull the thermoblock (16) out of its support (18). Version 1.0 EN Piccolo XS Service Manual...

  • Page 48: Assembly Tips

    REPAIR > REPLACE tHERMoBLoCK Assembly Tips Fig. 31  • See the assembly tips for the thermoblock NtC (19) → p. 43. • Replace the pressure hose (35) to the pump (15). • Cut a new pressure hose (35) with a length of 50 mm. •...

  • Page 49: Replace Power Cord

    REPAIR > REPLACE PoWER CoRD Replace Power Cord the illustration only shows the thermoblock and its support for better visibility. Fig. 32  Prerequisites • General disassembly → p. 29. Procedure 1. unplug all flat receptacles of the red wire from the thermoblock (16), pump (15) and main PCB (14).

  • Page 50: Assembly Tip

    REPAIR > REPLACE VALVE SWItCH Assembly Tip 8 mm min. Insulation sleeve Connecting wire Thermofuse Fig. 33  • Keep a minimum distance of 8 mm to the case of the thermofuse when bending its connecting wires. use a tool with no sharp edges (e.g. round nose pliers). Replace Valve Switch Fig.

  • Page 51: Replace Locking Handle Print

    REPAIR > REPLACE LoCKING HANDLE PRINt Replace Locking Handle Print Fig. 35  Prerequisites • General disassembly → p. 29. Procedure 1. open the locking handle (3). 2. Loosen 1 screw (tX10) from the rocker lever (A). 3. Push the locking handle (3) upwards until it releases. Assembly tip Fig.

  • Page 52: Replace Extraction Head

    REPAIR > REPLACE EXtRACtIoN HEAD Replace Extraction Head Fig. 37  Prerequisites • General disassembly → p. 29. Procedure 1. unplug the valve switch (32) connector from the main PCB (14). 2. Pull off the hose clips (37) and pressure hoses (35) from the extraction head (13) to the pump (15) and thermoblock (16).

  • Page 53: Assembly Tips

    REPAIR > REPLACE EXtRACtIoN HEAD Fig. 38  3. Loosen 2 screws (tX10 with safety pin) from extraction head (13). 4. tilt the extraction head (13) forward to release it from the frame (2). use a flat- head screwdriver as lever like shown if the extraction head is stuck. 5.

  • Page 54: Wiring Diagram

    WIRING DIAGRAM W I R I N G D I A G R A M Legend High Current (1.31mm , AWG16) Solder Connection Plug (JST: XH Series) Medium Current (0.75mm , ~AWG19) Faston Contact (4.8mm) Plug (JST: PH Series) Low Current (0.205mm , AWG24, 12V) Faston Contact (6.3mm) Crimp Connection...

  • Page 55: Final Tests

    FINAL tEStS > tESt EquIPMENt F I N A L T E S T S the tests in this chapter guarantee the correct function of the machine. the tests in the next chapter (→ p. 61) are mandatory by legal regulations if any housing parts have been removed.

  • Page 56: Cleaning Or Replacing The Needle Plate

    FINAL tEStS > CLEANING oR REPLACING tHE NEEDLE PLAtE Cleaning or Replacing the Needle Plate Danger of injury! Sharp pointed injector needle. Fig. 40  1. Move the locking handle to a point where you can see and access the front hole of the needle plate.
  • Page 57 FINAL tEStS > CLEANING oR REPLACING tHE NEEDLE PLAtE Fig. 41  5. If a dirty needle plate was replaced, check and clean the plate holder (c) and out- let (b) of the F-Connector. 6. Perform a complete descaling (→ p. 15) resp. rinsing cycle without the needle plate.

  • Page 58: Heating Up Time

    FINAL tEStS > HEAtING uP tIME Heating up Time If the heating up time is more than expected or less than 25 sec, replace the thermoblock or NtC. 1. Connect the power cord to the 3. Measure the heating up time until mains power socket.

  • Page 59: Flow Rate And Temperature

    FINAL tEStS > FLoW RAtE AND tEMPERAtuRE Flow Rate and Temperature Test Specifications Temperatures Max. temperature at outlet : +85 °C ± 5 °C (+185 °F ± 9 °F) temperature in cup : > +70 °C (+158 °F) Flow rates Capsule Weight at 30 s / Flow rate Barista/Ardenza...

  • Page 60: Test Procedure

    FINAL tEStS > FLoW RAtE AND tEMPERAtuRE Test Procedure approx. 3 mm 1. Push the selection lever to the 3. Measure the temperature with the “Hot” position. electronic thermometer: Place the 2. Start the stop watch as soon as the sensor approx.

  • Page 61: Moving Force Of Selection Lever

    FINAL tEStS > MoVING FoRCE oF SELECtIoN LEVER Moving Force of Selection Lever 1. Inspect the shutter assembly. 3. Switch the machine oN (i.e. pull out and insert the capsule holder). The shutter assembly must be 4. Wait until the machine is ready. clean and undamaged.

  • Page 62: Final Inspections

    FINAL INSPECtIoNS > GENERAL F I N A L I N S P E C T I o N S General Legal situation Repair centres can be legally obligated to ensure the safety and physical integrity of Check the legal situation in your the user/consumer by national regulations and standards.

  • Page 63: Protective Earthing (Pe) Test

    FINAL INSPECtIoNS > PRotECtIVE EARtHING (PE) tESt Protective Earthing (PE) Test this test makes sure that the protective earth conductor is not interrupted, the resistance between the ground contact of the coffee machine’s power plug and the metal housing of the thermoblock is within tolerance. Test procedure the coffee machine is assembled...

  • Page 64: Protective Insulation Test

    FINAL INSPECtIoNS > PRotECtIVE INSuLAtIoN tESt Protective Insulation Test this test verifies the insulation resistance between the protective earthing conductor of the coffee machine and the phase/neutral conductor of the coffee machine. of all conductive and touchable parts of the coffee machine (with the help of a test probe).
  • Page 65 FINAL INSPECtIoNS > PRotECtIVE INSuLAtIoN tESt Fig. 45  9. touch the screw that fixes both housing parts at the back of the coffee machine. 10. Press the start button (C) and read off the displayed resistance. The measured resistance must be higher than 2.0 MΩ with a test voltage of 500 VDC.

  • Page 66: Shipping

    SHIPPING > EMPty tHE FLuID SyStEM S H I P P I N G Empty the Fluid System For shipping a machine, it is important to empty the fluid system. the machine will not work without inserted capsule holder. 1. Remove and empty the water tank 3.

  • Page 67: Packing Instructions

    SHIPPING > PACKING INStRuCtIoNS Packing Instructions Risk of damage! • Wrap the coffee machine in a plastic foam bag to avoid scratches dur- ing transportation. • Use a new packaging for shipment if necessary. • Empty the fluid system before packing → p. 66. 1.

  • Page 68: Spare Parts

    SPARE PARtS > SPARE PARtS DRAWING S PA R E PA R T S Spare Parts Drawing 26 27 28 29 30 Piccolo XS Service Manual Version 1.0 EN...
  • Page 69 SPARE PARtS > SPARE PARtS DRAWING Spare Parts Drawing (contd.) Version 1.0 EN Piccolo XS Service Manual...
  • Page 70 SPARE PARtS > SPARE PARtS DRAWING Spare Parts Drawing (contd.) Piccolo XS Service Manual Version 1.0 EN...

  • Page 71: Spare Parts List

    SPARE PARtS > SPARE PARtS LISt Spare Parts List Pos. WIK Part no. Description Comment 9310779200 HouSING LEFt & RIGHt Joy DARK RED 9310779300 HouSING LEFt & RIGHt Joy BLACK 9310779400 HouSING LEFt & RIGHt Joy WHItE 9310779500 HouSING LEFt & RIGHt RIo FERRARI RED 9310779600 HouSING LEFt &...
  • Page 72 SPARE PARtS > SPARE PARtS LISt Pos. WIK Part no. Description Comment 9310786500 tHERMoBLoCK + SuPPoRt ASSEMBLy 230V 9310786600 tHERMoBLoCK + SuPPoRt ASSEMBLy 127V 9310786700 tHERMoBLoCK + SuPPoRt ASSEMBLy 120V 9310786800 tHERMoBLoCK + SuPPoRt ASSEMBLy 110V 9310786900 tHERMoBLoCK + SuPPoRt ASSEMBLy 100V 9310783000 tHERMoBLoCK SuPPoRt...

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