Crathco CC-302-20 Service Manual

Powdered beverage dispensers

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Service manual (68 pages)

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ABLE OF

Warning Labels....................................... 2

Installation.............................................. 4

Start up Procedures................................. 4

How To Dispense Cappuccino.................. 5

Adjustments............................................ 5

Cleaning.................................................. 7

Preventative Maintenance ..................... 11

Service

Light Bulbs................................... 12

Draining the Tank .......................12

Shipment Preparation .................12

Whipper Motors .........................13

Dump Valves .............................. 14

Grommets .................................. 14

Water Tank ............................... 14

Inlet Valve ................................. 16

Thermistor ................................ 17

Auger Motors ............................ 18

Blower Motor ............................ 18

Controller .................................. 18

Heater Relay ......................... ... 18

Transformer .............................. 18

Soluble Conversion .................. 19

Troubleshooting..................................... 20

Exploded Views......................................22

Wiring Diagram............................. ........50

Prior authorization must be obtained from

Grindmaster Corporation™ for all warranty claims.

PRINTED IN USA

Powdered Beverage Dispensers

Service Manual

PIC 1, 2, 3, 4, 5, 6

PSD 1, 2, 3, 4, 5, 6

PIC 23A, PIC33A, PIC43A, PIC5W

ONTENTS

for

PIC 2

PIC 1

PIC 5

Grindmaster Corporation™

4003 Collins Lane

Louisville, Kentucky 40245 USA

(502) 425-4776

(800) 695-4500 (USA and Canada only)

(800) 568-5715 (Technical Service only)

FAX: (502) 425-4664

www.grindmaster.com

PIC 33A

PIC 6

0807 Form # CC-302-20

Part # 62780

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Page 1: Table Of Contents
Soluble Conversion ... 19 Troubleshooting... 20 Exploded Views...22 Wiring Diagram..50 Prior authorization must be obtained from Grindmaster Corporation™ for all warranty claims. © Grindmaster Corporation™, 1996 PRINTED IN USA Service Manual PIC 1, 2, 3, 4, 5, 6 PSD 1, 2, 3, 4, 5, 6...
Page 2: Warning Labels
Warning Labels The following warning labels were on your dispenser when it was shipped from the factory. They should remain on your dispenser in good, readable condition at all times. If one of your labels is missing or damaged, order a replace- ment label immediately.
Page 3 Warning Labels (cont.) Part #61319, Located on the outside on the back of the dispenser Part #61326, Located on the outside on the left of the dispenser Part #61325, Located on the drain hose inside the dispenser Crathco® Powdered Beverage Dispensers Page 3...
Page 4: Installation
Installation Water Inlet Connection The following is required for water hook-up: 1. A quick disconnect water connection or enough coiled tubing so the machine can be moved for cleaning underneath. (required for NSF approved water hook-up) 2. A 1/4" male flare adapter is provided (packed inside the drain tray) to be attached by the installer to the back of the machine for hook-up to water supply.
Page 5: How To Dispense Cappuccino
Installation (cont.) Start-Up Procedures for Pump Units (PIC 2P & PIC 3P only) (cont.) NOTE: Do not let the end of the hose touch the bottom of the container. Shorten the hose if necessary. If you need a longer hose, remove the back access panel, unclamp existing hose, replace with longer hose and replace clamp.
Page 6: Thermostat Adjustment
Thermostat Adjustment NOTE: The thermostat range is approximately 160°F to 200°F. The tank temperature is factory set at 180°F, making the beverage temperature slightly lower than 180°F. 1. Unplug machine. 2. Remove the drip tray. 3. Remove the upper splash panel on the front of the machine by removing the four Phillips head screws. 4.
Page 7: Cleaning
Drink Strength Adjustment for Model PIC3E or PIC33AE when equipped with remote adjust knobs behind drip tray (Refer to Figure C) 1. Dispense a drink to determine if drink is too strong or too weak. 2. Remove drip tray. 3. Using a flat head screwdriver, adjust individual dispense heads by rotating appropriate adjustment knob.
Page 8 WEEKLY Removing and Cleaning the Chambers 1. Open the door and remove the mixing funnel shroud by pulling forward while turning 1/4 turn to the right. Lift off and remove. 2. Remove the mixing funnel by lifting the neck of the funnel out of the whipper chamber, then tilt counterclockwise.
Page 9 WEEKLY (cont.) Reassembling the Hoppers (PIC 1/2/3/5/6) (Refer to Figure I) IMPORTANT: All components must be completely dry prior to reassembly. 1. Place the drive shaft bearing inside the hopper with the threads going through the hole in the rear of the hopper. 2.
Page 10: Quarterly Cleaning
Weekly Cleaning (cont.) Reassembling the Hoppers (PIC 4) IMPORTANT: All components must be completely dry prior to reassembly. 1. Place the bearings inside the hopper in proper position. 2. Secure the bearings by attaching the nuts to the bearings at the outside rear hopper opening. Tighten using only your fingers.
Page 11: Preventative Maintenance
PIC Preventative Maintenance Checklist (Every 6 to 12 months) A preventative maintenance visit should be performed every 6 to 12 months, depending on usage. The following procedures should be performed during a preventative maintenance visit. Parts Required: One PM parts kit (PIC1 - Qty1 - 62707, PIC2 - Qty2 - 62707 or Qty1 - 60933, PIC3 - Qty1 - 60933, PIC4 - Qty1 - 60933 and Qty1 - 62707, PIC5 - Qty2 - 60933, PIC6 - Qty2 - 60933).
Page 12: Service
Service Changing the Lightbulb on Models With a Backlit Merchandiser (PIC 1/2/3/4/5/6) (Refer to Figure M) (Refer to serial tag to verify model number of your machine) WARNING: Disconnect machine from branch electrical supply before changing the lightbulb. NOTE: PIC2/3/4 uses a F8T5 12" 8 watt replacement bulb. PIC5/6 uses a 22W circular bulb. 1.
Page 13 Draining the Tank (PIC 2/3/4 ) (cont.) 7. Once the tank is empty, securely replace the plug and clamp on the end of the hose. Reposition the drain hose inside the hose clip on the left side wall. 8. Reassemble the front access panel and drain tray. Purging Machine of All Water for Shipment in Cold Areas WARNING: This procedure should be performed by a qualified service technician.
Page 14: Whipper Motors
Removal of Whipper Motor(s): 1. Disconnect power. 2. Remove front and side access panels. 3. Remove chamber. 4. Remove whipper base. (Figure Q) 5. Remove motor nuts and pull motor out of slot. (Figure R, S) 6. Disconnect wire connection. (Figure T) 7.
Page 15 Replacing Water Tank on Machines with Serial # 339304 and Lower: (cont.) 4. Disconnect dump valve wiring and tubing in left access opening and remove valves. 5. Disconnect tank fill tubing from inlet valve in rear of unit. 6. Remove screws holding water tank and mounting bracket.
Page 16: Inlet Valve
Removal of Water Tank on Machines with Serial # 339305UK and Higher: Disconnect power. Drain tank. (see page 12) Remove machine lid, rear access panel and dump valve access panel. (Figure BB) Disconnect wires from tank lid components and dump valves. (Figure CC) Disconnect hoses from dump valves.
Page 17: Thermistor
Removal of Thermistor 1. Disconnect power. 2. Remove machine lid. (Figure JJ) 3. Disconnect thermistor wires. (Figure KK) 4. Lift out thermistor and replace as needed. (Figure LL) 5. To replace with thermistor, add food grade lubricant. (Figure MM Figure JJ °C °F RESISTANCE (OHMS)
Page 18: Controller
Removal of Auger Motor(s) 1. Disconnect power. 2. Remove front and side access panels. 3. Remove hoppers. 4. Remove three screws and lock washers. (Figure NN) 5. Pull motor out of slot. (Figure OO) 6. Disconnect wire connection. 7. Replace motor as needed. Removal of Blower Motor 1.
Page 19 Crathco® Powdered Beverage Dispensers Page 19...
Page 20: Troubleshooting
Troubleshooting Guide Only a qualified service technician should perform Electrical and mechanical adjustments or repairs. Always disconnect power before attempting any maintenance procedures. PROBLEM No powder dispensed • Rinse switch turned to “RINSE ON” position into mixing funnel • Powder hopper dispense outlet clogged •...
Page 21: Grindmaster Corporation
8 am - 6 pm EST) or an authorized service center in your area. Please have the model and serial numbers ready so that accurate information may be given. Prior authorization must be obtained from Grindmaster Corporation’s Technical Services Department for all warranty claims. Crathco® Powdered Beverage Dispensers Diagnostics for all PIC2, PIC3, PIC4, PIC5, and PIC6’s:...
Page 22 PIC 1 Chassis Parts (units with serial numbers beginning with “L”) 63493 63493 63493 Page 22 Crathco® Powdered Beverage Dispensers...
Page 23 PIC 1 Hopper Bracket (units with serial numbers beginning with “L”) Crathco® Powdered Beverage Dispensers Page 23...
Page 24 PIC 1 Door Assembly (units with serial numbers beginning with “L”) Page 24 Crathco® Powdered Beverage Dispensers...
Page 25 PIC 1 Tank Assembly (units with serial numbers beginning with “L” or “T”) (*) = 71610 REPAIR KIT FOR DUMP VALVE (***) = 61365 DUMP VALVE O-RING Crathco® Powdered Beverage Dispensers Page 25...
Page 26 PIC 1 Chassis Parts (units with serial numbers beginning with “T”) 63493 63493 63493 Page 26 Crathco® Powdered Beverage Dispensers...
Page 27 PIC 1 Hopper Bracket (units with serial numbers beginning with “T”) Crathco® Powdered Beverage Dispensers Page 27...
Page 28 PIC 1 Door Assembly (units with serial numbers beginning with “T”) 63097 63097 63097 Page 28 Crathco® Powdered Beverage Dispensers...
Page 29 PIC 2/3 Chassis Parts Crathco® Powdered Beverage Dispensers Page 29...
Page 30 PIC 2/3 Hopper Bracket Page 30 Crathco® Powdered Beverage Dispensers...
Page 31 PIC 2/3 Tank Assembly Crathco® Powdered Beverage Dispensers Page 31...
Page 32 PIC 2/3 Door Assembly Page 32 Crathco® Powdered Beverage Dispensers...
Page 33 PIC 4 Chassis Parts 6 3 4 9 3 Crathco® Powdered Beverage Dispensers Page 33...
Page 34 PIC 4 Control Bracket Assembly Base Page 34 Crathco® Powdered Beverage Dispensers...
Page 35 PIC43A Control Bracket Assembly Crathco® Powdered Beverage Dispensers Page 35...
Page 36 PIC 4 Hopper Bracket Funnel Whipper Shroud Page 36 Crathco® Powdered Beverage Dispensers...
Page 37 PIC 4 Hopper 62639 Hopper Assy 5.5# PIC4 (use for sugar-based powders) 62640 Hopper Assy 11# PIC4 (use for sugar-based powders) PE 32 63078 Hopper Assy 5.5# PIC4 SOL (use for soluble coffee) Crathco® Powdered Beverage Dispensers Page 37...
Page 38 PIC 4 Tank Assembly Page 38 Crathco® Powdered Beverage Dispensers...
Page 39 PIC 4 Door Assembly Crathco® Powdered Beverage Dispensers Page 39...
Page 40 PIC 4 Final Assembly Page 40 Crathco® Powdered Beverage Dispensers...
Page 41 PIC 5 Casing Assembly (Part # 62813) 63493 PIC 5 Base Assembly (Part # 62819) Crathco® Powdered Beverage Dispensers Page 41...
Page 42: Door Assembly
PIC 5 Control Bracket Assembly (Part # 62974) ITEM NO. PART NO. DESCRIPTION 62849 Bracket, Control Mtg PIC5 No Display 61338 Terminal Board 61800 Controller,Pic 3 Portion 61131 Relay,12 vdc Coil 61481 Transformer,40VA 24/12S 61266 STANDOFF, RVRS EDGEMOUNT 10073 Label, Ground Symbol 60394 Bushing,Snap-7/8"OD x 3/4"...
Page 43 PIC 5 Hopper Bracket Assembly (Part # 62850) ITEM NO. PART NO. DESCRIPTION 1 62851 Bracket, Hopper PIC5 2 61461 Button, Restrictor 3 61847 Switch,Toggle-Spst 4 61226 Funnel, Disconnect Funnel Whipper 5 61221 6 61255 SHROUD 7 62823 Plate, Cover Plenum, 8 61116-01-1 Motor, Whipper 120V 9 61334 Washer, Slinger...
Page 44 Page 44 Crathco® Powdered Beverage Dispensers...
Page 45 PIC 5 Final Assembly PIC5 - FINAL ASSEMBLY ITEM NO. PART NO. DESCRIPTION 1 62813 Casing Assy,PIC 2 62819 Base Assy PIC6 3 63485 Hopper Brkt Asy PIC5 4 63060 Door Asy PIC5 5 62858 Tank Final Assy 6 62810 Lid Assy PIC6 7 62830 Bracket, Tank Retaining,...
Page 46 PIC 6 Casing Assembly (Part # 62872) 63493 PIC 6 Lid Assembly (Part # 62874) PIC 6 Base Assembly (Part # 62876) Page 46 Crathco® Powdered Beverage Dispensers...
Page 47 PIC 5/6 Control Bracket Assembly (Part # 62848) 62848 - Control Bracket Assy PIC6 PIC 6 Door Assembly (Part # 62875) PIC6 Manual-2 rev. REL MJB, 1/14/04 ECN1888 Crathco® Powdered Beverage Dispensers ITEM NO. PART NO. DESCRIPTION 1 62849 2 61338 3 61800 4 61131 5 61481...
Page 48 PIC 6 Hopper Bracket Assembly (Part # 62863) ITEM NO. PART NO. 61116-01-1 07023-04 61847-1 Page 48 DESCRIPTION 62864 Bracket, Hopper PIC6 61461 Button, Restrictor 61847 Switch,Toggle-Spst 61226 FTG, FUNNEL DISCONNECT Funnel Whipper 61221 61255 SHROUD 62879 Plate, Cover Plenum, Motor, Whipper 120V 61334 Washer, Slinger...
Page 49 PIC 6 Final Assembly 62917 62914 62981 Drain Grid PIC6 62922 62992 Crathco® Powdered Beverage Dispensers Page 49...
Page 50 PIC 1 120V and 120/240V “Q” Model Wiring Page 50 Crathco® Powdered Beverage Dispensers...
Page 51 PIC 1 230V “E” Model Wiring Crathco® Powdered Beverage Dispensers Page 51...
Page 52 PIC1KE or PIC1KAE, 230V “E” Model Wiring Page 52 Crathco® Powdered Beverage Dispensers...
Page 53 PIC1K or PIC1KA 120 & 120/240 “Q” Model Wiring Crathco® Powdered Beverage Dispensers Page 53...
Page 54 PIC1KAEW or PIC1KEW Wiring Page 54 Crathco® Powdered Beverage Dispensers...
Page 55 CAP1AE or CAP1E 230V “E” Model Wiring Crathco® Powdered Beverage Dispensers Page 55...
Page 56 PIC 2/3 120 & 120/240V “Q” Model Wiring Page 56 Crathco® Powdered Beverage Dispensers...
Page 57 Crathco® Powdered Beverage Dispensers Page 57...
Page 68 Grindmaster® Coffee Grinders and Brewers • PrecisionBrew™ Brewing Systems • Espressimo® Espresso Machines Crathco® Hot Beverage Dispensers • Crathco® Cold and Frozen Beverage Dispensers • AMW Coffee and Tea Systems Tel (502) 425-4776 • Fax (502) 425-4664 • 1-800-695-4500 (USA & Canada only) P.O.

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Crathco CC-302-20 Service Manual

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