Cornelius | QUEST 4000 | Service manual | Cornelius QUEST 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
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
! DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in
serious injury, death or equipment damage.
! WARNING:
Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.
! CAUTION:
Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.
SAFETY TIPS
© 2010-2015, Cornelius Inc.
•
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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Quest Elite 4000 Service Manual
•
Keep your unit in proper working condition and do not allow unauthorized
modifications to the unit.
QUALIFIED SERVICE PERSONNEL
! WARNING:
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:
! WARNING:
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.
! CAUTION:
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
! CAUTION:
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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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
MOUNTING IN OR ON A COUNTER
! WARNING:
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
Model QST ELITE 4000, 115 VAC, 5 amps, 1 phase 60 hertz, 6.34 – 6.41 oz. (180182) 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).
Concentrate Storage
Four 0.8 gallon (3.0 liter) disposable bottles.
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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
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.
! CAUTION:
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.
© 2010-2015, Cornelius Inc.
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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)
Publication Number: 620048956SER
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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
APPLICATIONS
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.
Water
Connection
! WARNING:
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.
© 2010-2015, Cornelius Inc.
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Quest Elite 4000 Service Manual
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.
! WARNING:
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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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
CHANGING CONCENTRATE CONTAINERS
1. Open the cabinet door and move the valve handle from the Dispense to
Flush position, see Figure 3.
Dispense/Flush
Levers
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.
Figure 4. Dispense Buttons
3. Open the cabinet door and return the handle to the Dispense position.
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
© 2010-2015, Cornelius Inc.
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Publication Number: 620048956SER
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.
Table 1.
Flavor
Publication Number: 620048956SER
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
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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
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.
Water Flow
Controls
Dispense/Flush Lever
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.
© 2010-2015, Cornelius Inc.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
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 Flush position. Place an empty cup on the
drip tray below each dispense nozzle (Figure 7).
Dispense/Flush
Levers
Mixing
Chambers
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 Dispense position.
4. Press each Dispense button for 1 to 2 seconds to release the water
pressure present in the concentrate pump system.
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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
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.
! WARNING:
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
above this range breaks down the chlorine count and
minimizes sanitation.
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.
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
© 2010-2015, Cornelius Inc.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
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 position.and close the door.
Dispense/Flush
Levers
Mixing
Chambers
Figure 9. Dispense/Flush Levers
3. Press and hold the dispense button for 90 seconds then release. Allow
sanitizing solution to remain in the lines for 5 minutes.
Figure 10. Dispense Buttons
4. After 5 minutes, dispense the remaining sanitizing solution.
Prepare Dispenser for Use
1. Replace sanitizing solution container with a concentrate container and close
the door.
2. Press and hold the dispense button until juice appears from the nozzle. Next
dispense and discard at least two 8 oz. (236.6ML) cups of juice in order to
prime the system and prepare it for operation.
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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
SEMI ANNUALLY
! CAUTION:
The following procedures require removal of the dispenser side panel(s).
Disconnect the power cord (See Figure 11.) from the receptacle prior to
proceeding.
Figure 11. Pull AC Plug from Wall Outlet
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
the right side of the dispenser. (See Figure 12)
4. Clean and reinstall the stainless steel water strainer.
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.
© 2010-2015, Cornelius Inc.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
Check and Top-Off Water Ice Bath
1. Remove the drip tray and lower splash panel.
Lower Splash Panel
Cup Rest
Drip Tray
Figure 13. Drip Tray and Cup Rest
If the Ice bath level is below the Full indicator, top it off with water. Refer to 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).
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© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
Bottle Adapter
Juice Inlet
Concentrate
Delivery Tubes
Water Inlet
Quick Connector
Pump Body Screws
Water Manifold
BRIX Adjustment Screw
Pump Motor
Locking Latch
Water Solenoid
Front & Rear
Pump Halves
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.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
1
4
2
3
Figure 15. Pump Body Screws
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.
Pump Tubing
Roller
Assembly
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.
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© 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.
© 2010-2015, Cornelius Inc.
Reinstall the pump platform in the reverse order given above.
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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.
Table 2
Symptom
Unit totally inoperative
Probable Cause
Remedy
A. No power to dispenser due to tripped
circuit breaker.


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. Loose or broken power supply connec- B. Repair connection.
tion inside dispenser.
No Cooling
A. Line voltage not within nameplate
specification causing compressor
overload to trip.
A. Contact an electrician.

B. No water in water ice bath or water
level extremely low, exposing ice bank
sensing probe.
B. Fill ice bath to proper water level.

C. Defective Ice Bank Control or sensing
probe.
C. Replace.
D. Cabinet fan inoperative resulting in
warm concentrate (water continues to
cool).
D. Replace.
E. Compressor short cycles on overload.

F. Compressor starts but hums & trips
overload.
E. Excessively high discharge pressure
due to restricted condenser or inoperative condenser fan motor.
F. Seized or shorted compressor,
replace.
G. Defective compressor overload or start G. Test & replace.
capacitor.
H. Compressor starts but does not switch H. Relay or compressor is defective. Test
off of start winding.
& replace faulty item.
I.
Publication Number: 620048956SER
Refrigerant leak.
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I.
Repair leak, evacuate & recharge system.
© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
Table 2
Symptom
No water dispensed,
concentrate only
Probable Cause
Remedy
A. No water in dispenser.
A. Restore water.
B. Water supply line inside refrigerated
cabinet disconnected from pump platform.
B. Reconnect
C. Water solenoid located on pump platform clogged or defective.
C. Disassemble & clean solenoid.
Replace if necessary.
D. Main water solenoid/strainer located at D. Remove & clean strainer. Confirm
24VDC is present at solenoid during
the rear of dispenser is clogged, binddispense. Confirm solenoid coil is not
ing or defective.
open. Disassemble & clean solenoid.
E. Water supply pressure is greater than
80 psi (5.5 bar) forcing BRIX flow control closed.
E. Add external regulator & lower pressure to 50 psi (3.5 bar).
F. Freeze-up of water coil in ice bath.
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.
No water & no conA. Black service switch located on the
centrate, refrigeration
rear of the cabinet door in OFF posiis working.
tion.
A. Turn on switch.
B. White door switch open

B. Door switch must be closed in order to
dispense. Check switch operation &
replace if necessary.
C. 6.25 amp fuse inside front electrical
box blown.
C. Replace with 6.25, 250VAC slow blow
fuse & test.
D. No output from transformer.
D. Confirm transformer output of 24VAC
+/-2. Replace transformer if necessary.
E. Defective voltage regulator board
(VRB) located inside front electrical
box.

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. Defective dispense push button or por- F. Test & replace if necessary.
tion control board.
No concentrate dispensed, water only.
© 2010-2015, Cornelius Inc.
A. Concentrate container not fully
engaged into receptacle on pump
platform.
A. Refer to Concentrate Loading section
of this manual.
B. Dispense/Flush lever in FLUSH position
B. Move lever to DISPENSE position
C. Concentrate too cold, not properly
thawed.
C. Concentrate should be 35 to 40°F (1.7
to 4.5°C) prior to loading.
D. Defective pump motor.
D. Replace pump motor.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
Table 2
Symptom
Probable Cause
Remedy
A. Ambient air around dispenser is too
warm.
A. Relocate dispenser.
B. Excessive demand on dispenser.
B. Add water pre-cooler or second dispenser
C. Dirty condenser coil.
C. Clean condenser coil.
D. Inoperative condenser fan.
D. Replace condenser fan motor.
E. Defective Ice Bank Control.
E. Test & replace if necessary.
F. Loss of refrigerant charge due to leak
in system.
F. Repair leak and recharge system.
Water continuously
drips from nozzle in
OFF mode.
A. Main water solenoid at base of unit or
water solenoid on pump platform not
shutting off completely.
A. Clean solenoid(s), replace parts as
necessary (refer to Planned Maintenance section).
Concentrate warm,
water cold.
A. Cabinet fan inoperable.
A. Check/replace fan.
B. Agitator motor/pump inoperable or
restricted.
B. Check/replace agitator motor.
C. Loss of refrigerant charge due to leak
in system.
C. Repair leak & recharge system.
A. Water supply pressure too low, less
than 20 psi (1.4 bar) flowing water
pressure.
A. Correct water supply problem to
ensure a constant 50 psi (3.5 bar)
flowing to dispenser.
B. Water flow control binding or spring is
defective.
B. Clean and/or replace parts as necessary.
Warm drinks
BRIX problem
C. Improperly thawed concentrate. BRIX
changes as concentrate temperature
C. Concentrate should be 35 to 40°F (1.7
changes (concentrate becomes thinner
to 4.5°C) prior to loading.
as temperature rises)
Pump inoperative
A. Pump motor defective.

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. 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 present when dispense button is pressed
(refer to Electrical Box Wiring Diagram
for VDC output location). Replace VRB
if necessary.
D. Test & replace if necessary.
Machine continues to A. Push button or portion control pad
dispense after disstuck in ON position.
pense button is

released or dispenses without operator input.
B. Relay on voltage regulator board
(VRB) stuck on.
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A. Disconnect wire harness from rear of portion 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).
© 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual
ASSEMBLY DRAWINGS
Figure 18. System Wiring Diagram Quest Elite 4 FL
© 2010-2015, Cornelius Inc.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
Figure 19. Main Electrical Box Wiring Diagram Quest Elite 4 FL
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© 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.
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Publication Number: 620048956SER
Quest Elite 4000 Service Manual
Publication Number: 620048956SER
- 26 -
© 2010-2014, Cornelius Inc.
Cornelius Inc.
www.cornelius.com
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