Cornelius QUEST ELITE 4000 Service Manual

QUEST ELITE 4000

Service Manual

Release Date: December 18, 2010

Publication Number: 620048956SER

Revision Date: January 6, 2015

Revision: G

Visit the Cornelius web site at www.cornelius.com

for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possi­ble contingency in the installation, operation or maintenance of this equipment. This manual assumes that the per­son(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic,
and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and
construction requirements are being met, in addition to the information contained in this manual.

This Product is warranted only as provided in Cornelius’ Commercial Warranty applicable to this Product and is sub­ject to all of the restrictions and limitations contained in the Commercial Warranty.

Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained per­sons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, oper­ating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.

Contact Information:

To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con­tact:

www.cornelius.com

800-238-3600

Trademarks and Copyrights:

This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.

This document contains the original instructions for the unit described.

CORNELIUS INC

101 Regency Drive

Glendale Heights, IL

Tel: + 1 800-238-3600

Printed in U.S.A.

TABLE OF CONTENTS

Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Different Types of Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unit Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Concentrate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Recommended Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Water Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Water Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ice Bank/Pull Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Plumbing Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Concentrate Handling and Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Loading Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Changing Concentrate Containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BRIXING Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Checking/Adjusting the BRIX Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Planned Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Flush System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Clean Splash Zones & Dispense Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Sanitize the Juice Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Sanitize Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Prepare Dispenser for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Semi Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Clean Water Inlet Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Clean Chassis Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Check and Top-Off Water Ice Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Replace Pump Tubing and Clean Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Removing Pump Platform(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Replacing the Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Assembly Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cornelius Standard Service Call Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Quest Elite 4000 Service Manual

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DANGER:

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CAUTION:

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SAFETY INSTRUCTIONS

READ AND FOLLOW ALL SAFETY INSTRUCTIONS

Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any

warning/caution labels on the unit (decals, labels or laminated cards).

• Read and understand ALL applicable OSHA (Occupational Safety and
Health Administration) safety regulations before operating this unit.

Recognition

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the unit, be alert
to the potential of personal injury or damage to the unit.

Different Types of Alerts

SAFETY TIPS

Indicates an immediate hazardous situation which if not avoided WILL result in
serious injury, death or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.

• Carefully read and follow all safety messages in this manual and safety
signs on the unit.

• Keep safety signs in good condition and replace missing or damaged items.

• Learn how to operate the unit and how to use the controls properly.

• Do not let anyone operate the unit without proper training. This appliance is
not intended for use by very young children or infirm persons without super­vision. Young children should be supervised to ensure that they do not play
with the appliance.

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CAUTION:

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CAUTION:

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• Keep your unit in proper working condition and do not allow unauthorized
modifications to the unit.

QUALIFIED SERVICE PERSONNEL

Only trained and certified electrical, plumbing and refrigeration technicians should
service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO

NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN
SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

SAFETY PRECAUTIONS

This unit has been specifically designed to provide protection against personal
injury. To ensure continued protection observe the following:

Disconnect power to the unit before servicing following all lock out/tag out
procedures established by the user. Verify all of the power is off to the unit before
any work is performed.

Failure to disconnect the power could result in serious injury, death or equipment
damage.

Always be sure to keep area around the unit clean and free of clutter. Failure to
keep this area clean may result in injury or equipment damage.

SHIPPING AND STORAGE

Before shipping, storing, or relocating the unit, the unit must be sanitized and all
sanitizing solution must be drained from the system. A freezing ambient
environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.

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MOUNTING IN OR ON A COUNTER

When installing the unit in or on a counter top, the counter must be able to support
a weight in excess of 189 lbs. (85.7 kg.) to insure adequate support for the unit.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH
OR EQUIPMENT DAMAGE.

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Quest Elite 4000 Service Manual

UNIT SPECIFICATIONS

Figure 1. Unit Dimensions

Nameplate Data

Concentrate Storage

Model QST ELITE 4000, 115 VAC, 5 amps, 1 phase 60 hertz, 6.34 – 6.41 oz. (180-

182) R-134a refrigerant. Test press: High side 400 psi (2757.9 kilopascals), (27.6

bar). Low side 88 psi (606.7 kilopascals), (6.1 bar).

Model Quest ELITE 4000, 230 VAC, 2 amps, 1 phase 50 hertz, 6.34 - 6.41 oz.
(180-182g) R-134a refrigerant. Test press: High side 400 psi (2757.9 kilopascals)
(27.6 bar). Low side 88 psi (606.7 kilopascals), (6.1 bar).

Model Quest ELITE 4000, 220 VAC, 2 amps, 1 phase 60 hertz, 6.34 - 6.41 oz.
(180-182g) R-134a refrigerant. Test press: High side 400 psi (2757.9 kilopascals)
(27.6 bar). Low side 88 psi (606.7 kilopascals), (6.1 bar).

Four 0.8 gallon (3.0 liter) disposable bottles.

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CAUTION:

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Recommended Clearance

12” (30.48 cm) on top and 4” (10.16 cm) required in back for air circulation and 4” at
the sides of the unit.

Electrical Connection

6 ft. long (1.83 m) power cord with 3-prong plug attached to dispenser. Export
models are shipped with a European plug.

ONLY trained and certified electrical technicians should replace the power cord or
the unit should be returned to an Authorized Service Center for power cord
replacement.” The replacement cord must meet all requirements of the original
equipment manufacturer.

Failure to comply could result in serious injury, death or damage to the
equipment.

Power Supply

15 amps at 120 volts dedicated power supply.

10 amps at 230 volts dedicated power supply.

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Quest Elite 4000 Service Manual

Water Connection

3/8 in. (0.95 cm) SAE male flare fitting on dispenser.

Water Supply Requirements

60 psi (413.7 kilopascals) (4.1 bar) maximum static pressure. 30 psi (206.8
kilopascals) (2.1 bar) minimum dynamic pressure; i.e., flowing pressure measured
at dispenser water inlet with 3 OZ (88.7 ml) per second water flow. Optimum
recommended pressure 50 psi (344.7 kilopascals) (3.5 bar) dynamic pressure.

Ice Bank/Pull Down

Weight 14-16 lbs. (6.35-7.25 kg.). Pull Down: 3.5-5.5 hours at 75°F (24°C)

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Water

Connection

This appliance is intended to be used in household and similar applications such as
the following:

• Staff kitchen areas in shops, offices and other working environments.

• Farm houses and by clients in hotels, motels and other residential type envi­ronments

• Bed and breakfast type environments

• Catering and similar non-retail applications

PLUMBING REQUIREMENTS

This dispenser must be connected to a COLD WATER system with operating
pressure between 20 and 100 psi (138 and 690 kPa). This water source must be
capable of producing a minimum flow rate of 3 fluid ounces (88.7 milliliters) per
second. A shut off valve should be installed in the line before the dispenser. Install a
regulator in the line when pressure is greater than 100 psi (690 kPa) to reduce it to
50 psi (345 kPa). The regulator is also necessary if the water source has pressure
flucuations. The main water inlet is a 3/8” (9.52 mm) MFL connection.

APPLICATIONS

This equipment must be installed to comply with the International Plumbing Code
of the International Code Council and the Food Code Manual of the Food and
Drug Administration (FDA). For models installed outside the U.S.A., you must
comply with the applicable Plumbing, Sanitation Code for your area.

Failure to comply could result in serious injury, death or damage to the
equipment.

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CONCENTRATE HANDLING AND LOADING

It is recommended that the concentrate be thawed in a refrigerated 35°F to 40°F
(1.6°C to 4.4°C) compartment for a minimum of 48 hours prior to loading it into the
Quest Juice Dispenser.

Concentrate must be completely thawed and within the temperature range of 35°F
to 40°F (1.6°C to 4.4°C) prior to loading. Failing to supply concentrate inside the
recommended temperature range, especially below 35°F (1.6°C), causes an out
of BRIX drink (refer to the BRIXing Procedure section for details).

LOADING CONCENTRATE

The Quest Juice Dispenser is designed to use either disposable juice concentrate
containers or the optional Cornelius generic refillable container (sold separately).

Figure 2. Refillable Concentrate Container

1. Thoroughly shake concentrate container prior to use.

2. Place concentrate containers on the dispensing platform shelf inside the
refrigerated cabinet.

3. Engage the concentrate container by pressing it downward into the bottle
adapter opening on the dispensing platform.

NOTE: Be sure to lubricate the o-ring seal on the container nozzle.

This ensures a good seal and allows the pumps to draw
concentrate from the containers more easily. Failure to create
a good seal at this connection may result in weak drinks and/or
seepage of concentrate.

4. Prime each pump by closing the cabinet door and press each dispense
button until concentrate flows from the dispense nozzles.

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Quest Elite 4000 Service Manual

Dispense/Flush

Levers

CHANGING CONCENTRATE CONTAINERS

1. Open the cabinet door and move the valve handle from the

Flush

position, see Figure 3.

Figure 3. Dispense/Flush Lever Location

2. Close the door. Depress and hold the dispense button (Figure 4) until clear
water flows from the dispense nozzle.

Dispense

to

Figure 4. Dispense Buttons

3. Open the cabinet door and return the handle to the

4. Depress and hold the dispense button for 1-2 seconds. This relieves water
pressure from the concentrate pump system.

5. Load the concentrate container (see Figure 5 )

Figure 5. Loading a Concentrate Container

Dispense

position.

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Quest Elite 4000 Service Manual

BRIXING PROCEDURE

NOTE: If concentrate is not properly thawed, it will adversely affect

the amount of concentrate dispensed. Thawed product should
be between 35°F/1.6°C to 40°F/4.4°C.

SUPPLIES

• 1 - Small 12 oz. cup (354.8 ml)

• 1 - Large 21 oz. cup (621.1 ml)

• 1 - Straw

• Paper Towels

• 1 - Thermometer

• 1 - Refractometer

• 1 - Flat Bladed Screwdriver

NOTE: The refractometer shown is P/N 511004000, and is available

through your local Cornelius Distributor.

CHECKING/ADJUSTING THE BRIX SETTING

The following instructions are for use with a refractometer.

1. Dispense approximately 8 oz. (237 ml) of drink and discard. Now draw a
second 8 oz. (237 ml) drink.

2. Check drink temperature with a accurate thermometer (target is 35 to 45°F,
or 1.6 to 7.2°C). Discard this drink after checking temperature.

NOTE: If drink temperature is not within the target range, refer to the

basic troubleshooting section.

3. Dispense a 12 oz (354.8 ml) drink sample into a clean, dry cup. Thoroughly
stir the sample using a straw.

4. Using the straw, transfer a small sample of the finished drink to the refractometer
lens (refer to operating instructions supplied with your refractometer). Check the
BRIX reading against the BRIX chart shown in Table 1.

NOTE: The BRIX chart shown in Table 1 is generic and intended for

reference use only. Contact your frozen concentrate supplier
for specific BRX readings.

Flavor Ratio BRIX

Orange Juice 4+1 11.8

Grapefruit Juice 5+1 10.6

Cranberry Cocktail 4+1 13.5

Apple Juice 5+1 12.0

Grape 5+1 13.0

Table 1.

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Quest Elite 4000 Service Manual

Dispense/Flush Lever

Water Flow

Controls

Table 1.

Flavor Ratio BRIX

Lemonade 5+1 10.5

Tropical Punch 5+1 11.8

Sweetened Ice Tea 7+1 6.0

Pineapple Juice 4+1 12.8

Prune Juice 2+1 16.0

5. To change the BRIX setting, simply readjust the water flow rate. Located on
each of the valve assemblies inside the refrigerated compartment are the
adjusting screws for the water flow rate (one per valve).

If the BRIX reading is too high or low, rotate the appropriate water flow control
according to Figure 6. Repeat steps 1-5 until the proper BRIX setting is achieved.

Figure 6. BRIX Adjustment

IMPORTANT: When making changes to the water flow control, do not

rotate more than 1/4 turn per adjustment. Additionally,
prior to taking your next BRIX reading, momentarily
press the corresponding dispense button several times
prior to drawing a sample. This clears any remnants
from the dispense nozzle AND helps move the flow
control to its new setting.

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Quest Elite 4000 Service Manual

Dispense/Flush

Levers

Mixing

Chambers

PLANNED MAINTENANCE SCHEDULE

DAILY

Flush System

1. Move all of the Dispense/Flush levers (located on the platform assembly in
the refrigerated cabinet) to the
drip tray below each dispense nozzle (Figure 7).

Flush

position. Place an empty cup on the

Figure 7. Platform Assembly with Dispense/Flush Levers

2. Close the door and depress each dispense button for 2-3 seconds or until
clear water flows from each dispense nozzle.

Figure 8. Dispense Buttons

3. Return the Dispense/Flush levers to the

4. Press each Dispense button for 1 to 2 seconds to release the water
pressure present in the concentrate pump system.

Dispense

position.

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Clean Splash Zones & Dispense Nozzles

1. On a daily basis, clean the external cabinet and splash areas using a clean
damp cloth. Remove and wash the cup rest and drip tray using mild dish
soap.

2. Remove the dispense nozzles and static mixers by rotating each 90° and
pulling down. Remove the mixing chambers by pulling straight forward.
Wash using mild dish soap.

IMPORTANT: DO NOT wash nozzles, static mixers, or mixing

chambers in a dish washer. This will distort the plastic
and damage the o-rings. Additionally, do not soak them
in sanitizing solution longer than 2 minutes.

Flush once a day for better quality drinks.

Do not leave the unit in FLUSH mode. Leaving the unit in flush mode may result in
damage.

WEEKLY

Check concentrate to water brix ratio (refer to the Checking/Adjusting the BRIX
Setting Section, Page 10).

Sanitize the Juice Dispenser

1. Rinse the unit with hot water.

2. Prepare two 2 oz. (59 ml) packets of Stera-Sheen Green Label sanitizing
solution (or similar brand) by dissolving each packet in 1 gallon (3.8L) of
potable water to insure 200 ppm of available chlorine.

IMPORTANT: Use potable water at 80°F-100°F (26.7°C-37.8°C). Water

3. Remove the juice concentrate containers and place them in separate
refrigerated compartment.

4. Flush the system by following the instructions in Flush System on page 12.

5. Fill a clean empty concentrate container with one quart of extremely hot tap
water, approximately 140°F (60°C) and place the container into the unit.
Dispense all of the hot water into a large container. Repeat for all the
remaining dispense valves.

6. Remove the mixing chambers, nozzles, and static mixers. Rinse in hot water
to remove excess pulp and concentrate.

above this range breaks down the chlorine count and
minimizes sanitation.

7. Place the mixing chambers, nozzles, and static mixers in a separate
container of sanitizing solution and agitate vigorously. Allow the parts to
soak for two minutes, then rinse thoroughly with fresh tap water.

8. Reinstall the static mixer, nozzles, and mixing chambers

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Quest Elite 4000 Service Manual

Dispense/Flush

Levers

Mixing

Chambers

Sanitize Pump System

1. Fill a clean concentrate container with 2 quarts (1.9L) of fresh sanitizing
solution.

2. Place Dispense/Flush levers (located on the platform assembly in the
refrigerated cabinet) to the

Dispense

Figure 9. Dispense/Flush Levers

position.and close the door.

3. Press and hold the dispense button for 90 seconds then release. Allow

4. After 5 minutes, dispense the remaining sanitizing solution.

Prepare Dispenser for Use

1. Replace sanitizing solution container with a concentrate container and close

2. Press and hold the dispense button until juice appears from the nozzle. Next

sanitizing solution to remain in the lines for 5 minutes.

Figure 10. Dispense Buttons

the door.

dispense and discard at least two 8 oz. (236.6ML) cups of juice in order to
prime the system and prepare it for operation.

Publication Number: 620048956SER - 14 - © 2010-2014, Cornelius Inc.

Quest Elite 4000 Service Manual

CAUTION:

!

SEMI ANNUALLY

The following procedures require removal of the dispenser side panel(s).
Disconnect the power cord (See Figure 11.) from the receptacle prior to
proceeding.

Clean Water Inlet Strainer

1. Remove the right side panel from the dispenser.

2. Turn off the water supply to the dispenser.

3. Remove the access port from the “Y” shaped water inlet solenoid located on

4. Clean and reinstall the stainless steel water strainer.

Figure 11. Pull AC Plug from Wall Outlet

the right side of the dispenser. (See Figure 12)

Figure 12. Right Side of Dispenser

Clean Chassis Interior

1. Clean the condenser cooling fins.

2. Clean the air inlet grilles located on the rear and top panels of the dispenser.

3. Clean the interior base.

4. Wipe the fan blades clean.

5. Reinstall the right side panel, turn on the water supply, and plug the
dispenser into the power receptacle.

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Quest Elite 4000 Service Manual

Drip Tray

Lower Splash Panel

Cup Rest

Check and Top-Off Water Ice Bath

1. Remove the drip tray and lower splash panel.

Figure 13. Drip Tray and Cup Rest

If the Ice bath level is below the
Filling the Ice Bath procedure in the Installation manual (P/N 620048956INS).

ANNUALLY

Replace Pump Tubing and Clean Cabinet

A replacement pump tubing kit, part # 45098, is available. The kit consists of one
pre-cut length of pump tubing, two white plastic hose clamps, and instructions.

Removing Pump
Platform(s)

1. Remove the concentrate containers from the dispenser and place them in a
refrigerator.

2. Remove the cabinet shelf that the concentrate containers sit on.

3. Flush the system prior to removing the pump platform (refer to the Daily
Section, Page 12). Remove the dispense nozzles and static mixers.

4. Unplug the water line quick disconnect by pressing the gray button (See
Figure 14).

Full

indicator, top it off with water. Refer to the

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Quest Elite 4000 Service Manual

Front & Rear

Pump Halves

Pump Motor

Water Manifold

Water Solenoid

Locking Latch

Bottle Adapter

Juice Inlet

Water Inlet

Quick Connector

Pump Body Screws

BRIX Adjustment Screw

Concentrate

Delivery Tubes

Figure 14. Interior Details

5. Slide the locking latch forward. Lift the platform slightly and pull forward to
gain access to the electrical connector (see Figure 14).

6. Unplug the electrical connector by squeezing the locking tabs on either side and
pulling out the connector. Lift and remove the pump platform (see Figure 14).

Replacing the Tubing When the pump platform has been removed, replace the tubing by performing the

following procedure.

1. Remove the two white plastic hose clamps from the pump tube connections
(See Figure 14) and remove the concentrate delivery tubes from the hose ends.

2. Loosen and remove the four screws from the pump body (See Figure 15).

© 2010-2015, Cornelius Inc. - 17 - Publication Number: 620048956SER

Quest Elite 4000 Service Manual

1

2

3

4

Pump Tubing

Roller

Assembly

3. Remove ONLY the rear pump body half to reveal the pump tubing and rollers
(See Figure 16).

4. Remove the old pump tubing from the pump body. If the roller assembly comes
out with the tubing, place it back into the pump housing. Make sure to align the
roller assembly shaft keyway to the motor shaft so that the two interlock.

5. Firmly press the new tubing into the pump body around the roller assembly,
making sure to keep the protruding ends even with each other.

6. Once the tubing is in place, hold the tubing with one hand, capture the lower
part of the tubing with the outer housing, then proceed to capture the shaft
of the roller assembly and push the rear pump housing into place. Make
sure to capture the tubing within the body and not pinch it between the
halves. Do not use any tool other than your finger tips to manipulate the
tubing into the housing or you may damage the tubing.

Figure 15. Pump Body Screws

Figure 16. Pump Assembly

7. While holding the pump halves together with your hand, reinsert the four
thumb screws (See Figure 15) and tighten using a cr i ss-cross pattern as
shown. The thumb screws should be tightened about 1/4 turn beyond snug.

8. Insert the two concentrate delivery tubes into the pump tubing ends and
secure them using the new hose clamps supplied in the kit. Be sure to use
pliers to squeeze and tighten the hose clamps.

Publication Number: 620048956SER - 18 - © 2010-2014, Cornelius Inc.

Quest Elite 4000 Service Manual

Cleaning the Cabinet The cabinet bottom surface and walls should be inspected and cleaned annually

according to the following steps:

1. Remove natural rubber nozzle bushing gasket (see Figure 17) and inspect it
and silicone RTV. If cracked, clean off RTV, and re-apply using kit P/N
729011013 per instructions provided with kit.

2. Re-apply nozzle bushing gasket so that the edges lie flat on the floor of the
cabinet.

Figure 17. Nozzle bushing gaskets - proper installation

3. Clean cabinet floor and walls of any spilled juice and let dry. Use a mild
soap/detergent and plain water.

4. Reinstall the pump platform in the reverse order given above.

© 2010-2015, Cornelius Inc. - 19 - Publication Number: 620048956SER

Quest Elite 4000 Service Manual

TROUBLESHOOTING GUIDE

The following tables contain trouble-shooting information intended to aid an
experienced service person in diagnosing operational problems that may occur. For
further assistance, contact the Cornelius Customer Services department at 800­283-3600 between the hours of 7:30A.M. and 5:00P.M. Central Standard Time. You
must have the model and serial number (Located on the right side of the dispenser)
when calling.

Symptom Probable Cause Remedy

Unit totally inopera­tive

No Cooling A. Line voltage not within nameplate

A. No power to dispenser due to tripped

circuit breaker.




B. Loose or broken power supply connec-

tion inside dispenser.

specification causing compressor
overload to trip.

B. No water in water ice bath or water

level extremely low, exposing ice bank
sensing probe.

C. Defective Ice Bank Control or sensing

probe.

D. Cabinet fan inoperative resulting in

warm concentrate (water continues to
cool).

E. Compressor short cycles on overload.



F. Compressor starts but hums & trips

overload.

G. Defective compressor overload or start

capacitor.

H. Compressor starts but does not switch

off of start winding.

I. Refrigerant leak.

Table 2

A. Reset circuit breaker. Confirm that

breaker is correct size & no other
equipment is operating on the same
circuit. Also confirm that supply voltage
is +/-10% of nameplate specification.

B. Repair connection.

A. Contact an electrician.



B. Fill ice bath to proper water level.



C. Replace.

D. Replace.

E. Excessively high discharge pressure

due to restricted condenser or inopera­tive condenser fan motor.

F. Seized or shorted compressor,

replace.

G. Test & replace.

H. Relay or compressor is defective. Test

& replace faulty item.

I. Repair leak, evacuate & recharge sys-

tem.

Publication Number: 620048956SER - 20 - © 2010-2014, Cornelius Inc.

Quest Elite 4000 Service Manual

Table 2

Symptom Probable Cause Remedy

No water dispensed,
concentrate only

No water & no con­centrate, refrigeration
is working.

A. No water in dispenser.

B. Water supply line inside refrigerated

cabinet disconnected from pump plat­form.

C. Water solenoid located on pump plat-

form clogged or defective.

D. Main water solenoid/strainer located at

the rear of dispenser is clogged, bind­ing or defective.

E. Water supply pressure is greater than

80 psi (5.5 bar) forcing BRIX flow con­trol closed.

F. Freeze-up of water coil in ice bath.

A. Black service switch located on the

rear of the cabinet door in OFF posi­tion.

B. White door switch open



A. Restore water.

B. Reconnect

C. Disassemble & clean solenoid.

Replace if necessary.

D. Remove & clean strainer. Confirm

24VDC is present at solenoid during
dispense. Confirm solenoid coil is not
open. Disassemble & clean solenoid.

E. Add external regulator & lower pres-

sure to 50 psi (3.5 bar).

F. Unplug dispenser & allow 2-4 hrs. to

thaw. Check operation of agitator motor
& ice bank control.
Refrigeration system may be low on
charge resulting in a deformed ice
bank & freeze-up of water coil in ice
bath.

A. Turn on switch.

B. Door switch must be closed in order to

dispense. Check switch operation &
replace if necessary.

No concentrate dis­pensed, water only.

C. 6.25 amp fuse inside front electrical

box blown.

D. No output from transformer.

E. Defective voltage regulator board

(VRB) located inside front electrical
box.



F. Defective dispense push button or por-

tion control board.

A. Concentrate container not fully

engaged into receptacle on pump
platform.

B. Dispense/Flush lever in FLUSH posi-

tion

C. Concentrate too cold, not properly

thawed.

D. Defective pump motor.

C. Replace with 6.25, 250VAC slow blow

fuse & test.

D. Confirm transformer output of 24VAC

+/-2. Replace transformer if necessary.

E. Measure across the VDC output of the

board. There should be 28VDC pres­ent when the dispense button is
pressed. Replace VRB if necessary.

F. Test & replace if necessary.

A. Refer to Concentrate Loading section

of this manual.

B. Move lever to DISPENSE position

C. Concentrate should be 35 to 40

to 4.5

°C) prior to loading.

D. Replace pump motor.

°F (1.7

© 2010-2015, Cornelius Inc. - 21 - Publication Number: 620048956SER

Quest Elite 4000 Service Manual

Symptom Probable Cause Remedy

Table 2

Warm drinks A. Ambient air around dispenser is too

warm.

B. Excessive demand on dispenser.

C. Dirty condenser coil.

D. Inoperative condenser fan.

E. Defective Ice Bank Control.

F. Loss of refrigerant charge due to leak

in system.

Water continuously
drips from nozzle in
OFF mode.

Concentrate warm,
water cold.

BRIX problem A. Water supply pressure too low, less

Pump inoperative A. Pump motor defective.

Machine continues to
dispense after dis­pense button is
released or dis­penses without oper­ator input.

A. Main water solenoid at base of unit or

water solenoid on pump platform not
shutting off completely.

A. Cabinet fan inoperable.

B. Agitator motor/pump inoperable or

restricted.

C. Loss of refrigerant charge due to leak

in system.

than 20 psi (1.4 bar) flowing water
pressure.

B. Water flow control binding or spring is

defective.

C. Improperly thawed concentrate. BRIX

changes as concentrate temperature
changes (concentrate becomes thinner
as temperature rises)



B. No power to transformer or no 24VAC

output from transformer.

C. Defective voltage regulator board

(VRB) located inside front electrical
box.



D. Defective dispense control board

(Push button or portion control).

A. Push button or portion control pad

stuck in ON position.



B. Relay on voltage regulator board

(VRB) stuck on.

A. Relocate dispenser.

B. Add water pre-cooler or second dis-

penser

C. Clean condenser coil.

D. Replace condenser fan motor.

E. Test & replace if necessary.

F. Repair leak and recharge system.

A. Clean solenoid(s), replace parts as

necessary (refer to Planned Mainte­nance section).

A. Check/replace fan.

B. Check/replace agitator motor.

C. Repair leak & recharge system.

A. Correct water supply problem to

ensure a constant 50 psi (3.5 bar)
flowing to dispenser.

B. Clean and/or replace parts as neces-

sary.

C. Concentrate should be 35 to 40

to 4.5

°C) prior to loading.

A. 28VDC should be present at pump

motor during dispense. If voltage is
present & motor does not start,
replace motor.

B. Confirm transformer has line voltage

present on primary side. If no 24VAC
output from secondary, replace trans­former.

C. Confirm board produces 28VDC pres-

ent when dispense button is pressed
(refer to Electrical Box Wiring Diagram
for VDC output location). Replace VRB
if necessary.

D. Test & replace if necessary.

A. Disconnect wire harness from rear of por-

tion control and close the door. If unit
does not dispense on its own, dispense
control board is bad (stuck on).

B. Disconnect 4-wire harness from lower

right comer of VRB. If unit continues to
dispense on its own VRB is defective
(relay stuck on).

°F (1.7

Publication Number: 620048956SER - 22 - © 2010-2014, Cornelius Inc.

Quest Elite 4000 Service Manual

ASSEMBLY DRAWINGS

Figure 18. System Wiring Diagram Quest Elite 4 FL

© 2010-2015, Cornelius Inc. - 23 - Publication Number: 620048956SER

Quest Elite 4000 Service Manual

Figure 19. Main Electrical Box Wiring Diagram Quest Elite 4 FL

Publication Number: 620048956SER - 24 - © 2010-2014, Cornelius Inc.

Quest Elite 4000 Service Manual

CORNELIUS STANDARD SERVICE CALL GUIDE

The parts warranty referenced in the Certificate of Warranty in this manual applies
to the replacement of the defective part. Cornelius Inc. will not accept parts
warranty claims for water leaks applicable to the installation, clogged drains,
adjustments of any kind including regulators, pumps, thermostats, ratio, or brix
settings, stratification issues, preventative maintenance, sanitizing, etc. Cornelius
Inc. will consider only actual service time on the equipment. Charges for mileage,
holiday pay, night charges, and overtime will not be considered. All parts claim that
are fare, reasonable, and within the terms of the warranty and allotted repair times
will be paid in U.S. Dollars.

Any questions regarding the warranty procedures can be directed to our Customer
Services group at 800-238-3600.

ITEM # PAGE # DESCRIPTION MAX HOURS

*Recovery and pump down require at least two hours depending on contamination
and is not included in the allotted repair time shown above.

© 2010-2015, Cornelius Inc. - 25 - Publication Number: 620048956SER

Quest Elite 4000 Service Manual

Publication Number: 620048956SER - 26 - © 2010-2014, Cornelius Inc.

Cornelius Inc.

www.cornelius.com