FMD-4
FMD-5
OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
To obtain the Illustrated Parts Catalog, visit the Bunn-O-Matic website, at www.bunn.com. This is absolutely FREE,
and the quickest way to obtain the catalog. Contact Bunn-O-Matic Corporation at 1-800-286-6070 to obtain a paper
copy of the required Illustrated Parts Catalog mailed via U.S. Postal Service.
35135.0000D
10/07 ©2003 Bunn-O-Matic Corporation
www.bunnomatic.com
BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY
Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:
1) All equipment other than as specified below: 2 years parts and 1 year labor.
2) Electronic circuit and/or control boards: parts and labor for 3 years.
3) Compressors on refrigeration equipment: 5 years parts and 1 year labor.
4) Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis:
parts and labor for 3 years or 30,000 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, damage or casualty. 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.
BrewWISE, BUNN Gourmet Ice, BUNN Pour-O-Matic, BUNN, Bunn-OMatic, Bunn-O-Matic, BUNNserve, BUNN Espress,
DBC, Dr. Brew, Dual, EasyClear, Easy Pour, FlavorGard, Gourmet Ice, Gourmet Juice, High Intensity, IMIX, Infusion Series, Legendary for Quality, The Mark of Quality in Beverage Equipment Worldwide, My Café, PowerLogic, Safety-Fresh,
Single, Smart Funnel, Smart Hopper, Soft Heat, SplashGard, System III, ThermoFresh, AXIOM, Beverage Profit Calculator,
Beverage Bar Creator, BrewLOGIC, BrewMETER, BrewWIZARD, BUNNlink, BUNNSERVE, BUNNsource, Coffee At Its Best,
Coffee Spot, Cool Froth, Digital Brewer Control, Earth-1st, Earth 1st, Earth First, EasyGard, Intellisteam, Nothing Brews
Like a BUNN, Pouring Profits, Pulse Wave, Quality Beverage Equipment Worldwide, Scale-Pro, Signature Series, Silver
Series, Smart Heat, SmartWAVE, Tea At Its Best, The Horizontal Red Line, Titan, Ultra, are either trademarks or registered
trademarks of Bunn-O-Matic Corporation.
2
35135 100407
INTRODUCTION
This equipment dispenses hot beverages or soups on demand from powdered product. It is for indoor use only on a sturdy counter
or shelf.
USER NOTICES
Carefully read and follow all notices on the equipment and in this manual. They were written for your protection. All notices are to be
kept in good condition. Replace any unreadable or damaged labels.
! WARNING
Fill water tank before turning - on thermostat or connecting appliance
to power source.
Use only on a properly protected
circuit capable of the rated load.
Electrically ground the chassis.
Follow national/local electrical codes.
Do not use near combustibles.
This equipment must be installed to comply with the
Basic Plumbing Code of the Building Officials and
Code Administrators International, Inc. (BOCA) and
the Food Service Sanitation Manual of the Food and
Drug Administration (FDA). For models installed
outside the U.S.A., comply with the applicable
Plumbing /SanitationCode.
00656.0000
FAILURE TO COMPLY RISKS EQUIPMENT
DAMAGE, FIRE, OR SHOCK HAZARD
READ THE ENTIRE OPERATING MANUAL
BEFORE BUYING OR USING THIS PRODUCT
THIS APPLIANCE IS HEATED WHENEVER
CONNECTED TO A POWER SOURCE
00831.0000F 3/98 ©1998 BUNN-O-MATIC CORPORATION
00831.0000
28368.0000
37881.0000
FMD-4 28964.0004
FMD-5 28964.0003
FMD-4 28328.0008
FMD-5 28328.0009
3
35135 100407
INITIAL SET-UP
1.
2.
Locate the drip tray assembly inside the dispenser door.
Remove the drip tray and the drip tray cover and set them aside.
CE REQUIREMENTS
•
•
•
•
•
•
This appliance must be installed in locations where it can be overseen by trained personnel.
For proper operation, this appliance must be installed where the temperature is between 0°C to 35°C. Appliance shall not be tilted more than 10° for safe operation.
An electrician must provide electrical service as specified in conformance with all local and national codes
This appliance must not be cleaned by water jet
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given instructions concerning use of this appliance by a person responsible for its safety.
ELECTRICAL REQUIREMENTS
CAUTION - The dispenser must be disconnected from the power source until specified in Initial Set-Up.
The 120 volt version of this dispenser has an attached cordset and requires 2-wire, grounded service rated 120 volts ac,
15 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-15R.
The 120/208 and the 120/240 versions of this dispenser has an attached cordset. The mating connector must be a NEMA
14-20R.
The 230 volt version of this dispenser has an attached cordset without plug
Refer to the dispenser’s dataplate and local/national electrical codes for exact voltage requirement.
Electrical Hook-Up
CAUTION – Improper electrical installation will damage electronic components.
1. An electrician must provide electrical service as specified.
2. Using a voltmeter, check the voltage and color coding of each conductor at the electrical source.
3. Open the front door of the dispenser and place the heater switch in the “OFF” (upper position).
4. Connect the dispenser to the power source.
5. If plumbing is to be hooked-up later be sure the dispenser is disconnected from the power source. If plumbing has
been hooked-up, the dispenser is ready for Initial Fill & Heat.
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 4.5 fluid ounces (133.1 ml) 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 water inlet fitting is 3⁄8" flare.
NOTE - At least 18 inches of an FDA approved flexible beverage tubing, such as reinforced braided polyethylene or silicone,
before the dispenser will facilitate movement to clean the countertop. Bunn-O-Matic does not recommend the use of a
saddle valve to install the dispenser. The size and shape of the hole made in the supply line by this type of device may
restrict water flow.
This equipment must be installed to comply with the Basic Plumbing Code of the Building Officials
and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the
Food and Drug Administration (FDA). For models installed outside the U.S.A., you must comply to
the applicable Plumbing/Sanitation Code for your area.
PLUMBING HOOK-UP
1.
2.
Flush the water line and securely attach it to the flare fitting on the bottom of the dispenser.
Turn-on the water supply.
4
35135 100407
INITIAL fill & heat
CAUTION - The dispenser must be disconnected from the power source throughout the initial set-up, except
when specified in the instructions.
1. Turn-on the water supply and connect the dispenser to the power source.
2. Water will automatically flow into the tank to the proper level and then shut-off. This will take less than five
minutes.
3. When the tank is full of water, open the front door and place the heater switch in the “ON” (lower) position.
A tank full of cold water will take approximately eighty minutes for the water to heat on 120 volt versions or
forty minutes for 120/208 volt versions, 120/240 volt versions, and 230 volt versions.
During this waiting period, complete these dispenser set-up steps:
a. Place the drip tray in front of the dispenser. Set the drip tray cover in place.
b. Place a set of keyholes in the cup locator plate over the screws beneath the hopper access door and push
down gently.
c. Fill the hoppers with the dry product to be dispensed.
LIQUID LEVEL CONTROL
The system automatically maintains the hot water tank’s level by energizing the refill solenoid when the water
level drops below the liquid level probe. If the system has not successfully refilled in 15 minutes, a refill error
occurs. When a refill error occurs, the refill solenoid is de-energized and the left rinse L.E.D. will flash about
once every 5 seconds. Once the cause of the refill error has been investigated (see the troubleshooting guide in
the Operating and Service Manual) and cured, the system can be reset by placing the Rinse/Run switch in the
programming (center) position, momentarily.
RINSE TIMERS
The dispenser is shipped from the factory with the rinse timers disabled. To enable the rinse timers, remove
power from the dispenser, remove the lower access panel, and remove the jumper from J1 of the control boards.
Replace the lower access panel, and return power to the dispenser. When enabled, the rinse timers automatically keep track of the time since the dispenser was last run through a rinse sequence. If the dispenser detects
that a rinse sequence has not been run for 8 hours, the appropriate rinse L.E.D. will flash continually. If, after
an additional 4 hours (12 hours total), a rinse sequence has still not been run, the appropriate rinse L.E.D. will
light continuously, and the appropriate hopper drives will be disabled until a rinse sequence has been run.
RUNNING A RINSE SEQUENCE
1. Place the rinse/run switch in the rinse position.
2. Sequentially, or simultaneously, at each of the positions dispense for at least 10 seconds.
3. After the rinse L.E.D. has extinguished, the rinse timer is reset.
4. Return the rinse/run switch to the run position.
DISPENSER USE
1. Simply place a cup on the drip tray beneath the dispensing tip.
2. Press the button and dispense the beverage.
3. Release the button when the cup is approximately 2/3 full and allow the whipper chamber to drain.
NOTE - The whipper chamber must drain at the end of each dispense.
5
35135 100407
COLD BEVERAGE SET-UP (OPTIONAL)
Cold beverages may be dispensed from the left dispense position. Simply place the HOT/COLD switch near the
left whipper chamber in the “COLD” (upper) position.
CLEANING
Refer to the decal on the rear of the dispenser door for cleaning recommendations and procedures.
The use of a damp cloth rinsed in any mild, non-abrasive, liquid detergent is recommended for cleaning all surfaces on Bunn-O-Matic equipment.
ADJUSTMENTS
The beverage solenoid is preset to dispense approximately 9/10 ounce per second. This amount can be adjusted:
1. Disconnect the dispenser from the power source.
2. Remove the small left side access panel to adjust dispense valves 1, 2 & 3, and remove the small right side
access panel to adjust dispense valves 4 & 5.
3. Rotate the control at the base of the solenoid clockwise to decrease or counterclockwise to increase the
amount of water.
4. Replace appropriate access panels when finished.
HOPPER MOTOR SPEED PROGRAMING
The hopper dispense rate is preset at the factory. With 22 tooth gear and auger wire the preset dispense rate is
approximately 3 to 5 grams per second. With 30 tooth gear and auger wire the preset dispense rate is approximately 5 to 7 grams per second. The hopper dispense rate can be adjusted to a range of dispense rates from
approximately 1.5 to 12 grams per second, as follows:
1. Place the rinse/run switch in the center (program) position.
2. Place the increase/decrease switch in the desired (increase or decrease) position.
3. Press and release the dispense switch for the chamber you wish to adjust. Each time the dispense switch
is pressed, the rinse L.E.D. will flash, and the motor speed for that hopper will be increased/decreased by
approximately 2-1/2%.
4. Return the rinse/run switch to the run position after hopper motor speed adjustments are complete.
6
35135 011906
DRAINING THE HOT WATER TANK
CAUTION - The dispenser must be disconnected from the power source throughout these steps.
1. Disconnect the dispenser from the power source.
2. Place the tank heater switch in the “OFF” position.
3. Shut-off and disconnect the incoming water supply.
4. Remove the front, lower access panel.
5. Pull out drain tube to empty into a sink or a container with a minimum of 6-1/2 gallon capacity.
6. Make sure drain clamp is closed. Then, remove drain plug.
7. Direct tube into sink or container and open drain clamp. Continue draining tank until ALL of the water is
out.
WARNING: Be very careful with the draining water because it can be very hot.
8. Close drain clamp, insert drain plug, place drain tube back into machine, and replace lower access panel.
NOTE - The dispenser must be refilled using the INITIAL FILL & HEAT steps before reconnecting to the power
source.
7
35135 012103
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, and repair of electrical equipment should be performed only by qualified service personnel.
• All electronic components have high voltage ac and low voltage dc potential on their terminals. Shorting of
terminals or the application of external voltages may result in board failure.
• Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If
an intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a
terminal or crimp.
• Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are
energized for more than ten minutes without a supply of water.
• The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened. This will
help to avoid twists and kinks in the tubing.
• Make certain that all plumbing connections are sealed and electrical connections tight and isolated.
• This unit is heated at all times. Keep away from combustibles.
WARNING
–
•
•
•
•
Exercise extreme caution when servicing electrical equipment.
Unplug the dispenser when servicing, except when electrical tests are specified.
Follow recommended service procedures
Replace all protective shields or safety notices
PROBLEM
PROBABLE CAUSE
REMEDY
Product will not dispense
1. No water
Water lines and valves to the dispenser
must be open.
2. No power or incorrect voltage to the
dispenser
(A1) Check for 120 volts across the
black and white wires on two wire 120
volt dispensers.
(A2) Check for 120 volts across the
red and white wires and the black and
white wires, 208 volts across the red
and black wires on three wire 120/208
volt dispensers and 240 volts across
the red and black wires on three wire
120/240 volt dispensers.
(A3) Check for 230 volts across the
black and white wires on two wire 230
volt dispensers.
(B) Check circuit breakers or fuses.
3. Dispense Switch
Refer to Service - Dispense Switch for
testing procedure. See page 23
4. Dispense Solenoid Valve
Refer to Service - Dispense Solenoid
Valve for testing procedures. See page
35
8
35135 100407
TROUBLESHOOTING (cont.)
PROBLEM
Product will not dispense (cont.)
PROBABLE CAUSE
5. Solenoid Valve (Inlet)
REMEDY
Refer to Service - Solenoid Valve
(Inlet) for testing procedures. See
page 37
6. Control Board #1 and Probe
Refer to Service - Control Board
and Probe for testing procedures.
See page 20
7. Auger Drive
Refer to Service - Auger Drive. See
page 13 & 15
8. Water Strainer
Remove the strainer and check for
obstructions. Clear or replace.
9. Lime build-up
Inspect the tank assembly for exCAUTION - Tank and tank compo- cessive lime deposits. Delime as
nents should be delimed regularly required.
depending on local water conditions. Excessive mineral build-up on
stainless steel surfaces can initiate
corrosive reactions resulting in serious leaks.
10. Transformer
Water is not hot
Refer to Service - Transformer for
testing procedures. See page 41
1. Limit Thermostat
Refer to Service - Limit Thermostat
CAUTION - Do not eliminate or by- for testing procedures. See page
pass limit thermostat. Use only BOM 31
replacement part #29329.1000
2. Control Thermostat
Refer to Service - Control Thermostat for testing procedures. See
page 19
3. Tank Heater
Refer to Service - Tank Heater for
testing procedures. See page 38
9
35135 012103
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Water is not hot (Cont.)
4. Tank Heater Switch
Refer to Service - Tank Heater
Switch for testing procedures. See
page 39
5. Relay (120V versions only)
Refer to Service - Relay for testing
procedures. See page 40
6. Control Board #2 (120V versions
only)
Refer to Service - Control Board
#2 for testing procedures. See page
22
Spitting or excessive steaming
1. Lime build-up
CAUTION - Tank and tank compo- Inspect the tank assembly for exnents should be delimed regularly cessive lime deposits. Delime as
depending on local water condi- required.
tions. Excessive mineral build-up on
stainless steel surfaces can initiate
corrosive reactions resulting in serious leaks.
2. Control Thermostat
Dripping from dispense tip
Water flows into tank continuously
Refer to Service - Control Thermostat for testing procedures. See
page 19
1. Lime build-up
Inspect the tank assembly for exCAUTION - Tank and tank compo- cessive lime deposits. Delime as
nents should be delimed regularly required.
depending on local water conditions. Excessive mineral build-up on
stainless steel surfaces can initiate
corrosive reactions resulting in serious leaks.
2. Dispense Solenoid Valve
Remove the dispense solenoid valve
and clear any obstructions. Rebuild
or replace the valve if necessary.
See page 35
1. Control Board #1 and Probe
Refer to Service - Control Board
and Probe for testing procedures.
See page 20
2. Solenoid Valve (Inlet)
Refer to Service - Solenoid Valve
(Inlet) for testing procedures. See
page 37
10
35135 012103
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Product overflows container
1. Dispense Switch
Refer to Service - Dispense Switch for
testing procedures. See page 23
2. Dispense Solenoid Valve
Remove the solenoid valve and clear
any obstructions. Rebuild or replace
the valve if necessary. See page 35
1. Water Temperature
Place an empty container beneath
the dispense tip. Initiate a dispense
cycle and check the water temperature
immediately below the dispense tip
with a thermometer. Reading should
be 180°F to 200°F (see thermostat
temperature settings decal in USER
NOTICES on page 3.)
2. Whipper Motor
Refer to Service - Whipper Motor for
testing procedure. See page 27
3. Frother
Refer to Service - Frother Components. See page 26
4. Dispense Solenoid Valve
Refer to Service - Dispense Solenoid
Valve for test procedures. See page
35
5. Auger Drive
Refer to Service - Auger Drive Components. See page 13 & 15
6. Auger Spring
Refer to Service - Auger Drive Components. See page 13 & 15
7. Auger Motor
Refer to Service - Auger Drive Components. See page 13 & 15
8. Rinse/Run Switch
Refer to Service - Rinse/Run Switch
for test procedures. See page 32
9. Rinse Timer
Refer to Operation - Rinse Timer.
See Page 5
10. Relay (120V versions only)
Refer to Service - Relay for testing
procedures. See page 40
11. Control Board #2 (120V versions
only)
Refer to Service - Control Board #2
for testing procedures. See page 22
Weak product
11
35135 012103
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Dispenser is making unusual
noises
1. Plumbing Lines
Plumbing lines should not be resting
on the counter top.
2. Water Supply
(A) The dispenser must be connected
to a cold water line
(B) Water pressure to the dispenser
must not exceed 100 psi (690 kPa).
Install a regulator if necessary to
lower the working pressure to approximately 50 psi (345 kPa).
3. Tank Heater
Remove and clean lime off the tank
heater. See page 38
Excess dust
1. Fan
Refer to Service - Fan for testing
procedures. See page 25
Display not lit
1. Lamp
Refer to Service - Lamp, see page
29 for lamp replacement.
2. Lamp Holder
Refer to Service - Lamp Holder for
testing procedures. See page 29
3. Starter - Lamp
Refer to Service - Starter for testing
procedures. See page 30
4. Ballast
Refer to Service - Ballast for testing
procedures. See page 18
12
35135 012103
SERVICE
AUGER DRIVE COMPONENTS FMD-4
This section provides procedures for testing and
replacing various major components used in this
dispenser 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 dispenser should be unplugged
when servicing, except when electrical tests are required and the test procedure specifically states to
plug-in the dispenser.
COMPONENT ACCESS
WARNING - Disconnect the dispenser from the power
source before the removal of any panel or the replacement of any component.
All components are accessible by opening the
door, removal of the door panels, dispenser top covers,
hopper(s), hopper support plate, splash guard, splash
panel w/drip tray, lower front access panel and rear
access cover.
Refer to the contents listing for component location.
Contents
P2635
FIG. 1 AUGER DRIVE COMPONENTS
Location
The auger components are located inside the bottom
part of the hopper except for the auger drive bracket,
spacer and retaining clip, which are located on the
outside rear of the hopper base. The auger motor is
located on the lower right rear of the motor mounting
panel. Refer to Fig. 2 for disassembly and assembly.
Auger Drive Components (FMD-4)......................... 13
Auger Drive Components (FMD-5)......................... 15
Ballast.................................................................... 18
Control Thermostat................................................ 19
Control Board......................................................... 20
Dispense Switch.................................................... 23
Fan......................................................................... 25
Frother................................................................... 26
Increase/Decrease Switch...................................... 28
Lamp Holder.......................................................... 29
Lamp .................................................................... 29
Lamp Starter and Socket........................................ 30
Limit Thermostat.................................................... 31
Rinse/Run Switch.................................................. 32
Hot/Cold Switch-Optional....................................... 33
Solenoid (Cold Water - Optional)........................... 34
Solenoid (Dispense)............................................... 35
Solenoid (Inlet)...................................................... 37
Tank Heater............................................................ 38
Tank Heater Switch................................................ 39
Tank Heater Relay.................................................. 40
Transformer........................................................... 41
Whipper Motor....................................................... 27
Wiring Diagram.................................................42-45
Test Procedures - Auger Motor
1. Disconnect the dispenser from the power
source.
2. Disconnect the white/red wire and the white wire
from the hopper speed control board.
3. Check the voltage across the white/red wire and
the white wire with a voltmeter. With the rinse/
run switch in the run (lower) position, connect
the dispenser to the power supply. The indication
must be:
a) 120 volts ac for two wire 120 volt models.
b)120 volts ac for three wire120/208 volt or
120/240 volt models.
c) 230 volts ac for two wire 230 volt models.
4. Disconnect the dispenser from the power supply.
If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
13
35135 100407
SERVICE
AUGER DRIVE COMPONENTS - FMD-4 (cont.)
1
5. Check the voltage across the positive (red wire)
terminal and the negative (black wire) terminal on
the auger motor with a voltmeter. With the rinse/
run switch in the run (lower) position press and
hold the dispense switch. Connect the dispenser
to the power supply. After a .6 second delay the
indication must be 4.0 to 24.5 volts dc.
2
3
4
5
12
13
14
6
If voltage is present as described, the auger motor
drive is operating properly. If auger does not turn,
replace the auger motor.
If voltage is not present as described, replace the auger
hopper drive board.
7
8
9
10
Removal, Cleaning and Replacement
Hopper & Auger
1. Open the dispenser door and raise the top front
cover.
2. Lift the hopper assy (15) over the pins on hopper
support plate (11) and slide hopper assembly out
the front of the dispenser.
3. Remove hopper lid (1) and empty product.
4. Pull off the ejector elbow (14).
5. Remove retainer clip (10) and washer (9) from the
bottom of the hopper base (8).
6. Remove whipper shaft (3), wiper blade (4) and
wiper drive gear (5) from the hopper base (8).
7. Remove auger wire (13) by pulling it out the front
of the hopper base (8).
8. Remove auger drive bracket (6) by unscrewing
left hand threads from auger drive shaft (12).
9. Slide spacer (7) and auger drive shaft bracket (6)
off of the auger drive shaft (12).
10.Remove auger drive shaft (12) from hopper base
(8).
11.Wash components in a mild solution of dish detergent using a bristle brush when needed.
12.Rinse and dry each item thoroughly.
13.Check for damaged or broken components, replace
any if necessary and reassemble hopper assembly.
14.Install hopper assy (15) in the dispenser by
sliding hopper assy on the hopper support plate
(11) until the slot in the rear of the hopper base
(8) seats against the pins in the hopper support
plate (11).
15
16 17 18 19 11
P2633
FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY
1. Hopper Lid
2. Hopper
3. Wiper Shaft
4. Wiper Blade
5. Wiper Drive Gear
6. Auger Drive Bracket
7. Spacer
8. Hopper Base
9. Washer
10. Retainer Clip
14
11. Hopper Support Plate
12. Auger Drive Shaft
13. Auger Wire
14. Ejector Elbow
15. Hopper Assembly
16. Auger Motor Bracket
17. Auger Motor
18. Dust Seal
19. Auger Motor Mounting
panel
35135 012103
SERVICE (cont.)
AUGER DRIVE COMPONENTS - FMD-4 & FMD-5
AUGER DRIVE COMPONENTS - FMD-4 (cont.)
Auger Drive Motor (Refer to Fig. 2)
1. Remove hopper assy (15), and set aside for reassembly.
2. Remove the four #8-32 screws securing the hopper
support plate (11), remove plate and set aside for
reassembly.
3. Remove the four #8-32 screws, located inside the
dispenser housing on the lower right front of the
auger motor mounting panel (19), securing auger
motor mounting bracket (16) and auger motor
(17) to the rear of the auger motor mounting panel
(19).
4. Disconnect the wires from the hopper drive
board.
5. Remove auger motor mounting bracket (16), auger
motor (17) and dust seal (18) as an assembly.
6. Remove dust seal (18) from auger motor (17).
7. Disconnect the wires from the auger motor (17).
8. Remove the four #8-32 screws securing the auger
motor (17) to the auger motor mounting bracket
(16).
9. Remove auger motor (17) and discard.
10.Using four #8-32 screws install new auger motor
(17) on mounting bracket (16).
11.Install dust seal (18) on auger motor shaft and
align notch in seal with motor casting.
12.Reconnect the wires to the terminals on the hopper
drive board.
13.Refer to Fig. 3 when reconnecting wires.
14.Using four #8-32 locking screws install auger motor, dust seal and mounting bracket to the rear of
the auger motor mounting panel (19).
15. Install hopper assy (15).
FIG. 4 AUGER DRIVE COMPONENTS
Location
The auger components are located inside the
bottom part of the hopper except for the auger drive
bracket, washer and locknut, which are located on the
outside bottom rear of the hopper. The auger motors
are located on the rear of the auger motor mounting
panel. Refer to Fig. 5 for disassembly and assembly.
Test Procedures - Auger motors
1. Disconnect the dispenser from the power
source.
2. Disconnect the wires from the motor to be tested.
3. Check the voltage across the positive (white/orange) wire for the right motor, or the positive
(white/red) wire for the left motor and the negative
(green) wire with a voltmeter. With the rinse/run
switch in the run (lower) position press and hold the
appropriate dispense switch. Connect the dispenser
to the power supply. After a .6 second delay the
indication must be 4.0 to 24.5 volts dc.
STATIONS 1 - 4
RED to BRN/WHI from
Control Board #1 J3-3
RED to WHI/RED from
Control Board #1 J3-2
RED to WHI/ORN from
Control Board #1 J3-1
RED to WHI/YEL from
Control Board #2 J3-3
BLK to GRN from
Control Board J3-4
FIG. 3 AUGER MOTOR TERMINALS
P2635
P1639
15
35135 012103
SERVICE (cont.)
AUGER DRIVE COMPONENTS - FMD-4 & FMD-5
(cont.)
1
2
4. Disconnect the dispenser from the power supply.
4
3
8
If voltage is present as described and the auger does
not turn, replace the auger motor.
If voltage is not present as described, refer to the
wiring diagrams and check the dispenser wiring harness.
5
7
9
10
6
Removal, Cleaning and Replacement
Hopper & Auger
1. Open the dispenser door and raise the top front
cover.
2. Lift the front edge of hopper assy (20) over the
tab on hopper support plate (19) and slide hopper
assembly out the front of the dispenser.
3. Remove hopper lid (1) and empty product.
4. Pull off the ejector elbow (13).
5. Remove agitator disc assy (2) by pulling agitator
support rod (4) towards agitator disc assy and
lifting agitator disc assy from hopper (10).
6. Remove auger (12) by pulling it out the front of
the hopper (10).
7. Remove auger drive shaft (5) by removing the
retaining clip (6) from auger drive shaft.
8. Slide washer (8) and auger drive shaft bracket
(7) off of the auger drive shaft (5).
9. Slide auger drive shaft (5) from auger drive shaft
bushing (3) and remove from hopper (10).
10. Remove locknut (9) from auger drive shaft bushing (3) and remove auger drive shaft bushing
from hopper (10).
11. Wash components in a mild solution of dish
detergent using a bristle brush when needed.
12. Rinse and dry each item thoroughly.
13. Check for damaged or broken components,
replace any if necessary and reassemble hopper
assy.
14.Install hopper assy (20) in the dispenser by sliding
hopper assy in the guides on the hopper support
plate (19) until the slot in the bottom rear the
hopper seats against the pin (18) in the hopper
support plate.
11
14 15 16 12 13
P2634
FIG. 5 AUGER DRIVE & HOPPER DISASSEMBLY
1. Hopper Lid
2. Mixing Blade
3. Agitator Disk
4. Auger Drive Shaft Bushing
5. Auger Drive Shaft
6. Locknut
7. Auger Drive Bracket
8. Hopper
16
9. Auger Wire
10. Ejector Elbow
11. Hopper Assy
12. Auger Motor Mounting Panel
13. Hopper Support Plate
14. Auger Motor Bracket
15. Auger Motor
16. Dust Seal
35135 012103
SERVICE (cont.)
AUGER DRIVE COMPONENTS - FMD-4 & FMD-5
(cont.)
STATIONS 1 - 5
RED to BRN/WHI from
Control Board #1 J3-3
RED to WHI/RED from
Control Board #1 J3-2
RED to WHI/ORN from
Control Board #1 J3-1
RED to WHI/YEL from
Control Board #2 J3-3
RED to WHI/BLU from
Control Board #2 J3-2
Auger Drive Motor (Refer to Fig. 5)
1. Remove all hopper assemblies (20) and set aside
for reassembly.
2. Remove the four #8-32 screws securing the hopper
support plate (19), remove plate and set aside for
reassembly.
3. Remove the four #8-32 locking screws, located
inside the dispenser housing on the front of the
auger motor mounting panel (14), securing auger
motor mounting bracket (15) and auger motor
(16) to the rear of the auger motor mounting panel
(14).
4. Disconnect the wires from the auger motor (16)
to be removed.
5. Remove auger motor mounting bracket (15), auger
motor (16) and dust seal (17) as an assembly.
6. Remove dust seal (17) from auger motor (16).
7. Remove the four #8-32 screws securing the auger
motor to the auger motor mounting bracket.
8. Remove auger motor and discard.
9. Using four #8-32 screws install new auger motor
(16) on mounting bracket (15).
10.Install dust seal (17) on auger motor shaft.
11.Using four #8-32 locking screws install auger motor, dust seal and mounting bracket to the rear of
the auger motor mounting panel (14)
12.Reconnect the wires to the terminals on the auger
motor.
13.Install hopper support plate (19) and all hopper
assemblies (20).
14.Refer to Fig. 6 when reconnecting wires.
BLK to GRN from
Control Board J3-4
P1639
FIG. 6 AUGER MOTOR TERMINALS
17
35135 012103
SERVICE (cont.)
Removal and Replacement
1. Loosen the three #8-32 screws securing the component bracket to the dispenser housing base.
2. Pull component bracket out the front of the dispenser far enough so the leads on each ballast can
be disconnected from the main wiring harness and
the door interconnect harness.
3. Remove the two #8-32 screws securing each ballast to the rear of the component bracket.
4. Remove and discard the ballast.
5. Install new ballast on the rear of the component
bracket and secure each with two #8-32 screws.
6. Refer to Fig. 8 and reconnect the wires.
7. Place the component bracket into position and
tighten the two #8-32 screws securing the component bracket to the dispenser housing base.
BALLASTS - FMD-4 & FMD-5
BLK to BLK
from Main
Wiring Harness
P2635
BLK to RED from
Main Harness
FIG. 7 BALLASTS
Location
The front door lamp ballast is located behind the
front access panel on the left front side of the component bracket.
FIG. 8 BALLAST TERMINALS
P1447
Test Procedure
1. Disconnect the dispenser from the power
source.
2. Disconnect the two black lead on the ballast from
the main harness.
3. Check for continuity between the two black leads
on the ballast.
If continuity is present as described the ballast is
operating properly.
If continuity is not present as described, replace the
ballast.
18
35135 012103
SERVICE (cont.)
Removal and Replacement.
1. 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.
2. Loosen the two #6-32 screws securing the thermostat to the front tank mounting bracket.
3. Disconnect the wires from the thermostat.
4. Remove thermostat and remove the screws and
spacers from the thermostat.
5. Discard thermostat.
6. Install two spacers and two #6-32 screws on the
new thermostat.
7. Position the thermostat on the botttom side of the
front tank mounting bracket and tighten the two
#6-32 screws.
8. Slide the grommet to the line 4.5” above the bulb
on the new capillary tube.
9. 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.
10.Carefully bend the capillary tube so that the tube
and bulb inside the tank are in the vertical position
and away from any electrical connections.
11.Refer to Fig. 10 and reconnect the wires.
NOTE - The capillary tube must be clear of any electrical
termination and not kinked.
CONTROL THERMOSTAT - FMD-4 & FMD-5
P2635
FIG. 9 CONTROL THERMOSTAT
Location
The control thermostat is located at the upper left
rear of the dispenser housing.
Test Procedure
1. Disconnect the dispenser from the power source.
2. Disconnect the black wire of the control thermostat
from the black lead from the limit thermostat.
3. Remove bulb from the tank.
4. Check the voltage across black wire on the control
thermostat and the white or red wire on the tank
heater with the tank heater switch in the “ON” lower
position with a voltmeter. Connect the dispenser to
the power source. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 208 volts ac for three wire 120/208 volt models.
c) 240 volts ac for three wire 120/240 volt models.
d) 230 volts ac for two wire 230 volt models.
5. Disconnect the dispenser from the power source.
BLK from Limit
Thermostat
BLK from Tank
Heater Switch
If voltage is present as described the control thermostat
is operating properly. Reinstall bulb into the tank.
If voltage is not present as described, replace the
thermostat.
FIG. 10 THERMOSTAT TERMINALS
19
P1668
35135 100407
SERVICE (cont.)
CONTROL BOARD
6. Disconnect the four pin connector from J4 of control
board #1.
7. Check the voltage across pins 1 & 4 of the four pin
connector on the wiring harness with a voltmeter.
Connect the dispenser to the power source. The
indication must be 120 volts ac for two wire 120
volt models, three wire 120/208 volt models, three
wire 120/240 volt models, or 230 volts ac for two
wire 230 volt models.
8. Disconnect the dispenser from the power source.
If voltage is present as described, proceed to step 9.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
9. Reconnect the four pin connector of the wiring
harness to J4 of control board #1.
10. Disconnect the ten pin connector from J2 of control
board #1.
11. Carefully connect a piece of insulated jumper wire
to pin 10 (top right) of J2 on the control board.
Keep the other end of this wire away from any metal
surfaces of the dispenser.
12. Check the voltage across the terminals of the
inlet solenoid valve with a voltmeter. Connect the
dispenser to the power source. The indication
must again be 120 volts ac for two wire 120 volt
models, three wire 120/208 volt models, three wire
120/240 volt models, or 230 volts ac for two wire
230 volt models after a delay of approximately 10
seconds.
13.Touch the free end of the jumper wire to the dispenser housing. The indication must be 0.
14. Move the jumper wire away from the housing. The
indication must again be 120 volts ac for two wire
120 volt models, three wire 120/208 volt models,
three wire 120/240 volt models, or 230 volts ac
for two wire 230 volt models after a delay of approximately 5 seconds.
15. Disconnect the dispenser from the power source
and remove the jumper wire.
#2
#1
FIG. 11 CONTROL BOARD
P2635
Location:
The Control Boards are located behind the lower front
access cover mounted on the component bracket.
Test Procedure:
Liquid Level Control Circuitry(Control Board #1):
1. Disconnect the dispenser from the power source.
2. Disconnect the six pin connector from J3 of the
control board.
3. Check the voltage across pins 5 & 6 of the six pin
connector on the wiring harness with a voltmeter.
Connect the dispenser to the power source. The
indication must be 24 volts ac.
4. Disconnect the dispenser from the power source.
If voltage is present as described, proceed to step 5.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
If voltage is present as described, proceed to step
16.
If the voltage is not present as described, replace
control board #1.
5. Reconnect the six pin connector of the wiring harness to J3 of the control board.
20
35135 100407
SERVICE (cont.)
CONTROL BOARD (CONT.)
Hopper Motor Control Circuitry (Stations 1-3, Control
Board #1 & Stations 4-5, Control Board #2):
1. Disconnect the dispenser from the power source.
2. Disconnect the six pin connector from J3 of the
appropriate control board.
3. Check the voltage across pins 5 & 6 of the six pin
connector on the wiring harness with a voltmeter.
Connect the dispenser to the power source. The
indication must be 24 volts ac.
4. Disconnect the dispenser from the power source.
16. Reconnect the ten pin connector of the wiring
harness to J2 of control board #1.
17. Gently pull the liquid level probe out of the tank lid
and inspect for corrosion. Replace it if necessary.
18. Place the probe so that neither end is in contact
with any metal surface of the dispenser.
19. Check the voltage across the terminals of the
inlet solenoid valve with a voltmeter. Connect the
dispenser to the power source. The indication
must again be 120 volts ac for two wire 120 volt
models, three wire 120/208 volt models, three wire
120/240 volt models, or 230 volts ac for two wire
230 volt models after a delay of approximately 10
seconds.
20.Move the probe’s flat end to the dispenser housing.
The indication must be 0.
21. Move the probe’s flat end away from the housing.
The indication must again be 120 volts ac for two
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models, or 230
volts ac for two wire 230 volt models after a delay
of approximately 5 seconds.
22.Disconnect the dispenser from the power source.
If voltage is present as described, proceed to step 5.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
5. Reconnect the six pin connector of the wiring harness to J3 of the control board.
6. Check that the rinse/run switch is in the run position.
7. Check the voltage across the red (+) terminal and
the black (-) terminal of the auger motor with a voltmeter. Connect the dispenser to the power source.
Press and hold the appropriate dispense switch.
After a delay of about .6 seconds, the indication
must be between +4.0 and +24.5 volts dc.
If the voltage is present as described, re-install the
probe. The liquid level control circuitry is operating
properly.
If the voltage is not present as described, check the pink
probe wire and green tank wire for continuity.
If the voltage is present as described, the hopper motor
control circuitry is operating properly.
If the voltage is not present as described, replace the
control circuit board.
21
35135 100407
Tank Heater Relay Control Circuitry (Control Board #2)
(120V dispensers only):
1. Disconnect the dispenser from the power
source.
2. Disconnect the six pin connector from J3 of control
board #2.
3. Check the voltage across pins 5 & 6 of the six pin
connector on the wiring harness with a voltmeter.
Connect the dispenser to the power source. the
indication must be 24 volts ac.
4. disconnect the dispenser from the power
source.
If voltage is absent as described, proceed to step
11.
If voltage is present, replace the control circuit board
#2.
11.Place containers below any three dispenser
nozzles.
12.Simultaneously initiate dispenses at each of the
selected dispense stations while monitoring the
voltage across the coil terminals of the tank heater
relay. The indication must be 120V ac.
If voltage is present as described, the control board
#2 is functioning correctly.
If voltage is not present as described, replace the
control circuit board #2.
If voltage is present as described, proceed to step 5.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
5. Reconnect the six-pin connector of the wiring
harness to J3 of control board #2.
6. Disconnect the four-pin connector from J4 of
control board #2.
7. Check the voltage across pins 1 & 4 of the four-pin
connector on the wiring harness with a voltmeter.
The indication must be 120 volts ac.
8. Disconnect the dispenser from the power
source.
Removal and Replacement:
1. Disconnect the three plugs on the main wiring harness from the connectors on the control board.
2. Remove the four #6-32 keps nuts securing the
control board to the component bracket.
3. Remove control board and discard.
4. Install new control board on the component bracket
using four #6-32 keps nuts.
5. Reconnect the three plugs on the main harness to
the connectors on the control board.
NOTE: J4 is not connected on Control Board #2 on
120/208 - 240V dispensers.
If voltage is present as described, proceed to step 9.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
CONTROL BOARD #1 J1 J2
J1 J2
9. Reconnect the four-pin connector of the wiring
harness to J4 of control board #2.
10.Check the voltage across the coil terminals of the
tank heater relay with a voltmeter. Connect the
dispenser to the power source. The indication
must be 0 volts ac.
J1
J2
J4
J3
J1
J2
J4
J4
J3
J3
CONTROL BOARD #2
J4
J3
P2637
FIG. 12 CONTROL BOARD CONNECTORS
22
35135 111103
SERVICE (cont.)
DISPENSE SWITCH(S) - FMD-4 & FMD-5
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Open the dispenser door and remove the bottom
door cover.
3. Disconnect the wires from the door interconnect wiring harness to the dispense switch to be
tested.
4. Check for voltage across the black and red/white
wires for the dispense switch to be teseted from
the door interconnect wiring harness. Connect
the dispenser to the power supply. The indication
must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
c) 230 volts ac for two wire 230 volt models.
5. Disconnect the dispenser from the power
source.
FMD-4
If voltage is present as described, proceed to #6.
If voltage is not present as described, refer to the
wiring diagram and check the dispenser wiring harness.
6. With a voltmeter, check the voltage across the
remaining two wires of the dispense switch being
tested from the door interconnect wiring harness.
Connect the dispenser to the power source. The
indication must be +5 volts dc.
If voltage is present as described, proceed to #7.
If voltage is not present as described, refer to the wiring
diagram and check the dispenser wiring harness.
FMD-5
FIG.13 DISPENSE SWITCHES
P2636
Location:
The dispense switches are located on the lower
outside of the dispenser door.
23
35135 100407
SERVICE (cont.)
DISPENSE SWITCHES (cont.)
BLK
RED/WHI
7. Check for continuity across the terminals (top
right to top left; bottom right to bottom left) of
the dispense switch with the switch in the “ON”
position. Continuity must not present when the
switch is in the “OFF” released position.
STATIONS
BLK/WHI -1- WHI/BLK
RED -2- RED/BLK
ORN -3- ORN/BLK
GRN/WHI -4- GRN/BLK
BLU -5- BLU/BLK
If continuity is present as described, reconnect the
connector to the door interconnect wiring harness,
the switch is operating properly.
If continuity is not present as described, replace the
switch.
P1449
Removal and Replacement
1. Open the dispenser door.
2. Remove the six #8-32 screws securing the bottom door cover and remove cover.
3. Disconnect the wires on the dispense switch from
the door interconnect wiring harness.
4. Compress the clips inside the door on the dispense switch and gently push the switch through
the opening
5. Push the new switch into the opening and spread
the clips to hold the switch in the door.
6. Reconnect the wires to the dispense switch from
the door interconnect wiring harness.
7. Reinstall the door bottom cover using six #8-32
screws.
8. Refer to Fig. 14 when reconnecting wires.
FIG. 14 DISPENSE SWITCH TERMINALS
24
35135 012103
SERVICE (cont.)
FAN
Removal and Replacement:
1. Disconnect the vacuum hose from the fan.
2. Remove the two #8-32 locking screws securing
the fan to the dispenser housing base plate.
3. Disconnect the wires from the fan terminals and
discard the fan
4. Refer to Fig. 16 and connect the wires to the new
fan.
5. Install new fan through the rear access hole and
secure to the dispenser housing base plate using
two #8-32 locking screws.
6. Reconnect the vacuum hose to the fan.
BLK from Main Harness
FIG. 15 FAN
P2635
Location:
The fan is located inside the dispenser housing on
the center rear of the dispenser base plate.
WHI from Main Harness
P1507
FIG. 16 FAN TERMINALS
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Disconnect the black and white wires from the fan
terminals.
3. Check the voltage across the black and white wires
on the main harness with a voltmeter. Connect the
dispenser to the power source. The indication must
be:
a) 120 volts ac for two wire 120 volts models.
b) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
c) 230 volts ac for two wire 230 volt models.
If voltage is present as described, replace the fan
If voltage is not present as described, refer to wiring
diagram and check the dispenser wiring harness.
25
35135 100407
SERVICE (cont.)
4.
FROTHER AND WHIPPER MOTOR - FMD-4 (shown)
& FMD-5
Disconnect the dispenser from the power
source.
If voltage is present as described, replace the motor.
If voltage is not present as described, refer to the
wiring diagrams and check the dispenser wiring harness.
10
7
1
2
4
P2635
11 12
FIG. 17 FROTHER AND WHIPPER MOTOR
13
9
8
3
6 5
P2628
FIG. 18 MIXING/WHIPPER CHAMBER
COMPONENTS
Location:
The frothers are located behind the dispenser
door, mounted on the front panel inside the whipper
chamber.
The whipper motors are located on the back side
of the whipper motor mounting panel.
1. 2. 3. 4. 5. 6.
7.
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Disconnect the red and white wires (FMD-1 & FMD2 left motor) or orange and white wires (FMD-2
right motor) of the main harness from the black
leads of the motor.
3. Press and hold the dispense switch and check the
voltage across the disconnected harness wires with
a voltmeter. Connect the dispenser to the power
source. The reading must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
c) 230 volts ac for two wire 230 volt models.
Steam Collector
Mixing Chamber
Dispense Tip
Whipper Chamber
O-Ring
Frother
Receptacle w/Seal
8. 9. 10.
11.
12.
13.
Nut
Slinger
Motor Assy.
Fan
Vacuum Hose
Baffle
Removal, Cleaning & Replacement (Refer to Fig.
18):
1. Open the dispenser door and raise the top front
cover.
2. Lift the front edge of the each hopper assembly
over the tab on the hopper support panel and
slide each hopper assembly out the front of the
dispenser. Set aside for reassembly.
3. Remove the four #8-32 screws securing the hopper support panel to auger motor mounting panel
and the whipper motor mounting panel. Set aside
for reassembly.
26
35135 100407
SERVICE (cont.)
22.Push frother (6) onto the motor shaft, making sure
the flat in the frother (6) lines up with the flat on
the motor shaft.
23.Install whipper chamber (4) on the whipper chamber receptacle (7) by twisting counterclockwise
until the tabs on the whipper chamber (4) lock
with the tabs on the whipper chamber receptacle
(7). Be sure dispense port is pointing down.
24.Install dispense tip (3) into the bottom of the whipper chamber (4).
25.Using two #4-40 screws secure the fan baffle to
the whipper motor mounting panel.
26.Install vacuum hose (12) on fan baffle (13).
27. Install hopper support panel using four #8-32
screws.
28.Slip the mixing chamber (2) onto the mixing
chamber water inlet tube far enough so the mixing
chamber (2) will seat inside the whipper chamber
(4).
29.Install the steam collector (1) onto the mixing
chamber (2) by pushing down and toward the
dispenser while twisting until the flange on the
steam collector lines-up with the slot in the front
panel.
30.Install hopper assembly in the dispenser by sliding hopper assembly on the hopper support panel
until the slot in the bottom rear of the hopper seats
against the shoulder screw in the hopper support
panel.
FROTHER AND WHIPPER MOTOR - FMD-4
(shown) & FMD-5 (cont.)
4. Disconnect vacuum hose (12) from fan baffle
(13).
5. Remove the steam collector (1) by pulling it forward
and at the same time twisting it clockwise.
6. Pull the mixing chamber (2) out of the whipper
chamber (4).
7. Remove the two #4-40 x .25” screws securing the
fan baffle (13) to the whipper motor mounting panel
and remove fan baffle. Set aside for reassembly.
8. Remove dispense tip (3) and twist the whipper
chamber (4) clockwise and pull it off the whipper
chamber receptacle (7).
9. Pull the frother (6) off the motor shaft. Notice the
flat side on the shaft and the matching flat inside
the frother. It is important that these two flats are
lined up when reassembling.
10.Slip the O-ring (5) off the whipper chamber receptacle (7).
11. Slide the receptacle w/seal off of the motor
shaft.
12.Slide the slinger (9) off of the motor shaft.
13.Remove the two nuts (8) securing whipper chamber
receptacle (7) and whipper motor (10) to the front
panel.
NOTE: To remove the receptacle only rotate clockwise
until the receptacle clears the nuts (8) and slide
off of the motor shaft.
14.Disconnect the black leads on the motor (10) from
the main wiring harness.
15.Remove motor and discard.
16.Install new motor (10) on rear of front panel and
secure with two nuts (8) and connect black leads
on the motor to the main wiring harness. Refer to
Fig. 19 when reconnecting wires
17.Slide slinger (9) onto the motor shaft flush against
the front panel.
18. Wash remaining components in a mild solution of
dish detergent using a bristle brush.
19.Rinse thoroughly and allow to dry before reinstalling in the dispenser.
20.Slide whipper chamber receptacle w/seal (7) and
O-ring (5) on to the motor shaft.
21.Rotate the receptacle w/seal (7) counterclockwise
until it snaps into place on the motor mounting
nuts (8).
BLK to Main Harness WHI
BLK to Main Harness BRN Station #1
BLK to Main Harness RED Station #2
BLK to Main Harness ORN Station #3
BLK to Main Harness YEL Station #4
BLK to Main Harness BLU Station #5
P1221
FIG.19 WHIPPER MOTOR TERMINALS
27
35135 012103
SERVICE (cont.)
INCREASE/DECREASE SWITCH
Removal and Replacement:
1. Open the dispenser door.
2. Remove the facenut securing the increase/decrease
switch to the whipper motor mounting panel.
3. Remove switch with wires attached from the back
side of the whipper motor mounting panel.
4. Disconnect the wires from the switch and discard
the switch.
5. Refer to Fig. 21 when connecting the wires to the
new switch.
6. Install new switch with wires attached through the
hole in the whipper mounting panel and secure
with facenut.
FIG. 20 INCREASE/DECREASE SWITCH
RED/BLK from Control
Board J2-6
GRN from Control
Board J2-9
WHI/VIO from Control
Board J2-1
P2635
Location:
The increase/decrease switch is located on the
lower left front of the whipper motor mounting
panel.
P1208
FIG. 21 INCREASE/DECREASE SWITCH
TERMINALS
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Disconnect the wires from the switch terminals.
3. Check for continuity between the center terminal
and upper terminal with switch in the decrease
position (lower). Check for continuity between
the center terminal and the lower terminal with
the switch in the increase position (upper).
If continuity is present as described, the switch is
operating properly.
If continuity is not present as described, replace the
switch.
28
35135 012103
SERVICE (cont.)
LAMP HOLDERS
1
3
4
6
2
5
FIG. 22 LAMP HOLDERS
P2638
1. Door Assy
4. Upper Panel
2. Lamp Holders
5. Lower Panel
3. Lamp
6. Starter W/Socket
Location:
The lamp holders are located on the front of the
upper panel behind the display panel.
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Remove upper door panel (4) and disconnect the
door wiring harness from the leads on the lamp
holders.
3. Remove lamp from lamp holders.
4. Check for continuity on each lead of the lamp
holders.
If continuity is present as described, lamp holders are
operating properly.
If continuity is not present as described replace the
lamp holder.
29
Removal and Replacement:
1. Open dispenser door (1).
2. Remove the six #8-32 screws securing lower door
panel (5) to the door (1) and remove cover.
3. Disconnect the door wiring harness from the door
interconnect wiring harness.
4. Remove three #8-32 screws securing the upper
door panel (4) to the door.
5. Remove the upper door cover (4), lamp (3), lamp
holders (2) and door wiring harness as an assembly.
6. Disconnect the wires from the lamp holder to be
replaced from the door wiring harness.
7. Rotate lamp (3) 90° and remove from lamp holders
(2).
8. Remove the #6-32 screw securing the lamp holder
(2) to be removed, remove lamp holder (2) and
discard.
9. Install new lamp holder (2) and secure with a #632 screw.
10.Connect the wires on the new lamp holder to the
door wiring harness.
11.Install lamp (3) into lamp holders (2) and turn 90°
until the pins snap in place.
12.Install upper door panel (4), lamp (3), lamp holders (2) and door wiring harness as an assembly
using three #8-32 screws.
13.Reconnect the plug on the door wiring harness
to the connector on the door interconnect wiring
harness.
14.Install the door lower panel (5) using six #8-32 screws.
LAMP REPLACEMENT (Refer to Fig. 22)
1. Open dispenser door (1).
2. Remove the six #8-32 screws securing lower door
panel (5) to the door (1) and remove cover.
3. Disconnect the door wiring harness from the door
interconnect wiring harness.
4. Remove three #8-32 screws securing the upper
door panel (4) to the door.
5. Remove the upper door cover (4), lamp (3), lamp
holders (2) and door wiring harness as an assembly.
6. Rotate lamp (3) 90° and remove from lamp holders
(2).
7. Install lamp (3) into lamp holders (2) and turn 90°
until the pins snap in place.
8. Install upper door panel (4), lamp (3), lamp holders (2) and door wiring harness as an assembly
using three #8-32 screws.
35135 012103
SERVICE (cont.)
LAMP REPLACEMENT (Refer to Fig.22)(cont.)
Removal and Replacement (Refer to Fig.22):
1. Open dispenser door assy (1)
2. Remove the four #8-32 screws securing the
door
lower panel (5) to the door assy (1).
3. Disconnect the leads on the starter socket from
the door wiring harness.
4. Remove lower door panel (5) and starter w/socket
(6) as assembly.
5. Compress the spring tabs on the socket and remove
socket from the door bottom cover (5).
6. Rotate starter 90° and remove from the starter
socket.
7. Insert new starter (6) into socket and turn 90° until
the pins snap in place.
8. Install new socket by compressing spring tabs
on the socket and pushing the socket up through
the hole in the lower door panel (5) and releasing
spring tabs.
9. Connect the sockets leads to the door wiring harness.
10.Install door lower panel (5) with starter and
starter socket on door assy (1) using four #8-32
screws.
9. Reconnect the plug on the door wiring harness
to the connector on the door interconnect wiring
harness.
10.Install the door lower panel (5) using six #8-32 screws.
LAMP STARTER and SOCKET (Refer to Fig. 22)
Location:
The lamp starter (6) is located inside the door assy
(1) on the top of the door lower panel (5).
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Disconnect the starter leads from the door wiring
harness.
3. Remove lamp starter from starter socket.
4. Check for continuity on each lead of the starter
socket.
If continuity is present as described the starter socket
is operating properly.
If continuity is not present as described replace the
starter socket.
5. Remove starter (6) from starter socket.
6. Check for continuity across the pins on the bottom
of the starter (6).
If continuity is present as described, replace the
starter.
If continuity is not present as described, starter is
operating properly.
Note: If continuity tests are both as described and
lamp does not light, replace the starter.
30
35135 012103
SERVICE (cont.)
LIMIT THERMOSTAT
Removal and Replacement:
1. Remove all wires from the limit thermostat terminals.
2. Carefully slide the limit thermostat out from under
the retaining clip and remove the limit thermostat.
3. Carefully slide the new limit thermostat into the
retaining clip.
4. Refer to Fig. 24 when reconnecting the wires.
BLK to Tank Heater
BLK to Control
Thermostat
P2635
FIG. 23 LIMIT THERMOSTAT
Location:
The limit thermostat is located in the center of the
tank lid.
FIG. 24 LIMIT THERMOSTAT TERMINALS
P1800
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Disconnect both black wires from the limit thermostat.
3. Check for continuity across the limit thermostat
terminals.
If continuity is present as described, the limit thermostat
is operating properly.
If continuity is not present as described, replace the
limit thermostat.
31
35135 012103
SERVICE (cont.)
RINSE/RUN SWITCH
Removal and Replacement:
1. Open the dispenser door.
2. Remove the facenut securing the run/rinse switch
to the whipper motor mounting panel.
3. Remove switch with wires attached from the back
side of the whipper motor mounting panel.
4. Disconnect the wires from the switch and discard
the switch.
5. Refer to Fig. 26 when connecting the wires to the
new switch.
6. Install new switch with wires attached through
the hole in the whipper motor mounting panel
and secure with facenut.
BRN/BLK to
Main Harness
P2635
FIG. 25 RINSE/RUN SWITCH
Location:
The rinse/run switch is located on the lower center
of the whipper motor mounting panel.
GRY to Control
Board J2-2
GRN to Control
Board J2-9
BLK from
Main Harness
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Check for continuity between the center left
terminal and left bottom terminal, also between
the center right terminal and the right bottom
terminal with the switch in the rinse position (upper). Check for continuity across the center left
terminal and the top left terminal, also between
center right terminal and the top right terminal
with the switch in the run position (lower). Continuity must not be present when the switch is
in the center position.
BRN/BLK to
Main Harness
WHI/GRY to Control
Board J2-3
P1644
FIG. 26 RINSE/RUN SWITCH TERMINALS
If continuity is present as described, the switch is
operating properly.
If continuity is not present as described, replace the
switch.
32
35135 012103
SERVICE (cont.)
If voltage is present as described, reconnect the four
pin plugs and proceed to #5.
If voltage is not present as described, refer to the Wiring
Diagrams and check the main wiring harness.
HOT/COLD SWITCH (Optional)
5. Disconnect the wires from the switch terminals.
6. With the switch in the “Cold” (upper) position
check for continuity between the center terminal and the bottom terminal. With the switch in
the “Hot” (lower) position check for continuity
between the center terminal and the upper terminal.
If continuity is present as described, the hot/cold
switch is operating properly.
If continuity is not present as described, replace the
switch.
P2635
Removal and Replacement:
1. Remove all wires from the switch terminals.
2. Remove the mounting nut on the front of the
whipper motor mounting panel.
3. Remove the hot/cold switch from the rear of the
front panel and discard.
4. Reconnect the wires to the terminals on the rear
of the new switch.
5. Push new hot/cold switch through the hole on the
left side of the whipper motor mounting panel and
secure with mounting nut.
6. Refer to Fig. 28 when reconnecting the wires.
FIG. 27 HOT/COLD SWITCH
Location:
The hot/cold switch is located on the left side of
the whipper motor mounting panel.
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Disconnect the four pin plug from the hot/cold
switch and the four pin connector on the main
wiring harness.
3. Press the left dispense switch on the door and,
with a voltmeter, check the voltage across the white
wire (pin 4) and red wire (pin 2) in the four pin
connector on the main wiring harness. Connect
the dispenser to the power source. The indication
must be:
a) 120 volts ac for two wire 120 volt models, and
three wire 120/208 volt and 120/240 volt models.
b) 240 volts ac for two wire 240 volt models.
c) 230 volts ac for two wire 230 volt models.
4. Disconnect the dispenser from the power
source.
TAN to Main Harness
RED to Main Harness
WHI/YEL to Cold
Solenoid
P1208
FIG. 28 HOT/COLD SWITCH TERMINALS
33
35135 100407
SERVICE (cont.)
6. Check the solenoid valve for coil action. Connect the
dispenser to the power source. With “HOT/COLD”
switch in the “COLD” (upper) position press the left
dispense switch and listen carefully in the vicinity of
the solenoid valve for a “clicking” sound as the coil
magnet attracts.
7. Disconnect the dispenser from the power source.
SOLENOID VALVE (COLD WATER - OPTIONAL)
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.
P2635
FIG. 29 COLD WATER SOLENOID VALVE
Removal and Replacement:
1. Loosen the two screws securing the component
bracket to the dispenser base. Lift the component
bracket off of the base and move to the right.
2. Remove the white and white/yellow wires from the
solenoid valve.
3. Turn off the water supply to the dispenser.
4. Disconnect the water lines to and from the solenoid
valve.
5. Loosen the two #8-32 screws and washers securing
the solenoid mounting bracket to the base. Remove
solenoid bracket and solenoid valve as an assembly.
6. Remove the two #10-32 screws and lockwashers securing the solenoid valve to the solenoid bracket.
7. Using two #10-32 screws and lockwashers install
new solenoid valve on solenoid mounting bracket.
8. Install the solenoid valve and bracket on the dispenser base and tighten the two #8-32 screws.
9. Securely fasten the water lines to and from the solenoid valve.
10.Refer to Fig. 30 when reconnecting the wires.
Location:
The cold water solenoid valve is located on the left
side of the dispenser base just behind the component
bracket.
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Disconnect the white and white/yellow wires from
the solenoid valve. With the “HOT/COLD” switch
in the “COLD” (upper) position press the left
dispense switch on front of the door.
3. With a voltmeter, check the voltage across the white
and white/yellow wires. Connect the dispenser to
the power source. The indication must be:
a) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt, and 120/240 volt models.
b) 240 volts ac for two wire 240 volt models.
c) 230 volts ac for two wire 230 volt models.
4. Disconnect the dispenser 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 dispenser wiring harness.
WHI/YEL to Hot/
Cold Switch
WHI to Main Wiring
Harness
5. Check for continuity across the solenoid valve coil
terminals.
If continuity is present as described, reconnect the
white and white/yellow wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
P1215
FIG. 30 COLD WATER SOLENOID TERMINALS
34
35135 100407
SERVICE (cont.)
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to wiring
diagram and check dispenser wiring harness.
SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
wires to the solenoid (see Fig. 32), proceed to #6
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect the
dispenser to the power source. With “RINSE/RUN”
switch in the “RINSE” upper position press the
dispense switch and listen carefully in the vicinity
of the solenoid valve for a “clicking” sound as the
coil magnet attracts.
7. Disconnect the dispenser 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 outlet 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.
P2635
FIG. 31 DISPENSE SOLENOID VALVE
Location:
The dispense solenoid is located on the upper left
center of the tank.
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Disconnect the two wires from the solenoid valve
that is being tested. With the “RINSE/RUN” switch
in the “RINSE” upper position press the dispense
switch on front of the door.
3. Check the voltage across the two wires with a
voltmeter. Connect the dispenser to the power
source. The indication must be:
a) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt, and 120/240 volt models.
b) 240 volts ac for two wire 240 volt models.
c) 230 volts ac for two wire 230 volt models.
4. Disconnect the dispenser from the power
source.
35
35135 100407
SERVICE (cont.)
SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5
(cont.)
Removal and Replacement:
1. Remove the four #8-32 screws securing the side
access panel to the housing. Remove panel and
set aside.
2. Remove the wires from the solenoid valve.
3. Turn-off the water supply to the dispenser.
4. Using the tank drain tube, drain enough water from
the tank so the water level is below the dispense
valve mounting hole.
5. Disconnect the water line from the solenoid
valve.
6. Remove the #8-32 keps nut securing the solenoid
valve bracket to side of the tank. Remove solenoid
valve.
7. Install new solenoid valve and o-ring on side of
the tank and secure in place with valve mounting
bracket and #8-32 keps nut.
8. Push the water line onto the tube on bottom of
solenoid valve.
9. Refer to Fig. 32 and reconnect the wires.
10.Reinstall side access panels.
WHIto Main Harness
TAN to Main Harness Station #1
RED to Main Harness Station #2
ORN to Main Harness Station #3
YEL to Main Harness Station #4
BLU to Main Harness Station #5
P1672
FIG. 32 DISPENSE SOLENOID VALVE
TERMINALS
36
35135 012103
SERVICE (cont.)
6. Check the solenoid valve for coil action. Connect
the dispenser to the power source. Listen carefully
in the vicinity of the solenoid valve for a “clicking”
sound as the coil magnet attracts.
7. Disconnect the dispenser from the power
source.
SOLENOID VALVE (INLET)
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 violet wires from the solenoid
valve.
2. Turn-off the water supply to the dispenser.
3. Disconnect the water lines to and from the solenoid
valve.
4. Remove the two #8-32 screws securing the solenoid to the rear of the dispenser housing. Remove
solenoid.
5. Remove the two #8-32 U-Type fasteners from the
solenoid bracket.
6. Install the two #8-32 U-Type fasteners and the two
#8-32 screws on the new solenoid.
7. Install new solenoid on rear of dispenser housing
and tighten the two screws
8. Securely fasten the water lines to and from the
solenoid valve.
9. Refer to Fig. 34 and reconnect the wires.
P2635
FIG. 33 INLET SOLENOID VALVE
Location:
The inlet solenoid is located on the lower left side
near the rear panel.
Test Procedures:
1. Disconnect the dispenser from the power
source.
2. Disconnect the white and violet wires from the
solenoid valve.
3. Check the voltage across the white and violet
wires with a voltmeter. Connect the dispenser to
the power source. The indication must be:
a) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt, and 120/240 volt models.
b) 240 volts ac for two wire 240 volt models.
c) 230 volts ac for two wire 230 volt models.
4. Disconnect the dispenser from the power
source,
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to the wiring
diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve coil
terminals.
If continuity is present as described, reconnect the
white and violet wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
WHI from Main Harness
VIO from Main Harness
P2641
FIG. 34 INLET SOLENOID VALVE TERMINALS
37
35135 100407
SERVICE (cont.)
TANK HEATER
FIG. 35 TANK HEATER
P2635
Location:
The tank heater is located inside the tank and secured
to the tank lid.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Check the voltage across the black and white wires
120 volt models or black and red wires for 120/208
volt models or 120/240 volt models with a voltmeter. Connect the dispenser to the power source. The
indication must be:
a) 120 volts ac for two wire 120 volt models;
b) 208 volts ac for three wire 120/208 volt models.
c) 240 volts ac for three wire 120/240 volt models.
d) 230 volts ac for two wire 230 volt models.
3. Disconnect the dispenser from the power source.
If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the dispenser
wiring diagram and check the wiring harness.
4. Disconnect the black wire and the white or red wire
from the tank heater terminals.
5. Check for continuity across the tank heater terminals.
If continuity is present as described, reconnect the wires,
the tank heater is operating properly.
If continuity is not present as described, replace the
tank heater.
NOTE - If the tank heater remains unable to heat, remove
and inspect heater for cracks in the sheath.
38
Removal and Replacement:
1. Disconnect the dispenser from the power source.
2. Disconnect the water supply tube on the tank lid.
3. Disconnect the black wires on the limit thermstat.
4. Disconnect the black wire and the white or red wire
from the tank heater terminals.
5. Disconnect the pink wire from the liquid level probe
and the green wire from the tank.
6. 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.
7. Remove the ten #8-32 nuts securing the tank lid to
the tank.
8. Remove tank lid with limit thermostat, liquid level
probe and tank heater as an assembly.
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.
11.Install tank lid with limit thermostat, liquid level
probe and tank heater on the tank and secure with
ten #8-32 hex nuts.
12.Connect water inlet line to the tank lid.
13.Reconnect the black wires to limit thermostat, the
pink wire to the liquid level probe and the green
wire to the tank. Refer to the limit thermostat and
the liquid level board and probe sections in this
manual when reconnecting wires.
14.Refer to Fig. 36 when reconnecting the wires to the
tank heater.
WHI or RED to
Main Harness
BLK to Limit
Thermostat
FIG. 36 TANK HEATER TERMINALS
P1218
35135 100407
SERVICE (cont.)
TANK HEATER SWITCH
Removal and Replacement:
1. Remove the switch mounting nut on the front of
the front panel.
2. Remove switch with wires attached from the rear
of the front panel.
3. Remove the wires from the switch terminals and
discard switch.
4. Connect the wires to the new switch, refer to Fig.
38.
5. Push new switch through hole in the front panel
and secure with facenut.
BLK to Main
Harnesss
FIG. 37 TANK HEATER SWITCH
BLK from Main
Harness
P2635
Location:
The tank heater switch located inside the dispenser
on the upper right of the front panel.
P1219
FIG. 38 TANK HEATER SWITCH TERMINALS
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Disconnect the black wires from the main wiring
harness.
3. With the switch in the “ON” lower position check
for continuity between the center and the upper
terminal. With the switch in the “OFF” upper position no continuity should be present between
center and upper terminals.
If continuity is present as described, the tank heater
“ON/OFF” switch is operating properly.
If continuity is not present as described, replace the
switch.
39
35135 012103
SERVICE (cont.)
6. With an ohmmeter, check for continuity between
the normally closed (NC-5) and common (COM-3)
terminals of the relay.
7. Place containers below any three dispense nozzles.
8. Connect the dispenser to the power source.
9. Simultaneously initiate dispenses at each of the
selected dispense stations while monitorintg continuity across the referenced terminals of the tank
heater relay. The indication must be open circuit.
TANK HEATER RELAY (120V Dispensers only)
If continuity is absent as described, the relay is functioning correctly.
If continuity is present, replace the relay.
Removal and Replacement:
1. Loosen the three #8-32 screws securing the component bracket to the dispenser housing base.
2. Pull component bracket out the front of the dispenser far enough so the tank heater relay can be
disconnected from the main wiring harness.
3 Disconnect the tank heater relay from the main
wiring harness.
4. Remove the two #8-32 screws securing the
tank heater relay to the rear of the component
bracket.
5. Remove and discard the tank heater relay.
6. Install new tank heater relay on the rear of the
component bracket and secure with two #8-32
screws.
7. Connect the tank heater relay to the main wiring
harness (see Fig. 40).
8. Place the component bracket into position and
tighten the three #8-32 screws.
P2635
FIG. 39 TANK HEATER RELAY
Location:
The tank heater relay is located behind the lower
front access cover, mounted on the left rear side of the
component bracket.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Place the tank heater switch in the “OFF” (upper)
position.
3. With an ohmmeter, check for continuity between
normally closed (NC-5) and common (COM-3)
terminals of the relay. The indication must be less
than 1 ohm.
If continuity is present as described, proceed to step
4.
If continuity is not present as described, replace the
relay.
4. With an ohmmeter, check the resistance across the
coil terminals (1 & 2) of the relay. The indication
must be approximately 4,000 ohms (4kΩ).
BRN/BLK from
Main Harness
BLK from
Main Harness
If the resistance measures as described, proceed to
step 5.
If the resistance does not measure as described, replace
the relay.
BLK from
Main Harness
WHI from
Main Harness
No Connection
P2639
FIG. 40 TANK HEATER RELAY TERMINALS
5. Disconnect the wires from the normally closed (NC5) and common (COM-3) terminals of the relay.
40
35135 012103
SERVICE (cont.)
5. Check the voltage between J3-5 and J3-6 on the
six pin connector at either control board. Connect
the dispenser to the power source. The indication
must be 24 volts ac.
TRANSFORMER
If voltage is present as described the transformer is
operating properly.
If voltage is not present as described, replace the
transformer.
Removal and Replacement:
1. Loosen the three #8-32 screws securing the component bracket to the dispenser housing base.
2. Pull component bracket out the front of the
dispenser far enough so the transformer can be
disconnected from the main wiring harness.
3 Disconnect the transformer from the main wiring
harness.
4. Remove the two #8-32 screws securing the transformer to the rear of the component bracket.
5. Remove and discard the transformer.
6. Install new transformer on the rear of the component bracket and secure with two #8-32 screws.
7. Connect the transformer to the main wiring harness (see Fig. 42).
8. Place the component bracket into position and
tighten the three #8-32 screws.
P2635
FIG. 41 TRANSFORMER
Location:
The transformer is located behind the lower front
access cover, mounted on the right rear side of the
component bracket.
Test Procedure:
1. Disconnect the dispenser from the power
source.
2. Disconnect the four wires of the main harness
from the transformer.
3 Check the voltage across black wire and the white
wire on the main harness. Connect the dispenser
to power source. The indication must be:
a. 120 volts ac for two wire 120 volt models.
b. 120 volts for three wire 120/208 volt models
and three wire 120/240 volt models.
c) 230 volts ac for two wire 230 volt models.
4. Disconnect the dispenser from the power
source.
E
LIN
WHI from
Main Harness
WHI/GRN from
Main Harness
BLK from
Main Harness
WHI/BLK from
Main Harness
P2640
FIG. 42 TRANSFORMER TERMINALS
If voltage is present as described reconnect the wires
and proceed to #5.
If voltage is not present as described, refer to the wiring
diagrams and check the main wiring harness.
41
35135 100407
42
35135 111103
43
35135 111103
44
35135 012103
45
35135 012103
SCHEMATIC WIRING DIAGRAM FMD-5A
L1
L2
GRN
TANK HEATER
SWITCH
BLK-16
BLK-16
CONTROL
THERMOSTAT
K
LIMIT
THERMOSTAT
BLK-16
THERMAL
FUSE
TANK HEATER
BLK-16
BLK-16
WHI
BRN/BLK
WHI
BLK
THERMAL
FUSE
WHI-16
K
J4-1
J4-4
FAN
BLK
BLK
BLK
WHI
VIO
WHI
WHI/VIO
J4-1
C
O
N
T
R
O
L
C
I
R
C
U
I
T
B
O
A
R
D
#
1
BLK
J4-4
LAMP #1 BLK
BALLAST
RED
RED
BLK LAMP #2 BLK
BALLAST
WHI
M
BLK
WHI/BLU
WHI/YEL
GRN
WHI/GRN
WHI/BLK
WHI
REFILL VALVE
BLK
LOAD 240V : 24V AC LINE
TRANSFORMER
WHI
WHI/GRN
WHI/BLK
OVERFLOW PROTECTION SWITCH
RED
RED
WHI/VIO
BLK
BLK
VIO
WHI/VIO
GRY
WHI/GRY
WHI/BLU
BLU/BLK
RED/BLK
WHI/YEL
WHI/ORN
WHI
SOL
WHI
WHI/ORN
WHI/RED
BRN/WHI
GRN
WHI/GRN
WHI/BLK
J3-1
J3-5
WHI/BLK
J3-1
J3-5
J2-1
J2-5
C
O
N
T
R
O
L
C
I
R
C
U
I
T
B
O
A
R
D
#
2
J2-10
J1-1
WHI/VIO
GRY
WHI/GRY
WHI/RED
TAN
RED/BLK
WHI/BLK
WHI/ORN
GRN
PNK
WHI
WHI
SOL
WHI
1
ORN
WHI
SOL
M
GRN
STATION #5
WHIPPER
BLK
STATION #4
DISPENSE
VALVE
YEL
SOL
BLK
BLK
WHI
M
BLK
STATION #5
DISPENSE
VALVE
BLU
SOL
WHI
BLK
BLU
STATION #3
DISPENSE
VALVE
M
GRN
STATION #4
WHIPPER
BLK
M
RED
WHI
1
RED
RED
TAN
WHI
HOT/COLD SWITCH
COLD
WHI/YEL
SOL
HOT
RED
RED
RED
JUMPER PLUG MUST BE
USED WHEN COLD
DRINK FEATURE NOT
INSTALLED
4
4
GRN
BLK/RED
WHI
PNK
BLU/RED
WHI
6
HOPPER #5
WHI/BLU
BLK
BLK/RED
WHI
BLU/RED
RED/WHI
BLU/WHI
GRY
1
"RINSE" #1-3 L.E.D.
1
RED
WHI
RED
BRN
RED
ORN
YEL
BLU
BRN/BLK
6
M
COLD DRINK OPTION (LEFT ONLY)
BRN
BRN
TAN
WHI
WHI/BLK
RED/BLK
ORN/BLK
GRN/BLK
BLU/BLK
BLK
1
BLK/WHI
RED
ORN
GRN/WHI
BLU
WHI/RED
1
WHI/BLK
WHI/RED
WHI/ORN
WHI/YEL
WHI/BLU
GRN
TAN
GRN
BLU/BLK
GRN
PNK
BLK
WHI
STATION #2
DISPENSE
VALVE
RED
RED
WHI
SOL
WHI/YEL
STATION #3
WHIPPER
BLK
M
WHI
TAN
RUN
HOPPER #4
BLK
M
WHI
BLK
WHI
BRN
BLK
RED
STATION #2
WHIPPER
BLK
STATION #1
DISPENSE
VALVE
GRN
RUN
RINSE
PGM
M
WHI
BRN/BLK
PGM
BLK
RED
RINSE/PROGRAM/
RUN SWITCH
WHI/GRY RINSE
WHI/ORN
GRN
STATION #1
WHIPPER
PROBE
GRY
BRN/BLK
HOPPER #3
BLK
M
WHI
RED
GRN
WHI/RED
BLU
HOPPER #2
BLK
YEL
M
WHI
RED
YEL
HOPPER #1
BRN/WHI
WHI
INCREASE/
DECREASE
SWITCH
ORN
WHI/VIO
GRN
D
E
C
ORN
I
N
C
J1-4
GRN
J1-1
RED
J2-10
J1-4
GRN
J2-5
WHI/RED
RED/BLK
J2-1
RED/GRN
ORN/RED
RED
RED
RED
BLU
BLK
WHI
BLU
BLU/BLK
WHI/RED
BLK
BLK
STARTER BLK
5
GRN/WHI
GRN/BLK
BLU
RED
WHI/RED
BLK
WHI
BLK
4
ORN
ORN/BLK
RED
BLU
WHI/RED
BLK
BLK
WHI
3
RED
RED/BLK
RED
RED
WHI/RED
BLK
BLK
STARTER BLK
2
BLK/WHI
WHI/BLK
BLU
RED
1
WHI/RED
BLK
WHI
BLK
GRY
1
"RINSE" #4 & 5 L.E.D.
230 VOLTS AC
2 WIRE + GND
SINGLE PHASE, 50/60HZ
34820.0002B 04/05 ©2005 BUNN-O-MATIC CORPORATION
46
35135 100407