Bunn Coffee Maker C-APS Service Manual
C, CS, CT, CWTF,
CRT, CRTF Series
Including
DV, MV, APS/TC/TS,
Single CW & Twins
Supercedes Service Manual: 41711.0000
SERVICE & REPAIR MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
41711.0001B 05/12 ©2009 Bunn-O-Matic Corporation
BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY
Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:
1) Airpots, thermal carafes, decanters, GPR servers, iced tea/coffee dispensers, MCP/MCA pod brewers thermal servers
and Thermofresh servers (mechanical and digital)- 1 year parts and 1 year labor.
2) All other equipment - 2 years parts and 1 year labor plus added warranties as specified below:
a) Electronic circuit and/or control boards - parts and labor for 3 years.
b) Compressors on refrigeration equipment - 5 years parts and 1 year labor.
c) Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis - parts
and labor for 4 years or 40,000 pounds of coffee, whichever comes first.
These warranty periods run from the date of installation BUNN warrants that the equipment manufactured by it will be
commercially free of defects in material and workmanship existing at the time of manufacture and appearing within the
applicable warranty period. This warranty does not apply to any equipment, component or part that was not manufactured
by BUNN or that, in BUNN’s judgment, has been affected by misuse, neglect, alteration, improper installation or operation,
improper maintenance or repair, non periodic cleaning and descaling, equipment failures related to poor water quality,
damage or casualty. In addition, the warranty does not apply to replacement of items subject to normal use including but
not limited to user replaceable parts such as seals and gaskets. This warranty is conditioned on the Buyer 1) giving BUNN
prompt notice of any claim to be made under this warranty by telephone at (217) 529-6601 or by writing to Post Office
Box 3227, Springfield, Illinois 62708-3227; 2) if requested by BUNN, shipping the defective equipment prepaid to an
authorized BUNN service location; and 3) receiving prior authorization from BUNN that the defective equipment is under
warranty.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of BUNN are not authorized to make
modifications to this warranty or to make additional warranties that are binding on BUNN. Accordingly, statements by such
individuals, whether oral or written, do not constitute warranties and should not be relied upon.
If BUNN determines in its sole discretion that the equipment does not conform to the warranty, BUNN, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the
applicable parts and labor warranty periods specified above) to repair the defective components, provided that this repair
is done by a BUNN Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for
the equipment.
THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS
EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AT BUNN’S SOLE OPTION
AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND.
In no event shall BUNN be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of
use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities
or services, or any other special, incidental or consequential damages.
392, AutoPOD, AXIOM, BrewLOGIC, BrewMETER, Brew Better Not Bitter, BrewWISE, BrewWIZARD, BUNN Espress, BUNN
Family Gourmet, BUNN Gourmet, BUNN Pour-O-Matic, BUNN, BUNN with the stylized red line, BUNNlink, Bunn-OMatic,
Bunn-O-Matic, BUNNserve, BUNNSERVE with the stylized wrench design, Cool Froth, DBC, Dr. Brew stylized Dr. design,
Dual, Easy Pour, EasyClear, EasyGard, FlavorGard, Gourmet Ice, Gourmet Juice, High Intensity, iMIX, Infusion Series, Intellisteam, My Café, Phase Brew, PowerLogic, Quality Beverage Equipment Worldwide, Respect Earth, Respect Earth with
the stylized leaf and coffee cherry design, Safety-Fresh, savemycoffee.com, Scale-Pro, Silver Series, Single, Smart Funnel,
Smart Hopper, SmartWAVE, Soft Heat, SplashGard, The Mark of Quality in Beverage Equipment Worldwide, ThermoFresh,
Titan, trifecta, Velocity Brew, A Partner You Can Count On, Air Brew, Air Infusion, Beverage Bar Creator, Beverage Profit
Calculator, Brew better, not bitter., BUNNSource, Coffee At Its Best, Cyclonic Heating System, Daypart, Digital Brewer
Control, Nothing Brews Like a BUNN, Pouring Profits, Signature Series, Tea At Its Best, The Horizontal Red Line, Ultra are
either trademarks or registered trademarks of Bunn-O-Matic Corporation.
Page 2
41711.1 030912
Contents
Trouble Shooting .............................................................................................................. 4
Component Access ........................................................................................................ 10
Control Thermostat ........................................................................................................ 10
Electronic Thermostat .................................................................................................... 11
ON/OFF Switch ............................................................................................................... 12
Start Switch (Brew) ........................................................................................................ 13
Solenoid (Inlet) .............................................................................................................. 14
Tank Heater .................................................................................................................... 16
Fill Basin ........................................................................................................................ 16
Tank Heater Switch ........................................................................................................ 18
Thermal Cut-Off ............................................................................................................. 20
Coil/Faucet ..................................................................................................................... 21
Limit Thermostat ............................................................................................................ 22
Recovery Booster ........................................................................................................... 23
Timer (Early Model) ....................................................................................................... 24
Freshness Timer (Early Models)..................................................................................... 25
Digital Brew Timer (Late Model) .................................................................................... 26
Warmer Elements........................................................................................................... 28
Schematic Wiring Diagrams .......................................................................................... 29
Page 3
41711.1 052009
TROUBLESHOOTING
A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic
Technical Service Department.
• Inspection,testing,andrepairofelectricalequipmentshouldbeperformedonlybyqualiedservicepersonnel.
• Allelectroniccomponentshave120voltacandlowvoltagedcpotentialontheirterminals.Shortingof
terminals or the application of external voltages may result in board failure.
• Intermittentoperationofelectroniccircuitboardsisunlikely.Boardfailurewillnormallybepermanent.If
an intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a
terminal or crimp.
• Solenoidremovalrequiresinterruptingthewatersupplytothevalve.Damagemayresultifsolenoidsare
energized for more than ten minutes without a supply of water.
• Theuseoftwowrenchesisrecommendedwheneverplumbingttingsaretightenedorloosened.Thiswill
help to avoid twists and kinks in the tubing.
• Makecertainthatallplumbingconnectionsaresealedandelectricalconnectionstightandisolated.
• Thisbrewerisheatedatalltimes.Keepawayfromcombustibles.
WARNING – • Exerciseextremecautionwhenservicingelectricalequipment.
• Unplugthebrewerwhenservicing,exceptwhenelectricaltestsarespecied.
• Followrecommendedserviceprocedures
• Replaceallprotectiveshieldsorsafetynotices
PROBLEM
Brew cycle will not start
PROBABLE CAUSE
1. No water
2. No power or incorrect voltage
to the brewer
REMEDY
Water lines and valves to the
brewer must be open.
(A1) Check the terminal block for
120 volts across the black and
white terminals on two wire 120
volt brewers.
(A2) Check the terminal block
for 120 volts across the red and
white terminals and the black
and white terminal on three wire
120/240 volt brewers.
(A3) Check the terminal block for
200 volts on "B Series" brewers
or 240 volts on "A Series" brewers across the red and black
terminals.
Page 4
(B) Check circuit breakers or
fuses.
41711.1 052009
TROUBLESHOOTING (cont.)
PROBLEM
Brew cycle will not start (cont.)
PROBABLE CAUSE
3. ON/OFF Switch
4. Start Switch
5. Timer
6. Solenoid Valve
7. Water strainer/flow control
(.222 GPM) Early models
REMEDY
Refer to Service - ON/OFF
Switch for testing.
Refer to Service - Start Switch
for testing procedures.
Refer to Service - Timer for testing procedures.
Refer to Service - Solenoid Valve
for testing procedures.
(A) Direction of flow arrow must
be pointing towards brewer.
(B) Remove the strainer/flow
control and check for obstructions. Clear or replace.
Water is not hot
1. Tank Heater Switch
2. (A) Limit Thermostat
(B) Thermal Cut-Off (Brewers
with Faucet)
CAUTION - Do not eliminate
or bypass limit thermostat or
thermal cut-off. Use only BOM
replacement parts.
3. Control Thermostat
4. Tank Heater
Refer to Service - Tank Heater
Switch for testing procedures.
Refer to Service - Limit Thermostat for testing procedures.
Thermal Cut-Off for testing
procedures.
Refer to Service - Control Thermostat for testing procedures.
Refer to Service - Tank Heater
for testing procedures.
Page 5
41711.1 052009
TROUBLESHOOTING (cont.)
PROBLEM
Inconsistent beverage level in
dispenser
PROBABLE CAUSE
1. Strainer /flow control (.222
GPM) Early models.
2. Syphon System
3. Lime Build-up
CAUTION - Tank and tank
components should be delimed
regularly depending on local water conditions. Excessive mineral build-up on stainless steel
surfaces can initiate corrosive
reactions resulting in serious
leaks.
REMEDY
(A) Direction of flow arrow must
be pointing towards the brewer.
(B) Remove the strainer/flow
control and check for obstruction. Clear or replace.
The brewer must be level or
slightly lower in front to syphon
properly.
Inspect the tank assembly for
excessive lime deposits. Delime
as required.
Consistently low beverage level
in the dispenser
Spitting or excessive steaming
4. Water Pressure
1. Timer
2. Strainer/flow Control (.222
GPM)
1. Lime Build-up
CAUTION - Tank and tank
components should be delimed
regularly depending on local water conditions. Excessive mineral build-up on stainless steel
surfaces can initiate corrosive
reactions resulting in serious
leaks.
Page 6
The water pressure to the
brewer must be at least 20 psi
(138 kPa).
Timer must be set for at least
two minutes and fifteen seconds.
(A) Direction of flow arrow must
be pointing towards brewer.
(B) Remove the strainer/flow
control and check for obstructions. Clear or replace.
Inspect tank assembly for excessive lime deposits. Delime as
required.
41711.1 052009
TROUBLESHOOTING (cont.)
PROBLEM
Spitting or excessive steaming
(cont.)
Dripping from sprayhead
PROBABLE CAUSE
2. Control Thermostat
1. Syphon System
2. Lime Build-up
CAUTION - Tank and tank components should be delimed
regularly depending on local
water conditions. Excessive mineral build-up on stainless steel
surfaces can initiate corrosive
reactions resulting in serious
leaks.
3. Solenoid Valve
REMEDY
Refer to Service - Control Thermostat for testing procedures.
The brewer must be level or
slightly lower in front to syphon
properly.
Inspect the tank assembly for
excessive lime deposits. Delime
as required.
Remove the solenoid valve and
clear any obstructions. Rebuild
or replace the valve if necessary.
Water flows into tank continuously (ON/OFF Switch "ON")
Water flows into tank continuously (ON/OFF Switch "OFF")
Beverage overflows dispenser
1. Timer
1. Solenoid Valve
1.Dispenser
2. Timer
3. Solenoid Valve
Refer to Service - Timer for testing procedures.
Remove the Solenoid Valve and
clean any obstruction. Rebuild
or replace the valve if necessary.
The dispenser must be completely empty before starting a
brew cycle.
Refer to Service - Timer for testing procedures.
Remove the Solenoid Valve and
clean any obstruction. Rebuild
or replace the valve if necessary.
Page 7
41711.1 052009
TROUBLESHOOTING (cont.)
PROBLEM PROBABLE CAUSE
Weak beverage
1. Filter Type
2. Coffee Grind
3. Sprayhead
4. Funnel Loading
5. Water Temperature
REMEDY
BUNN® paper filters must be used
for proper extraction.
A fine or drip grind must be used
for proper extraction.
A six-hole stainless steel sprayhead must be used for proper
extraction.
The BUNN® paper filter must be
centered in the funnel and the
bed of ground leveled by gentle
shaking.
Place an empty funnel on an empty
dispenser beneath the sprayhead.
Initiate a brew cycle and check the
water temperature immediately
below the sprayhead with a thermometer. The reading should not
be less than 195°F (76°C). Adjust
the control thermostat to increase
the water temperature. Replace if
necessary.
Dry coffee grounds remain in
the funnel
Brewer is making unusal noises
1. Funnel Loading
1. Solenoid
2. Plumbing Lines
3. Water Supply
Page 8
The BUNN® paper filter must be
centered in the funnel and the
bed of grounds leveled by gently
shaking.
The nut on the solenoid must
be tight or it will vibrate during
operation.
Plumbing lines should not resting
on the counter top.
(A) The brewer must be connected
to a cold water line.
(B) Water pressure to the brewer
must not exceed 90 psi (620 kPa).
Install a regulator if necessary to
lower the working pressure to approximately 50 psi (345 kPa).
41711.1 052009
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Brewer is making unusal noises
(cont.)
Low beverage serving temperature
4. Tank Heater
1. Warmer
2. ON/OFF Switch
Remove and clean lime off the
tank heater.
Refer to Service - Warmer element for testing procedures.
Refer to Service - ON/OFF
Switch for testing procedures.
Page 9
41711.1 052009
SERVICE
This section provides procedures for testing and
replacing various major components used in this
brewer should service become necessary. Refer to
Troubleshooting for assistance in determining the
cause of any problem.
WARNING - Inspection, testing, and repair of electrical equipment should be performed only by qualified
service personnel. The brewer should be unplugged
when servicing, except when electrical tests are required and the test procedure specifically states to
plug-in the brewer.
COMPONENT ACCESS
WARNING - Disconnect the brewer from the power
source before the removal of any panel or the replacement of any component.
All components are accessible by the removal of
the top cover, front inspection panel, warmer plate(s)
and rear utility cover (Twins only).
CONTROL THERMOSTAT
3. Gently remove the capillary bulb and grommet
from the tank.
4. Check for continuity across the thermostat terminals. The indication must be:
a) Continuity with knob rotated fully clockwise.
b) No continuity with knob rotated fully counter-
clockwise. NOTE: First style does not have the ON/
OFF feature, simply check continuity.
If continuity is not present as described, replace control
thermostat.
If continuity is present as described, refer to the wiring
diagrams and check the brewer wiring harness.
Removal and Replacement:
1. Disconnect the control thermostat wires.
2. Remove the thermostat capillary bulb by firmly
pulling up on the capillary at the tank lid. This will
disengage the grommet from the tank lid.
3. Remove the one #8-32 screw securing the control
thermostat to the component bracket inside the
trunk.
4. Slide the grommet to the line 4.5" above the bulb
on the new capillary tube.
5. Insert the capillary bulb through the hole in the
tank lid and press the grommet firmly and evenly
so that the groove in the grommet fits into the tank
lid.
6. Carefully bend the capillary tube so that the tube
and bulb inside the tank are in the vertical position.
FIG. 10-1 CONTROL THERMOSTAT
Location:
The control thermostat is located inside the trunk
on the upper left side of the component bracket.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the leads from control thermostat.
Page 10
NOTE - The capillary tube must be clear of any electrical termination and not kinked.
7. Using #8-32 screw(s), secure the control thermostat to the component bracket inside the trunk.
8. For first type thermostat, refer to Wiring Diagrams
when reconnecting thermostat wires.
9. Adjust the control thermostat as required.
NOTE: First type will only turn approximately one
turn. Clockwise to the stopper is approximately
180° F, maximum counterclockwise to stopper is
approximately 200° F.
Later types will be approximately 200° F when
turned maximum clockwise. Turning it counterclockwise until it clicks will turn off (open contacts).
41711.1 052009
SERVICE (cont.)
OPTIONAL ELECTRONIC THERMOSTAT (ERT):
The ERT is located inside the trunk on the upper left
side of the component bracket.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Gently remove the temperature sensor and grommet from the tank.
3. Check voltage across the blue wire from limit
thermostat and the white wire at the terminal
block. Connect the brewer to the power source.
The indication must be: 120Vac.
If voltage is not present as described, refer to the wiring
diagrams and check the brewer wiring harness
If voltage is present as described, proceed to #4.
4. Disconnect the brewer from the power source.
5. With the temperature sensor and grommet still out
of the tank, check voltage across the black wire
to the heater and the white wire at the terminal
block. Connect the brewer to the power source.
The indication must be: 120Vac.
If voltage is not present as described, replace ERT.
If voltage is present as described, the ERT is functioning properly.
First Type
Second Type
Removal and Replacement:
1. Disconnect the control thermostat wires.
2. Remove the temperature sensor by firmly pullingup on the metal sheath at the tank lid. This will
disengage the grommet from the tank lid.
3. Remove the one #8-32 screw securing the ERT to
the component bracket inside the trunk.
4. Slide the grommet to the top of the sheath.
5. Insert the temperature sensor through the hole
in the tank lid and press the grommet firmly and
evenly so that the groove in the grommet fits into
the tank lid.
6. Using the #8-32 screw, secure the ERT to the
component bracket inside the trunk.
7. For first type thermostat, refer to Wiring Diagrams
when reconnecting ERT wires.
8. Adjust the ERT as required.
Page 11
Third Type
ERT
FIG 11-1 THERMOSTAT TERMINALS
NOTE: The ERT has a range of 170° - 210°F. Use care
not to set it too high or boiling could occur.
41711.1 052009
SERVICE (cont.)
ON/OFF WARMER SWITCH
FIG. 12-1 ON/OFF WARMER SWITCHES
Location:
The ON/OFF switch(s) are located on the front of
the hood.
Test Procedure:
1. Disconnect the brewer from the power source.
2. Viewing the switch from the back remove the white
or red wire from the upper terminal and the black
wire from the center terminal.
3. Check the voltage across the white wire or red wire
and the black wire with a voltmeter. Connect the
brewer to the power source. The indication must
be:
a) 120 volts ac for two wire 120 volt models and
three wire 120/240 volt models.
b) 200 to 240 volts ac for two wire 200 or 240 volt
models.
4. Disconnect the brewer from the power source.
Removal and Replacement:
1. Remove the wires from the switch terminals.
2. Compress the clips inside the hood and gently
push the switch through the opening.
3. Push the new switch into the opening and spread
the clips to hold switch in the hood.
4. Refer to Fig.7 when reconnecting the wires.
(3) WHI to Neutral or RED to L2
(2)BLKtoL1
(1) To Warmer
WARMER SWITCH
(1) LOAD (WARMER)
(2) LINE (L1)
(3) NEUTRAL (L2)
FIG. 12-2 WARMER SWITCH TERMINALS
If voltage is present as described, reconnect the white
or red wire and proceed to #5.
If voltage is not present as described, refer to the Wiring
Diagrams and check the brewer wiring harness.
5. With the black wire removed, remove the wire from
the lower terminal.
6. Check for continuity across the center and lower
terminal with the switch in the "ON" position.
Continuity must not be present when the switch
is in the "OFF" position.
If continuity is present as described, reconnect the
black wire to the center terminal and the remaining
wire to the lower terminal.
If continuity is not present as described, replace the
switch.
Page 12
41711.1 052009
SERVICE (cont.)
START SWITCHES
CT SERIES
CRT/CRTF
Test Procedure:
1. Disconnect the brewer from the power supply.
2. Disconnect the blue wire and the white/red wire
from the switch terminals.
3. Check for continuity across the two terminals on
the switch when it is held in the "pressed-in" position. Continuity must not be present across these
terminals in the released position.
If continuity is present as described, reconnect the blue
wire and the white/red to the switch terminals.
If continuity is not present as described, replace the
switch.
Removal and Replacement:
1. Remove the blue wire and white/red from the start
switch.
2. Remove round retaining nut from the front of
the switch and remove switch and internal tooth
lockwasher from the inside of the hood.
3. Push new switch with internal tooth lockwasher
through the hole in the hood and secure with round
retaining nut.
4. Refer to Fig. 11 when reconnecting the wires.
FIG. 13-1 START SWITCH
Location: CRT/CRTF
On brewers w/out fresh light, the start switch is
located in the right front of the hood.
On brewers w/fresh light, the start switch is located
on the right side of the hood.
Location: CT/CWT/CWTF/TWINS
On most "CT" series brewers, the start switch is
located in the front of the hood.
On some "convertible" or "CS" brewers, the start
switch is located on either the right or left side of the
hood.
NOTE: Optional on the left and right side warmer
housings on 0/6 TWINS, connected in parallel to front
mounted start switches.
CRT/CRTF
WHI/RED to
Timer P3
BLU to Timer P1
CT/CWT/CWTF/TWINS
(3) WHI to Neutral or RED to L2
(2)BLKtoL1
START SWITCH
FIG. 13-2 START SWITCH TERMINALS
Page 13
41711.1 052009
SERVICE (cont.)
SOLENOID VALVES
EARLY MODELS LATE MODELS
FIG. 14-1 SOLENOID VALVE
Location:
The solenoid valve is located inside the trunk on
the lower center part of the component bracket.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the white and black wires from the
solenoid valve. With the "ON/OFF" switch in the
"ON" upper position press the start switch.
3. Check the voltage across the white and black wires
with a voltmeter. Connect the brewer to the power
source. The indication must be:
a) 120 volts ac for two wire 120 volt models and
three wire 120/240 volt models.
b) 200 to 240 volts ac for two wire 200 or 240 volt
models.
4. Disconnect the brewer from the power source,
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to Wiring
Diagrams and check brewer wiring harness.
6. Check the solenoid valve for coil action. Connect
the brewer to the power source. With "ON/OFF"
switch in the "ON' upper position press start switch
and listen carefully in the vicinity of the solenoid
valve for a" clicking" sound as the coil magnet
attracts.
7. Disconnect the brewer from the power source.
If the sound is heard as described and water will not
pass through the solenoid valve, there may be a blockage in the water line before the solenoid valve or, the
solenoid valve may require inspection for wear, and
removal of waterborne particles.
If the sound is not heard as described, replace the
solenoid valve.
Removal and Replacement:
1. Remove the white and black from the solenoid
valve.
2. Turn off the water supply to the brewer.
3. Disconnect the water lines to and from the solenoid
valve.
4. Remove the two #8-32 screws securing the solenoid mounting bracket to the component bracket.
Remove solenoid bracket and solenoid valve as an
assembly.
5. Remove the two #10-32 screws and lockwashers securing the solenoid valve to the solenoid
bracket.
6. Using two #10-32 screws and lockwashers install new solenoid valve on solenoid mounting
bracket.
7. Using two #8-32 screws install solenoid valve and
bracket to the component bracket.
8. Securely fasten the water lines to and from the
solenoid valve.
9. Refer to Fig. 9 when reconnecting the wires.
WHI from Timer
5. Check for resistance across the solenoid valve coil
terminals.
If resistance is present as described, reconnect the
white and black wire from the timer.
If resistance is not present as described, replace the
solenoid valve.
Page 14
BLKfromTimer
FIG. 14-2 SOLENOID VALVE TERMINALS
41711.1 052009
SERVICE (cont.)
SOLENOID VALVES
Disassembly:
1. Use of the basin wrench 01060.0000 is recom-
mended for disassembly of early style valves as
illustrated below.
2. Disconnect from power source and turn off the
water supply to the brewer.
3. Disconnect the water lines to and from the solenoid
valve.
4. Remove the two #8-32 screws securing the sole-
noid mounting bracket to the component bracket.
Remove solenoid bracket and solenoid valve as an
assembly.
5. Remove the two #10-32 screws and lock wash-
ers securing the solenoid valve to the solenoid
bracket.
6. Disassemble the valve according to the illustrations
that correspond to the particular valve you have.
7. On early style valves, leave the fittings installed
in the base to use as leverage. DO NOT CLAMP
THE BASE WITH LOCKING PLIERS AS THIS CAN
CAUSE DAMAGE!
8. Refer to Illustrated Parts Catalogs for replacement
solenoids and repair/rebuild kits.
120VAC - 334
120VAC - 247
240VAC - 757
FIG. 15-1 FIRST STYLE
Page 15
FIG. 15-2 SECOND STYLE
120VAC-1.18K
240VAC-3.76K
FIG. 15-2 THIRD STYLE
41711.1 052009
SERVICE (cont.)
FILL BASIN
FIG.16-1TANKHEATER
TANK HEATER
FIG.16-2TANKHEATER
Disassembly:
1. Use of the basin wrench 01060.0000 is recommended for removal of the fill basin.
2. Disconnect from power source and turn off the
water supply to the brewer.
3. Remove top cover.
4. Use the basin wrench (as shown above) turning
counterclockwise to remove inlet fitting.
5. Lift basin off of the tank inlet.
6. Use new inlet gasket when reinstalling.
Location:
The tank heater is located inside the tank and
secured to the tank lid.
Test Procedures:
1. Disconnect the brewer from the power supply.
2. Check the voltage across the black and white wires
on 120 volt models or the black and red wires for
120/240 volt models, 200 volt models and 240
volt models with a voltmeter. Connect the brewer
to the power source. The indication must be:
a) 120 volts ac for two wire 120 volt 20 amp
models .
b) 240 volts ac for three wire 120/240 volt mod-
els.
c) 200 to 240 volts ac for two wire 200 or 240 volt
models.
3. Disconnect the brewer from the power source.
If voltage is present as described, proceed to #4
If voltage is not present as described, refer to the Wiring Diagrams and check wiring harness.
Page 16
4. Disconnect the wires from the tank heater terminals.
5. Check resistance value across tank heater terminals
and compare to chart.
41711.1 052009
SERVICE (cont.)
HEATER RESISTANCE
1800W-120V 7.40 - 8.70
1850W-220V 24.40 -28.40
3500W-200V 10.70 -12.36
3500W-240V 15.36 -17.90
TERMINAL TO SHEATH - INFINITE (OPEN)
FIG.17-1TANKHEATERRESISTANCE
If resistance is present as described, reconnect the
wires, the tank heater is ok.
If resistance is not present as described, replace the
tank heater.
NOTE- If any resistance is read between sheath and
either terminal, remove and inspect heater for cracks
in the sheath.
TANK HEATER (Cont.)
11. Install tank lid with limit thermostat, sprayhead
tube, tank heater, coil assembly (brewers with
faucet) and control thermostat with bracket (early
brewers only) using eight #8-32 hex nut.
12. Reconnect the inlet and outlet water lines to the
faucet coil assembly.
13. Secure sprayhead tube to hood using a hex nut.
14. Install sprayhead.
15. Reconnect the wires to the limit thermostat, tank
heater and control thermostat. See limit thermostat
and control thermostat sections in this manual
when reconnecting wires.
16. Install fill basin, secure with tank inlet fitting and
gasket. Insert water supply line through grommet
in fill basin.
17. Refer to Fig.13 when reconnecting the tank heater
wires.
Removal and Replacement:
1. Disconnect the water supply tube from the fill
basin.
2. Remove the tank inlet fitting securing the fill basin
to the tank lid, remove fill basin and tank inlet
gasket. Set all three parts aside for reassembly.
3. On brewers with faucet, shut-off water supply
to the brewer and disconnect the inlet and outlet
water lines to the faucet coil assembly.
4. Disconnect the black wire on the limit thermostat
from the tank heater switch. On late model brewers also disconnect the blue wire from the limit
thermostat to the control thermostat.
5. Disconnect the black wire and the white or red
wire from the tank heater terminals.
6. Remove sprayhead and the hex nut securing the
sprayhead tube to the hood. Set aside for reassembly.
7. Remove the eight #8-32 nuts securing the tank lid
to the tank.
8. Remove the tank lid with limit thermostat, sprayhead tube, tank heater, coil assembly and control
thermostat w/bracket (early models only).
9 Remove the two hex nuts securing the tank heater
to the tank lid. Remove tank heater with gaskets
and discard.
10. Install new tank heater with gaskets on the tank
lid and secure with two hex nuts.
Page 17
WHI to Terminal Block
(White Insert on 230V
Two Wire Models)
RED to Terminal Block
(Red Insert on 120/240V
Three Wire Models or
200V and 240V Two
Wire Models
FIG.17-2TANKHEATERTERMINALS
BLK to Control Ther-
mostat (Brewers W/
Out Faucet)
ThermalCut-OfftoBLK
from Control Thermostat (Brewers W/
Faucet)
41711.1 052009
SERVICE (cont.)
TANK HEATER SWITCH
FIG18-1TANKHEATERSWITCH
Location:
The tank heater switch is located on the rear of
the brewer on the upper left side of the trunk.
Test Procedure:
1. Disconnect the brewer from the power source.
2. Disconnect the black wire from the limit thermostat.
3. With the tank heater switch in the "ON" position
and with a voltmeter, check the voltage between
the black wire removed from the limit thermostat
and the white wire or red wire on the tank heater.
Connect the brewer to the power source. The
indication must be:
a) 120 volts ac on two wire 120 volt models.
b) 240 volts ac on three wire 120/240 volt mod-
els.
c) 200 to 240 volts ac on 200 volt or 240 volt
models.
4. Disconnect the brewer from the power source.
If voltage is not present as described, proceed to
#5.
If voltage is present as described, the switch is working properly.
5. With the tank heater switch in the "ON" upper position, check for continuity between the black wire
removed from the limit thermostat and the black
insert on the terminal block. Continuity should
not be present in the "OFF" lower position.
If continuity is present as described, the tank heater
switch is operating properly.
If continuity is not present as described, replace the
tank heater switch.
Removal and Replacement:
1. Shut off and disconnect the incoming water supply
to the brewer.
2. On automatic brewers gently remove the fill tube
from back of fill basin.
3. Remove the tank inlet fitting securing fill basin the
tank lid. Remove fill basin and gasket. Set all three
parts aside for reassembly.
4. On brewers with faucets, disconnect the water
supply to coil assembly and remove the tube from
the tank to the faucet.
5. Remove sprayhead and hex nut securing sprayhead
tube to the hood. Set aside for reassembly.
6. Disconnect the wires on the limit thermostat and
the tank heater and the control thermostat (early
models).
7. Gently pull the thermostat sensor and grommet
from the tank lid.
8. Insert a tube to the bottom of the tank and syphon
ALL of the water out.
9. Remove the two #8-32 screws securing the tank
assembly to the hood.
10. Lift tank and components out as an assembly and
set aside for reassembly.
11. Disconnect the two black wires from the tank heater
switch.
12. Remove the plastic facenut, hex facenut and the
switch indicator/guard bracket that secures tank
heater switch to the rear of the brewer. Remove
switch and discard.
13. Insert new tank heater switch through the hole in
the upper left rear of the trunk and secure with
switch indicator/guard bracket, hex facenut and
plastic facenut.
14. Reconnect the two black wires to the tank heater
switch terminals.
Page 18
41711.1 052009
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