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Crathco / Grindmaster PIC-1 Service manual
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Crathco® Powdered Beverage Dispensers Service Manual for PIC 1, 2, 3, 4, 5, 6 PSD 1, 2, 3, 4, 5, 6 PIC 23A, PIC33A, PIC43A, PIC5W TABLE OF CONTENTS Warning Labels....................................... 2 Installation.............................................. 4 Start up Procedures................................. 4 How To Dispense Cappuccino.................. 5 Adjustments............................................ 5 Cleaning.................................................. 7 Preventative Maintenance ..................... 11 Service Light Bulbs................................... 12 Draining the Tank .......................12 Shipment Preparation .................12 Whipper Motors .........................13 Dump Valves .............................. 14 Grommets .................................. 14 Water Tank ............................... 14 Inlet Valve ................................. 16 Thermistor ................................ 17 Auger Motors ............................ 18 Blower Motor ............................ 18 Controller .................................. 18 Heater Relay ......................... ... 18 Transformer .............................. 18 Soluble Conversion .................. 19 Troubleshooting..................................... 20 Exploded Views......................................22 Wiring Diagram............................. ........50 Prior authorization must be obtained from Grindmaster Corporation™ for all warranty claims. PIC 2 PIC 1 PIC 5 PIC 33A PIC 6 Grindmaster Corporation™ 4003 Collins Lane Louisville, Kentucky 40245 USA (502) 425-4776 (800) 695-4500 (USA and Canada only) (800) 568-5715 (Technical Service only) FAX: (502) 425-4664 www.grindmaster.com © Grindmaster Corporation™, 1996 PRINTED IN USA 0807 Form # CC-302-20 Part # 62780 Warning Labels The following warning labels were on your dispenser when it was shipped from the factory. They should remain on your dispenser in good, readable condition at all times. If one of your labels is missing or damaged, order a replacement label immediately. Part #62981 (PIC 5-6) - Located on the upper splash panel on the front of the dispenser WARNING Contents can cause severe burns if handled improperly. ADVER AD VERTENCIA TENCIA Contenidos pueden causar quemaduras severas si el uso es inadecuado. AVER VERTISSEMENT TISSEMENT Contenu peut provoquer des brûlures grâves si il est manipulé incorrectement. PN# 62981 Part #61321 (PIC 1-4) - Located behind the drip pan on the front of the dispenser WARNING: Risk of electric shock. Disconnect from power before servicing. Hot parts and surfaces inside and outside machine may cause burns. Tank drain hose inside machine dispenses very hot water. Will cause burns and/or personal injury. Must have five gallon heat resistant container to catch hot water. Hot water may splash. Do not attempt to stop hot water once it begins flowing. Replace plug and clamp prior to refilling tank. Part #100268 (PIC 5-6) - Located behind the drip pan on the front of the dispenser Page 2 Crathco® Powdered Beverage Dispensers Warning Labels (cont.) Part #61319, Located on the outside on the back of the dispenser Part #61326, Located on the outside on the left of the dispenser Part #61325, Located on the drain hose inside the dispenser Crathco® Powdered Beverage Dispensers Page 3 Installation Water Inlet Connection The following is required for water hook-up: 1. A quick disconnect water connection or enough coiled tubing so the machine can be moved for cleaning underneath. (required for NSF approved water hook-up) 2. A 1/4" male flare adapter is provided (packed inside the drain tray) to be attached by the installer to the back of the machine for hook-up to water supply. 3. Installation to a water filter system is required to prevent lime and scale build up in the machine. 4. Water pipe connections and fixtures directly connected to potable water supply shall be sized, installed, and maintained in accordance with Federal, State, and Local codes. (required for NSF approved water hook-up) 5. Equipment is to be installed with adequate backflow protection to comply with applicable Federal, State, and local codes. (required for NSF approved water hook-up) Start-up Procedure for Standard Units NOTE: NSF requires installation of 4” legs for PIC 2,3,4,5,6. 1. 2. 3. 4. Install drip tray in front of machine. Connect the 1/4" male flare fitting to the inlet valve on the back of the machine. Flush the water line to purge any debris from the supply line. Connect a 1/4" water line to the 1/4" male flare connection and turn the water supply on. a. Minimum water pressure to the machine: 20 psi b. Maximum water pressure to the machine: 100 psi 5. Plug the power cord into a proper electrical outlet. 6. Turn the power switch to the “ON” position and allow the water tank to fill. The machine will make a subtle hissing sound when this occurs. Allow 3-4 minutes (5 minutes for PIC 5 or PIC 6) for fill time depending on inlet water pressure. NOTE: If water supply is allowed to run dry, watchdog timer circuit may disable fill circuit. If this occurs, ensure adequate water supply for machine, then reset machine by turning power switch “OFF” for 1 second and then turning the power switch back “ON”. NOTE: Watchdog timer might engage on initial fill on PIC 5 and PIC 6. 7. After the water tank has filled, allow 15-45 minutes (45-60 minutes for PIC 5/6) for the water to reach operating temperature. (Green ready light will illuminate when tank is up to preset temperature.) 8. Remove the powder hoppers, rotate the dispense elbow to the “up” position, and fill with desired powder product. IMPORTANT: Check to make sure that the auger inside the hopper is correctly installed prior to filling. Reinstall powder hoppers. Turn dispense elbow down toward the mixing funnel. 9. Peel protective film off photo merchandiser cover. (Install graphic if needed) 10. Install flavor decals as needed. (Place one on each hopper, and place the corresponding decal on the dispense section of the front door of the unit) POWER CORD TABLE Models Standard Models Q Z* Volts 120V 120V 120V 120/208-240 208-240 Watts 1400W 1650W 1650W 2500W 2500W Phase Single Phase 60Hz Supply Cord 14-3 14-3 12-3 12-4 12-4 Attachment Plug 5-15 5-15 5-20 L14-20 L14-20 Agency UL, UL, UL, UL, UL, CUL, NSF CUL, CUL, CUL, NSF NSF NSF NSF * For Z model neutral is not required. Start-Up Procedures for Pump Units (PIC 2P & PIC 3P only) NOTE: Pump units are not designed to be plumbed to pressurized water source. 1. Place a five gallon water container within 3 feet vertically and 2 feet horizontally of the machine. 2. Drop the hose at the rear of the machine into the water container (The hose should extend to approximately 1” from the bottom of the water container.) Page 4 Crathco® Powdered Beverage Dispensers Installation (cont.) Start-Up Procedures for Pump Units (PIC 2P & PIC 3P only) (cont.) NOTE: Do not let the end of the hose touch the bottom of the container. Shorten the hose if necessary. If you need a longer hose, remove the back access panel, unclamp existing hose, replace with longer hose and replace clamp. 3. Proceed with fifth step under Start Up for Standard Units. How to Dispense a Cup of Cappuccino On models with manual dispense switches (Refer to serial tag to verify model number of your machine) 1. Place cup under the selected drink dispense nozzle. 2. Push and hold the appropriate switch on the touchpad until cup is 2/3 full and then release switch. On models with portion control (single portion or 3 portion per head): (optional on PIC 2, 3, & 4 only) 1. Place cup under the selected drink dispense nozzle. 2. Push appropriate switch on the touch pad, then release to dispense one preset serving. (see Portion Control Adjustment to set portion size) NOTE: Portion may be cancelled by push and release of the switch during dispensing. Cup must rest flat on tray with a 1/4” (6 mm) clearance between cup and spout. Contents can CAUTION: cause severe burns if handled improperly. Adjustments Portion Adjustment If machine is a manual dispense, there are no portion control adjustments to be made. (Please refer to serial tag to reference model number.) SETTING SINGLE PORTION CONTROL 1. Place a cup under the selected drink dispense nozzle. 2. Press and hold the dispense switch. 3. After a 10 second time delay, the machine is triggered into program mode and will begin dispensing. 4. Continue pressing the button until cup is approximately 2/3 full, then release the switch to prevent overfill. The elapsed portion dispense time is saved to memory and will remain until the dispense switch is reprogrammed. 5. Check the portion size by placing an empty cup under the desired dispense nozzle, then press and release the dispense switch. The machine will dispense the preprogrammed portion size. 6. If the portion size is incorrect, repeat above steps until the desired portion size is achieved. Each dispense switch needs to be set separately. SETTING THREE PORTION SIZES PER HEAD (optional on PIC 2/3/4 only) 1. Place a cup under the selected drink dispense nozzle. 2. Press and hold the size button on the touch pad that you wish to program or set. (Hold button throughout entire procedure.) 3. Press and release the manual (top-off) button. After releasing the manual (top-off) button, the 10-second delay is activated. 4. Continue pressing the size button until cup is approximately 2/3 full, then release the switch to prevent overfill. The elapsed portion dispense time is saved to memory and will remain until the dispense switch is reprogrammed. 5. Check the portion size by placing an empty cup under the desired dispense nozzle, then press and release the dispense switch. The machine will dispense the preprogrammed portion size. 6. If the portion size is incorrect, repeat above steps until the desired portion size is achieved. Each portion size for each head needs to be set separately. Crathco® Powdered Beverage Dispensers Page 5 Thermostat Adjustment NOTE: The thermostat range is approximately 160°F to 200°F. The tank temperature is factory set at 180°F, making the beverage temperature slightly lower than 180°F. 1. 2. 3. 4. 5. Unplug machine. Remove the drip tray. Remove the upper splash panel on the front of the machine by removing the four Phillips head screws. Locate the thermostat adjustment dial on the control board(s). To adjust the temperature of the water being dispensed, turn the adjustment dial on the large* control board. (Turn clockwise to increase the water temperature or counterclockwise to decrease the water temperature) NOTE: It will take time for the water tank temperature to reach its adjusted temperature setpoint. CAUTION: Do not force the adjustment dial beyond its 270° of rotation or damage to the control board may occur. *NOTE: PIC 4, 5, and 6 have a second controller. The temperature dial on the right hand board is not active on this board. PIC 1 and PIC 4 (Right Head) Control Board Drink Strength Adjustment (Refer to Figure A and B) Tools Required: #2 Phillips Screwdriver Warning: Risk of Electric Shock! Always turn off power to machine while servicing or making internal adjustments to machine. 1. Dispense a drink to determine if drink is too strong or too weak. 2. Turn off power to machine at power switch. 3. Remove upper front splash cover below dispense heads in front of machine. 4. Using a flat head screwdriver, adjust individual dispense heads by rotating appropriate Figure A Operates PIC and right head on PIC4. adjustment knob. Turn on power to machine and Thermostat dial on this board is not used on PIC4. dispense a drink to determine if drink strength is acceptable. If drink is not CONTROL BOARD FOR PIC2/3/4/5/6 acceptable, turn off power to machine and repeat adjustment steps until desired drink strength is achieved. Note: Clockwise rotation will result in a stronger drink and counterclockwise will result in a weaker drink. Note: Water flow rate is factory preset at approximately 0.80 ounces per second. 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Figure B One controller used for PIC2, PIC3. Remote Auger Jumper Position Page 6 On-Board Auger Jumper Position One (Fig A) controller and one (Fig B) controller used for PIC4. Two controllers used for PIC43, PIC5, PIC6. Thermostat dial is not used on PIC43, PIC5, PIC6 right controller. On Right Controller: Left dial operates #4 head, middle dial operates #5 head, and right dial operates #6 head. Crathco® Powdered Beverage Dispensers Drink Strength Adjustment for Model PIC3E or PIC33AE when equipped with remote adjust knobs behind drip tray (Refer to Figure C) 1. Dispense a drink to determine if drink is too strong or too weak. 2. Remove drip tray. 3. Using a flat head screwdriver, adjust individual dispense heads by rotating appropriate adjustment knob. Clockwise rotation will result in a stronger drink and counterclockwise rotation will result in a weaker drink. 4. Dispense a drink to determine if drink strength is acceptable, repeat adjustment steps until desired drink strength is achieved. NOTE: Water flow rate is factory preset at approximately 24mL (0.80 ounces) per second. Figure C Drink Strength Adjustment for Model PIC2J & PIC3J (Refer to Figure D) Tool required: #2 Flat Head screwdriver 1. Dispense a drink to determine if drink is too strong, weak or if portion size is correct. 2. Turn off power to machine at power switch. 3. Drink strength and portion size controls will be found behind the drain tray. (Refer to Figure D) For portion size adjustment, turn dial clockwise to increase dispense volume. To decrease volume turn dial counterclockwise. For drink strength adjustment turn dial clockwise to increase drink strength. To decrease strength turn dial counterclockwise. Turn on power to machine and PORTION SIZE ADJUSTMENT dispense a drink to determine if drink strength or TURN DIAL CLOCKWISE TO INCREASE DISPENSE VOLUME portion is acceptable. If drink strength or portion is COUNTERCLOCKWISE TO DECREASE DISPENSE not acceptable, turn off power to machine and VOLUME repeat adjustment steps until desired drink strength or portion is achieved. Note: Clockwise rotation will result in a stronger drink and DRINK STRENGTH ADJUSTMENT counterclockwise will result in a weaker drink. TURN DIAL CLOCKWISE TO INCREASE DRINK STRENGTH Note: Water flow rate is factory preset at approximately COUNTERCLOCKWISE TO DECREASE STRENGTH 0.80 ounces per second. Figure D * To adjust flow rate, remove left side upper panel. Use flat head screwdriver and turn knob on respective dump valve. WARNING: Do not adjust flow rate above the factory setting to prevent funnel overflow. Cleaning CAUTION: When cleaning the unit, do not use cleansers, liquid bleach, powders or any other substance that contains chlorine. These products promote corrosion of stainless steel and plastic parts. Use of these products will void the warranty. Water Inlet Fitting Mixing Funnel Shroud Water Inlet Pipe Funnel O-Ring DAILY 1. Empty the drip pan as needed and wash daily in a solution of dish detergent. 2. Rinse out the whipper chambers by placing the rinse switch (located on the right of the dispensing valves when the door is open) in the “ON” position. Dispense one to two cups until the water is clean. Short bursts of dispensing may also help clean the chambers more effectively. When completed, return the rinse switch to the “OFF” position. 3. Remove the hoppers and refill with product. Crathco® Powdered Beverage Dispensers Mixing Funnel Whipper Chamber Whipper Base Motor Shaft Whipper Base Seal Whipper O-Ring Whipper Blade Dispense Nozzle Figure E Page 7 WEEKLY Removing and Cleaning the Chambers 1. Open the door and remove the mixing funnel shroud by pulling forward while turning 1/4 turn to the right. Lift off and remove. 2. Remove the mixing funnel by lifting the neck of the funnel out of the whipper chamber, then tilt counterclockwise. With one hand on the water inlet fitting on the back panel, pull the funnel out of the white ring. 3. Remove the whipper chamber by rotating it 1/8 of a turn clockwise, then pull to remove. 4. Remove dispense nozzle from whipper chamber by pulling it apart. 5. Remove the whipper blade by grasping the whipper blade with two fingers and firmly pulling to remove. 6. Remove the o-ring on the whipper shaft near the whipper and wipe the motor shaft with a clean towel. 7. All parts in contact with food must be washed, rinsed, sanitized and air-dried. ! CAUTION: Do not wash parts in dishwasher. Dishwashers will cause damage to parts. To Reassemble 1. Replace the o-ring onto the whipper shaft. 2. Replace the whipper blade by aligning the flat side inside the blade with the flat side of the motor shaft. Push blade firmly onto shaft. 3. Press dispense nozzle into whipper chamber. 4. Replace the whipper chamber by positioning the medium sized opening up and tilting 1/8 of a turn clockwise. Put the whipper chamber over the whipper blade and turn counterclockwise until it locks into place. 5. Replace the mixing funnel by positioning the large opening up and tilting it slightly counterclockwise. Lubricate the o-ring on the water inlet pipe with a film of food grade lubricant. Insert the water inlet pipe into the water inlet fitting on the back panel, then rotate the funnel to the right until the neck of the funnel seats inside the whipper chamber opening. 6. Replace the shroud by placing it on the mixing funnel with the opening to the right. Turn the shroud to the left until the opening in the shroud rests inside the opening in the back panel. 7. If shroud doesn’t rest inside the opening on the front panel, push in or lift up on the funnel. Disassembling & Cleaning the Hoppers (PIC 1/2/3/5/6) IMPORTANT: Do not wash hopper without first disassembling. 1. Open the door and rotate the dispense elbow on the hopper to the “UP” position to prevent spillage. (Figure F) 2. Remove the hopper from the cabinet. 3. Remove the hopper cover and empty hopper contents. 4. Pull off the elbow. 5. Remove the auger pinwheel by pulling it forward while stretching out the sides of the hopper. (Figure G) 6. Remove the drivelink and washer at the rear of the hopper by holding the auger spring with one hand at the front of the hopper while turning the drivelink clockwise with the other hand. (Figure H) 7. Remove the auger spring and auger spring drive shaft by pulling them out through the lower front opening of the hopper. 8. Remove the palnut at the rear of the hopper by turning it counterclockwise, then remove the drive shaft bearing from the inside of the hopper. 9. All parts in contact with food must be washed, rinsed, sanitized and air-dried. Page 8 Figure F Figure G Figure H Crathco® Powdered Beverage Dispensers WEEKLY (cont.) Reassembling the Hoppers (PIC 1/2/3/5/6) (Refer to Figure I) IMPORTANT: All components must be completely dry prior to reassembly. 1. Place the drive shaft bearing inside the hopper with the threads going through the hole in the rear of the hopper. 2. Secure the bearing by attaching the palnut to the bearing at the outside rear hopper opening. Tighten using only your fingers. Use one hand inside the hopper to push the bearing outward while turning the palnut clockwise. 3. Install the auger spring drive shaft and the auger spring by inserting the flat end of the spring into the hole in the auger drive shaft. 4. Insert assembly into the lower front hopper opening, making sure the threaded end of the auger spring Figure I drive shaft completely inserts into the drive shaft bearing in the rear of the hopper. The drive shaft bearing threads should be accessible from the outside rear of the hopper. 5. Place the washer over the drive shaft bearing threads followed by securing the drivelink onto the drive shaft bearing by turning counterclockwise. Secure the auger spring with one hand while attaching the drivelink with the other. 6. Replace the auger pinwheel making sure the pins are securely positioned inside the locator holes in the hopper. 7. Replace the dispense elbow in the “UP” position. 8. Fill the hopper with product and replace the cover. 9. Reinstall the hopper into the machine; making sure it is properly positioned inside the notches under the hopper. 10. Turn the elbow down toward the mixing funnel, keeping it lined up over the funnel opening. Disassembling & Cleaning the Hoppers (PIC 4) IMPORTANT: Do not wash hopper without first disassembling. 1. Open the door and rotate the dispense elbow on the hopper to the “UP” position to prevent spillage. 2. Remove the hopper from the cabinet. 3. Remove the hopper cover and empty hopper contents. 4. Pull off the elbow. 5. Pull off hopper base. 6. Remove the auger pinwheel by pulling it forward while stretching out the sides of the hopper (thin hopper only). *See below for wide hopper. 7. Remove the coupling at the rear of the hopper by holding the auger spring with one hand at the front of the hopper while turning the coupling clockwise with the other hand. 8. Remove the auger with o-ring by pulling them out through the lower front opening of the hopper. 9. Remove the nuts at the front and rear of the hopper by turning counterclockwise, then remove the bearings from the inside of the hopper. 10. All parts in contact with food must be washed, rinsed, sanitized and air dried. * For wide hoppers: Remove wing nut and flat washer on outside of hopper and remove pinwheel assembly (gear with spring and pinwheel with 2 springs) Crathco® Powdered Beverage Dispensers Page 9 Weekly Cleaning (cont.) Reassembling the Hoppers (PIC 4) IMPORTANT: All components must be completely dry prior to reassembly. 1. Place the bearings inside the hopper in proper position. 2. Secure the bearings by attaching the nuts to the bearings at the outside rear hopper opening. Tighten using only your fingers. 3. Insert auger into the lower front hopper opening, making sure the threaded end of the auger spring drive shaft completely inserts into the rear bearing in the rear of the hopper. The auger threads should be accessible from the outside rear of the hopper. 4. Secure the coupling onto the auger by turning counterclockwise. Secure the auger with one hand while attaching the coupling with the other. 5. Replace the auger pinwheel making sure the pins are securely positioned inside the locator holes in the hopper (this hopper only). * See below for wide hopper. For either hopper, turn coupling and make sure pinwheel in properly installed and turns freely. 6. Replace the dispense elbow in the “UP” position. 7. Fill the hopper with product and replace the cover. 8. Reinstall the hopper into the machine; making sure it is properly aligned. 9. Turn the elbow down toward the mixing funnel, keeping it lined up over the funnel opening. * For wide hopper: Replace pinwheel assembly by inserting gear through the pinwheel and inserting threads through the hopper wall. Insert flat washer on outside and finger-tighten wing nut securely. Cleaning the Steam Plenum Tray (PIC 2/3/4/5/6 only) (Refer to Figure L) CAUTION: Do not pour liquid into tray. Failure to comply will damage the dispenser and void the warranty. 1. Rotate dispense elbows on the hoppers to the “up” position and remove hoppers from machine. 2. Remove cover plate inside machine cabinet, located below hoppers. 3. Using a damp towel, wipe powder build up from inside steam plenum tray. 4. Replace cover plate. 5. Replace hoppers and turn elbows down to the dispense position. Quarterly Cleaning Cleaning the Steam Recovery Plenum Tray WARNING: Risk of electric shock; Disconnect from power before servicing! 1. Remove the side access panel (Refer to figure K) 2. Disconnect the flexible vent tube attached to the Figure J recovery tray. 3. Remove the two screws which fasten the recovery tray to the sheetmetal enclosure and remove the recovery tray through the side access hole. 4. Remove the back access plate (refer to figure L). Disconnect and remove the flexible vent tube from the blower housing. Carefully remove the flexible vent tube from the machine's cabinet. 5. Wash, rinse, sanitize, and air dry the recovery tray and hose. Note: A long soft bristle brush or small cloth towel may be used to clean the internal passage of the flexible vent tube by pushing it through the tube. Rinse, sanitize and air dry the tube. 6. Reassemble the parts in reverse order. NOTE: PIC 5 and PIC 6 contain two ports on the plenum, three flexible tubes and a barbed tee. Page 10 Figure K Figure L Crathco® Powdered Beverage Dispensers PIC Preventative Maintenance Checklist (Every 6 to 12 months) A preventative maintenance visit should be performed every 6 to 12 months, depending on usage. The following procedures should be performed during a preventative maintenance visit. Parts Required: One PM parts kit (PIC1 - Qty1 - 62707, PIC2 - Qty2 - 62707 or Qty1 - 60933, PIC3 - Qty1 - 60933, PIC4 - Qty1 - 60933 and Qty1 - 62707, PIC5 - Qty2 - 60933, PIC6 - Qty2 - 60933). Tools Required: 11/32 nut driver, needle nose pliers, phillips head screwdriver, food grade lubricant. The following procedures should be performed by a qualified service technician. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. WARNING - Risk of electric shock and burns. Disconnect power before servicing. Use care in handling hot liquids. Document model and serial number of equipment above. Disconnect unit from power supply and turn power off. Then remove all access panels. Shut off the water supply valve to the machine. Open front door of unit and remove product hoppers. Clean hoppers following procedures on the decal on panel behind hoppers or as stated in instruction manual. Remove the plenum chamber access panel, if so equipped (located below hoppers on newer units). Wipe out exposed plenum. Locate the tank drain hose. It is located behind the bottom access panel. It is a white silicone tubing that has a 3/8” stainless steel barb plug and a black 5/8” hose clamp on it. PIC 1, 2, 3, and 4: Using a 5 gallon, heat resistant container, route the drain hose into the container. PIC 5 and 6 contain over 5 gallons of hot water and require a minimum 6 gallon heat resistant container. Remove the clamp, pinch the tube and remove the plug. Drain all of the water out of the tank into the container (about 3.5 gallons). Warning: the water from the tank is very hot (180°F plus). May cause burns and/or personal injury. Hot water may splash. Do not attempt to stop flow of hot water once it begins flowing through drain hose. Replace the drain hose plug and secure the clamp back onto the drain hose. Place the drain hose back inside the machine, to its original location. Carefully empty the drain bucket. Do not refill the unit at this time. Delime tank if needed. Remove the mixing funnel shroud and mixing funnel from each chamber. Remove and discard the o-ring on the mixing funnel. Set the shroud and funnel aside. Remove each whipper chamber and whipper blade. Check for wear and replace if necessary. Then remove and discard the small whipper shaft o-rings from each dispense head. Remove the two screws from each whipper base and save the screws. Discard the old whipper base and slinger washer, and replace with the new parts in the PM kit. Clean the whipper motor shaft and clean all dried product in this area under where the whipper base was located. Install the new slinger washer onto the whipper motor shaft, and up to hopper mounting bracket. Lubricate inside of whipper base with a food grade lubricant. Then install whipper base over the whipper motor shaft and check alignment of holes. If alignment is off, rotate base 180° to make sure holes line up. Hold base securely, and carefully tighten mounting screws. Check whipper motor shaft to ensure it can turn freely using fingers. If shaft is hard to turn, remove screws, rotate base 180°, and re-tighten. Install the new, red, small o-rings, along with the whipper blades, and whipper chambers. Clean the funnel shrouds and funnels. Install each new funnel o-ring and lubricate. Then install funnel and shroud. When complete, put the plenum chamber access panel back in place, if so equipped. Remove plenum through side access hole and remove the plenum hose(s) from the blower to the plenum chamber. Clean the plenum and either clean or replace the hose(s) (part# 61123, not in kit). Re-install clean parts. Remove the dump valves located behind side access panels, by loosening the dump valve bracket nuts with the 11/32 nut driver and lifting bracket up. Then pull dump valve from grommet and then remove the grommets from the tank with needle nose pliers and discard. Then remove the o-rings from the dump valves and discard. Replace with new tank grommets and new o-rings for each valve. Re-install the dump valves and secure back onto the tank. Tighten nuts on dump valve bracket. Locate power supply and verify proper electrical supply to unit. Find the water supply line. Turn on water supply, and verify adequate water flow. Turn power supply back on. Then turn main power switch to “on”. Verify water tank in unit is filling. After the tank is full, verify that the heating cycle has started. Allow unit to fill and shut off. Check around dump valves and any tubing for signs of water leaks. Replace all access panels and reinstall hoppers inside the unit. Verify nut on back of hopper is secure. Verify each dispense head is operating properly and that the settings are correct. Adjust if necessary. Check for proper product temperature and check mix ration for proper setting, and adjust if necessary. Review proper care, cleaning and maintenance procedures with store personnel. Crathco® Powdered Beverage Dispensers Page 11 Service Changing the Lightbulb on Models With a Backlit Merchandiser (PIC 1/2/3/4/5/6) (Refer to Figure M) (Refer to serial tag to verify model number of your machine) Disconnect machine from branch electrical supply before changing WARNING: the lightbulb. NOTE: PIC2/3/4 uses a F8T5 12" 8 watt replacement bulb. PIC5/6 uses a 22W circular bulb. 1. All: Remove the front merchandiser photo and cover by grasping the edges of the merchandiser. 2. PIC1: Lift bulb out of socket vertically. PIC 2/3/4: Remove the old lightbulb by gently turning the lightbulb 1/4 turn to the left and pulling the bulb from the socket. PIC5/6: Disconnect cable from bulb and pull bulb from holder. 3. PIC2/3/4: Install the new bulb by lining up the pins on either end of the bulb parallel with the socket opening. 4. PIC2/3/4: Gently insert both ends of the bulb into the socket and turn the bulb 1/4 turn to the right until the bulb locks into place. 5. All: Replace the merchandiser photo and cover. Figure M To Prepare for Shipment Important: Always completely empty water tank and POWDER HOPPERS prior to shipping unit. (See draining the tank and cleaning the hoppers sections) NEVER SHIP UNIT WITH POWDER IN HOPPER - THIS WILL CAUSE IRREPARABLE DAMAGE. Draining the Tank (PIC 2/3/4 ) Always empty the tank before shipping. NOTE: PIC 1 contains 2 gallons of hot water. PIC 2, PIC 3 and PIC 4 contain 3-1/2 gallons of hot water. PIC 5 and PIC 6 contain 5-1/2 gallons of hot water. Draining of tank should be performed by a qualified service technician. The tank contains WARNING: very hot water. May cause severe burns. 1. 2. 3. 4. Prepare a heat resistant container to drain the tank water into. Unplug the machine. Remove the drain tray and front access panel. (Figure N) Locate the silicone drain hose on the left side wall. Put the end of the drain hose into the container. Secure the end of the drain hose (i.e. with tape) into the container. (Figure O) 5. Remove the hose clamp and plug. (Figure P) 6. Allow the tank to drain completely. NOTE: It may be necessary to pinch the hose and stop the water before container is full. Carefully re-install plug, then empty container. Repeat steps 4-6 to completely drain tank. Figure N Page 12 Figure O Figure P Crathco® Powdered Beverage Dispensers Draining the Tank (PIC 2/3/4 ) (cont.) 7. Once the tank is empty, securely replace the plug and clamp on the end of the hose. Reposition the drain hose inside the hose clip on the left side wall. 8. Reassemble the front access panel and drain tray. Purging Machine of All Water for Shipment in Cold Areas WARNING: This procedure should be performed by a qualified service technician. 1. Turn the power switch to the "OFF" position. 2. Drain the water tank (refer to instructions on page 12). Do not replace the drain hose plug and clamp until further instructed. 3. Turn the power switch to the "ON" position. The ready light should turn itself "ON" within 12 seconds. The 12 second delay signals that the heating element has been disabled due to the lack of water in the tank after it is drained. IMPORTANT: If the ready light does not turn itself "ON" within 12 seconds, turn the power "OFF" to avoid burning out the heating element. 4. Listen for the inlet valve to energize. To purge the inlet valve and water inlet tube, apply 10-20 psi compressed air to the inlet valve connection for 10 to 20 seconds while the inlet valve is energized. NOTE: Do not energize the inlet valve for more than 5 minutes at a time. Otherwise, the watchdog timer will disable the inlet valve. If this occurs, reset the machine by flipping the power switch “OFF” then “ON”. 5. After the inlet valve and water inlet tube are purged, purge the dump valves and dispense lines. While applying 10-20 psi compressed air to the inlet valve connection, press and hold each dispense button for 1-2 seconds. 6. Turn the power switch to the “OFF” position. Replace the drain hose plug and clamp. Reposition the drain hose inside the hose clip on the left side wall. 7. Reassemble the front access panel and drain tray. Replacing Whipper Motors on Machines Manufactured Prior to Fall 1998: 1. Left motor may be changed with 61116-01 (round motor) if you install a single pole switch (part # 61847) in place of the existing power switch. 2. Middle motor may be changed with 61116-01 directly. 3. Right motor can only be changed with 61116R (Oval (double-D) shaped motor). Replacing Whipper Motors on Machines Manufactured After Fall 1998: 1. Place motor in mounting location, install lock washers and loosely tighten acorn nuts on motor mounting studs. Hold motor while shaft is centered inside hole then tighten nuts securely. 2. Install white slinger washer over the motor shaft and up to hopper mounting bracket. 3. Lubricate inside of whipper base then install over the motor shaft and check alignment of holes. If alignment is off, rotate base 180° to make sure holes line up. Hold base securely, and carefully tighten mounting screws. 4. Check the motor shaft to ensure it can turn freely with fingers. If shaft is still hard to turn, reposition motor and repeat. 120V Whipper Motor Replacement Kit # 62528 230V Whipper Motor Replacement Kit # 62530 Quantity Part # Description Quantity Part # Description 1 61523 Whipper Base Assembly 1 61523 Whipper Base Assembly 1 61116-01 or 61867 62529 Motor, Whipper, 120V Instruction Sheet 1 61117-01 1 62529 Motor, Whipper, 230V Instruction Sheet 1 Crathco® Powdered Beverage Dispensers Page 13 Removal of Whipper Motor(s): 1. 2. 3. 4. 5. 6. 7. Disconnect power. Remove front and side access panels. Remove chamber. Remove whipper base. (Figure Q) Remove motor nuts and pull motor out of slot. (Figure R, S) Disconnect wire connection. (Figure T) Replace motor as needed. Figure Q Figure R Figure S Figure T Replacing Dump Valves, Dump Valve O-rings, and/or Tank Grommets 1. Remove the dump valves located behind side access panels, by loosening the dump valve bracket nuts with 11/32 nut driver and lifting bracket up. (Figure U, V) 2. Pull dump valve from grommet and then remove the grommets from the tank with needle nose pliers and discard. (Figure W) 3. Remove the o-rings from the dump valves and discard. Replace with new tank grommets and new o-rings for each valve. (Figure X) 4. Re-install the dump valves and secure back onto the tank. 5. Tighten nuts on dump valve bracket. Figure U Figure V Figure W Figure X Replacing Water Tank on Machines with Serial # 339304 and Lower: (Refer to Figures Y, Z, AA) 1. Switch off and unplug unit, disconnect from water supply, and drain tank completely. 2. Remove top of cabinet, left side and rear access panels. 3. Disconnect tank ground, heating element, thermal probe, water probe and hi-level thermostat wires and vent tubing in top of unit. Page 14 Crathco® Powdered Beverage Dispensers Replacing Water Tank on Machines with Serial # 339304 and Lower: (cont.) 4. Disconnect dump valve wiring and tubing in left access opening and remove valves. 5. Disconnect tank fill tubing from inlet valve in rear of unit. 6. Remove screws holding water tank and mounting bracket. Remove tank, bracket and old tubing (NOTE: Do not discard dump valve tubing). 7. Remove heating element, thermal probe, water probe, vent fittings, and valve retaining clip from old tank. Examine to determine if these items need to be replaced. Remove and discard old hi-level thermostat and mounting bracket. Figure Y 8. Drill holes in cabinet per sketch below and deburr. (Figure Y) 9. Install (3) #8-32 x 3/8" machine screws (07026-07) in new holes in sides of casing. Lower new tank retaining bracket (61845) from the top of the unit until it rests on the machine screws. Add locknuts (71261) and tighten. NOTE: Instructions above are for units with a stainless steel casing, for units with a black powder coat casing, use black screws (61303). 10. Install new dump-valve grommets (61243) and plugs (61229) (for PIC2 only) in side of new tank (61841). 11. Install new probe grommets (71147), heating element with new hi-level thermostat (62305), mounting bracket (62238) and (2) #8-32 x ¼" SS screws (61353), thermal probe, water probe, and vent fittings in new tank cover (61842) as shown in sketch below. Figure Z 12. Place tank gasket (61844) over top of new tank (61841), aligning holes with studs, and lower new tank cover (61842) over studs. Bolt tightly with (10) #8-32 locknuts (71261). 13. Lower tank onto retaining bracket, feeding fill fitting in tank bottom through the hole in the bracket. Bolt tank to the back of casing with (2) lock washers (61186) and (2) #8-32 x 3/8" machine screws (07026-07) for stainless casings, or #8-32 x 3/8" black screws for black powder coat units. 14. Install new o-rings (61365) on dump valves and insert them into side of tank from the access panel in the side of the casing. Secure with valve retaining clip, reconnect all wires and dump valve tubing. 15. Measure and cut new 29" vent tubing (05826), connect one end to the vent fitting in the top of tank and run the Figure AA other end down the side of the tank to the bottom of the unit. Reconnect all wires to tank ground, heating element, thermal probe, water probe, and hi-level thermostat. 16. Cut and install new tubing (05826) from inlet valve to tank fill fitting and drain per sketch. NOTE: Apply tank drain hose decal (61325) to drain hose after installing and feeding drain hose through hole in control mounting bracket in bottom of the unit. 17. Replace all panels and reconnect to water and electrical supply. Crathco® Powdered Beverage Dispensers Page 15 Removal of Water Tank on Machines with Serial # 339305UK and Higher: 1. 2. 3. 4. 5. 6. 7. 8. Disconnect power. Drain tank. (see page 12) Remove machine lid, rear access panel and dump valve access panel. (Figure BB) Disconnect wires from tank lid components and dump valves. (Figure CC) Disconnect hoses from dump valves. Remove mounting screws from rear of tank. (Figure DD) Disconnect drain hose from bottom of tank. (Figure EE) Lift out tank and replace as needed. (Figure FF) Figure BB Figure CC Figure DD Figure EE Figure FF Removal of Inlet Valve 1. 2. 3. 4. 5. 6. 7. 8. Disconnect power. Drain tank. (see page 12) Remove rear access panel. Disconnect black hose from fan. Remove two screws and lock nuts. (Figure GG) Remove valve. (Figure HH) Disconnect wire connection, hose clamp and hose. (Figure II) Replace valve as needed. Figure GG Page 16 Figure HH Figure II Crathco® Powdered Beverage Dispensers Removal of Thermistor 1. 2. 3. 4. 5. Disconnect power. Remove machine lid. (Figure JJ) Disconnect thermistor wires. (Figure KK) Lift out thermistor and replace as needed. (Figure LL) To replace with thermistor, add food grade lubricant. (Figure MM) Figure JJ Figure KK Figure LL Figure MM THERMISTOR CURVE °C °F RESISTANCE (OHMS) °C °F RESISTANCE (OHMS) 0 32 16325 60 140 1244 5 41 12697 65 149 1041 10 50 9951 70 158 875 15 59 7856 75 167 740 20 68 6246 80 176 628 25 77 5000 85 185 535 30 86 4028 90 194 458 35 95 3266 95 203 393 40 104 2663 100 212 339 45 113 2185 105 221 294 50 122 1802 110 230 255 55 131 1493 Crathco® Powdered Beverage Dispensers Page 17 Removal of Auger Motor(s) 1. 2. 3. 4. Disconnect power. Remove front and side access panels. Remove hoppers. Remove three screws and lock washers. (Figure NN) 5. Pull motor out of slot. (Figure OO) 6. Disconnect wire connection. 7. Replace motor as needed. Figure NN Figure OO Removal of Blower Motor 1. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect power. Drain tank. (see page 12) Remove rear access panel. Disconnect black hose from fan. Disconnect hose from inlet valve if needed. Remove two screws from side. Remove fan. (Figure PP) Disconnect wires. Replace motor as needed. Figure PP Removal of Controller 1. Disconnect power. 2. Remove front access panels. 3. Carefully remove connectors from controller. (Do not pull on wires.) 4. Carefully press black clips back and pull out controller. (Do not pull on controller components pull only on green board.) 5. Carefully remove controller. (Figure QQ) (Handle controller only on edges of green board.) 6. Replace controller as needed. Ballast p/n 61196 Transformer p/n 61481 Heater Relay p/n 61131 Controller Removal of Heater Relay 1. Disconnect power. 2. Remove front access panels. 3. Remove wires from relay. (Note locations of wires before removing.) 4. Remove screws and lift out relay. (Figure QQ) 5. Replace relay as needed. Figure QQ Removal of Transformer 1. 2. 3. 4. 5. Disconnect power. Remove front access panels. Remove wires from transformer. (Note locations of wires before removing.) Remove screws and lift out transformer. (Figure QQ) Replace transformer as needed. Page 18 Crathco® Powdered Beverage Dispensers Crathco® Powdered Beverage Dispensers Page 19 Troubleshooting Guide Only a qualified service technician should perform Electrical and mechanical adjustments or repairs. Always disconnect power before attempting any maintenance procedures. PROBLEM No powder dispensed into mixing funnel PROBABLE CAUSE • • • • Rinse switch turned to “RINSE ON” position Powder hopper dispense outlet clogged No or low powder level in hopper Hopper drivelink not engaged with motor • Hopper elbow is not directed into the mixing funnel Machine will not dispense any product (water or powder) Product not whipping • Power turned “OFF” to machine CORRECTIVE ACTION • • • • Flip rinse switch to “RINSE OFF” position Refer to Cleaning of Hoppers section Refill hopper Remove and reinstall hopper and ensure engagement with motor • Turn down dispense elbow; line it up with mixing funnel • Faulty transformer • Faulty control board • Ensure power switch is in “ON” position, machine is plugged in and water is turned on • Reset machine by flipping power switch “OFF” then “ON” once (the maximum run time per head is limited to 40 seconds before watchdog timer disables the dispense heads) • Contact factory for assistance • Contact factory for assistance • Whipper blade broken or missing • Verify blade is in place. Replace if broken or missing • Dispense cycle watchdog timer has tripped Water overflows mixing • Water flow too fast funnel • Whipper chamber outlet restricted • Whipper blade broken or missing • Contact factory for assistance Dump valves to be adjusted • Remove obstruction • Verify blade is in place. Replace if broken or missing Drink is too weak or strong Refer to Drink Strength Adjustment section (page 6) Drink is too hot or cold Refer to Thermostat Adjustment section (page 6) No hot water from dispense head • Thermostat not adjusted • Faulty heater relay • Dump tube from water tank is kinked • Water shorting out probe connections • Refer to Controller Diagnostics section (page 20) • Ensure that water supply to machine is “ON” and reset power to machine • See Thermostat Adjustment section (page 6) • Replace heater relay (page 18) • Check tubing for obstructions • Dry connections on tank Water tank boils water • Check for flashing lights on controller • Thermostat adjustment set too high • Faulty heater relay • Refer to Controller Diagnostics section (page 20) • Refer to Thermostat Adjustment section (page 6) • Replace heater relay (page 18) No water dispensed from dispense nozzle • Water supply to machine turned “OFF” • Check for flashing lights on controller • Faulty dump valve • Turn “ON” water supply to machine • Refer to Controller Diagnostics section (page 20) • Replace dump valve (page 14) Water overflows from water tank • • • • • • • • Machine inadvertently dispenses from dispense heads • Wet wiring connections on harness or controller • Allow connections to dry Drink is cold and ready light is on • Check for flashing lights on controller • Refer to Controller Diagnostics section (page 20) Page 20 • Check for flashing lights on controller • Water level in tank is below water probe Leaky inlet water valve Faulty level probe connection Faulty level probe due to mineral build-up Inlet water pressure too high (greater than 120 psi) Replace inlet water valve Check level probe connections Replace probe Install pressure regulator to water inlet Crathco® Powdered Beverage Dispensers Troubleshooting Guide (cont.) Only a qualified service technician should perform Electrical and mechanical adjustments or repairs. Always disconnect power before attempting any maintenance procedures. Diagnostics for all PIC2, PIC3, PIC4, PIC5, and PIC6’s: WTR FAIL = Light flashes when watchdog timer disables machine after 300 seconds of continuous inlet valve operation. THERM FAIL = Light flashes when thermistor fails or thermistor is disconnected. WTR HEATER = Light flashes when heater is on. POWER OK = Light stays on when transformer is supplying proper voltage to controller. FRONT VIEW OF CONTROL BOARD (BEHIND FRONT ACCESS PLATE) If WTR FAIL light is flashing: Ensure water supply to machine is turned “on”. Reset machine power “off” then “on”. If THERM FAIL light is flashing: Reset machine power “OFF” then “ON”. If green ready light does not turn off after 10 seconds then: Check thermistor connections. If connected properly, replace faulty thermistor. (Mineral build-up may be the cause.) WTR HEATER light will flash on and off when the water tank is being heated: Note: When green “ready” light on front of machine is “Off” WATER HEATER light should flash. If light works properly and machine is not heating, replace faulty heater. (Mineral build-up may be the cause.) If POWER OK light is off: Make sure power switch is on and machine is plugged in. If switch is on, and light is off, call factory for assistance. Note: PIC 4/5/6 - If water gets cut off to machine for 5 minutes during operation, tank water will not replenish, heater circuit will be disabled, and heads #1-3 will be disabled. Other heads will still operate. Left controller will read “WATER FAIL”. What could happen is that other heads will dispense low or no water (possibly cold) and full amounts of powder. Note: PIC 4/5/6 - “Thermistor Fail” - When the thermistor reads out of range or is disconnected, the machine shuts down the dispensing and heating. Only heads #1-3 are disabled, other heads can still operate. This can cause cold drinks to be dispensed out of the right head(s). If you still need help, call our service department at (800) 695-4500 (USA and Canada only) or (502) 425-4776 (Monday through Friday, 8 am - 6 pm EST) or an authorized service center in your area. Please have the model and serial numbers ready so that accurate information may be given. Prior authorization must be obtained from Grindmaster Corporation’s Technical Services Department for all warranty claims. Crathco® Powdered Beverage Dispensers Page 21 PIC 1 Chassis Parts (units with serial numbers beginning with “L”) 63493 Page 22 63493 63493 Crathco® Powdered Beverage Dispensers PIC 1 Hopper Bracket (units with serial numbers beginning with “L”) Crathco® Powdered Beverage Dispensers Page 23 PIC 1 Door Assembly (units with serial numbers beginning with “L”) Page 24 Crathco® Powdered Beverage Dispensers PIC 1 Tank Assembly (units with serial numbers beginning with “L” or “T”) ( * ) ( *** ) (*) = 71610 REPAIR KIT FOR DUMP VALVE (***) = 61365 DUMP VALVE O-RING Crathco® Powdered Beverage Dispensers Page 25 PIC 1 Chassis Parts (units with serial numbers beginning with “T”) 63493 Page 26 63493 63493 Crathco® Powdered Beverage Dispensers PIC 1 Hopper Bracket (units with serial numbers beginning with “T”) $2!7).'Ĥ' %80,/$%$Ĥ6)%7Ĥ (/4 $ #/, 0!24Ĥ.5-"%23 6/,4% 6/,4* 6/,41 6/,4Ĥ* ./4% ./ 6/,4 .! .! .! .! .! .! .! .! .! $%3#2)04)/. 37)4#(Ĥ30$4Ĥ4/'',% ,!"%,Ĥ(/4Ĥ/2Ĥ#/,$ (!2.%33Ĥ!-"Ĥ4%-0 /04)/.!,Ĥ!-")%.4Ĥ4%-0%2!452% 3% 2). & /& !$ 2% /. 0/ 7% 9 /. 2 /. & /& 6 * !$ ,)' 0/ 7% 9 (4 2 /. /. /& & /. & /& 0!24Ĥ.5-"%23 6 6 1 * 0!24Ĥ.5-"%23 6 % 2% ./4% ./ 6/,4 $%3#2)04)/. ./4% ./ "2!#+%4Ĥ(/00%2Ĥ-/5.4 #(!-"%2Ĥ7()00%2 ",!$%Ĥ7()00%2Ĥ&/52 7!3(%2Ĥ3,).'%2 3%!,Ĥ,)0ĤĤ)$ĤXĤĤ/$ "!3%Ĥ7()00%2Ĥ3%,&,/#!4).' 0,%.5-Ĥ34%!-Ĥ2%#/6%29 45").'ĤĤĤ)$Ĥ&,%8)",% /2).'ĤĤ)$ĤXĤĤ/$ &5..%, %,"/7Ĥ(/00%2 &)44).'Ĥ&5..,Ĥ15)+Ĥ#.#4 30!#%2 3(2/5$Ĥ34%!-Ĥ2%#/6%29 (/00%2Ĥ!33%-",9Ĥ/&Ĥ," (/00%2Ĥ!33%-",9Ĥ/&Ĥ," -/4/2Ĥ6$#Ĥ!5'%2 37)4#(Ĥ4/'',%Ĥ!Ĥ$034 -/4/2Ĥ7()00%2 ,!-0Ĥ'2%%. ,!-0Ĥ2%$ !')4!4/2Ĥ,/7%2Ĥ0).7(%%, !')4!4/2Ĥ500%2Ĥ0).7(%%, $%#!,Ĥ0/7%2Ĥ/./&& $%#!,Ĥ2).3%Ĥ/./&& $%#!,Ĥ0/7%2Ĥ/.Ĥ Crathco® Powdered Beverage Dispensers 6/,4 6 % 6 * .! .! 6 1 .! 6 * .! $%3#2)04)/. $%#!,Ĥ2%!$9 (/00%2ĤLB (/00%2ĤLB !5'%2Ĥ34!.$!2$ ,).+Ĥ!5'%2Ĥ$2)6% $2)6%3(!&4Ĥ!5'%2Ĥ302).' #/6%2ĤLBĤ(/00%2 302).'Ĥ,72Ĥ0).7(,Ĥ!')42 302).'Ĥ502Ĥ0).7(,Ĥ!')42 "544/.Ĥ2%342)#4/2Ĥ!.',%$ 30/54Ĥ03$Ĥ,/.'%2 "%!2).'Ĥ$2)6%3(!&4 0!,.54ĤĤ5.# 7!3(%2Ĥ&,!4ĤĤ3!%Ĥ33 (!2.%33Ĥ(/00%2Ĥ"2!#+%4 0,5'Ĥ!-")%.4Ĥ37)4#(Ĥ(/,% "%!2).'ĤĤ)$ĤXĤĤ/$ 45").'ĤĤ)$ĤĤ7!,, #/6%2ĤLBĤ(/00%2 #,!-0ĤĤ)$Ĥ(/3% 3%!,Ĥ#,/3%$Ĥ#%,,Ĥ&/!3%!,Ĥ(/00%2Ĥ"+4 342!).Ĥ2%,)%&Ĥ(%9#/Ĥ 3#2%7ĤĤ+.52, /2).'ĤĤXĤ 37)4#(Ĥ3034Ĥ2).3% Page 27 PIC 1 Door Assembly (units with serial numbers beginning with “T”) 63097 Page 28 63097 63097 Crathco® Powdered Beverage Dispensers PIC 2/3 Chassis Parts Crathco® Powdered Beverage Dispensers Page 29 PIC 2/3 Hopper Bracket Page 30 Crathco® Powdered Beverage Dispensers PIC 2/3 Tank Assembly Crathco® Powdered Beverage Dispensers Page 31 PIC 2/3 Door Assembly Page 32 Crathco® Powdered Beverage Dispensers PIC 4 Chassis Parts 63493 Crathco® Powdered Beverage Dispensers Page 33 PIC 4 Control Bracket Assembly Lid Page 34 Base Crathco® Powdered Beverage Dispensers PIC43A Control Bracket Assembly Crathco® Powdered Beverage Dispensers Page 35 PIC 4 Hopper Bracket Funnel Whipper Shroud Page 36 Crathco® Powdered Beverage Dispensers PIC 4 Hopper 62639 Hopper Assy 5.5# PIC4 (use for sugar-based powders) 62640 Hopper Assy 11# PIC4 (use for sugar-based powders) PE 32 63078 Hopper Assy 5.5# PIC4 SOL (use for soluble coffee) Crathco® Powdered Beverage Dispensers Page 37 PIC 4 Tank Assembly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age 38 ,7(012 3$5712 '(6&5,37,21 &ODPS+RVH,'+H\FR 3OXJ%DUE 7XELQJ,'[:/6LOLFRQH 7XELQJ,'[:/6LOLFRQH 0DUNHWLQJVKHHWUHY% 7XELQJ,'[:/6LOLFRQH (&1-5( 'HFDO7DQN'UDLQ+RVH Crathco® Powdered Beverage Dispensers PIC 4 Door Assembly Crathco® Powdered Beverage Dispensers Page 39 PIC 4 Final Assembly Page 40 Crathco® Powdered Beverage Dispensers PIC 5 Casing Assembly (Part # 62813) 63493 PIC 5 Base Assembly (Part # 62819) Crathco® Powdered Beverage Dispensers Page 41 PIC 5 Control Bracket Assembly (Part # 62974) 2 PIC 5 Lid Assembly (Part # 62810) 1 11 4 6 4 1 3 5 3 12 5 3 2 ITEM NO. PART NO. DESCRIPTION 1 62849 Bracket, Control Mtg PIC5 No Display 2 61338 Terminal Board 3 61800 Controller,Pic 3 Portion 4 61131 Relay,12 vdc Coil 5 61481 Transformer,40VA 24/12S 6 61266 STANDOFF, RVRS EDGEMOUNT 7 10073 Label, Ground Symbol 8 60394 Bushing,Snap-7/8"OD x 3/4" ITEM NO. PART NO. DESCRIPTION 1 62811 Panel, Lid, 2 61303 Screw, #8 x 3/8 black trilobe 3 61217 Spring, Hopper Retaining 4 62812 Flashing Top PIC5 5 86877 SCRW, #8X1/2 PH TR HD T/AB ZNC 9 61303 Screw, #8 x 3/8 black trilobe 10 61272 SCRW, #8X3/8 PH PN T/B ZNC/GN 11 62890 Harness, Chassis PIC5/6 12 62928 DECAL, CONTROLLER PIC5/6 23 7 3 1 8 13 PIC 5 Door Assembly (Part # 63060) 10 6 11 12 22 Door Assembly 63060 - PIC5 63484 - PIC5W ITEM NO. PART NO. DESCRIPTION 14 20 21 PLUG HOLE WITH #71138 IF NO HOT WATER 2 ITEM NO. PART NO. DESCRIPTION 1 63482 Door Plastic PIC5W w hole 13 63061 2 62915 Switch, Dispns PIC5/6 No Wafer 14 61327 Decal, Light Replace 3 62884 Door Brkt Wldmt, 15 71129 NUT, 8-32 KEPS SS 4 62904 Cover,PIC5 Graphic 16 60394 Bushing,Snap-7/8"OD x 3/4" 5 62905 Graphic,PIC5 17 61272 SCRW, #8X3/8 PH PN T/B ZNC/GN 6 62856 Decal, 2/3 Full PIC5/6 18 61187 Washer, #8 Star Lock 7 62847 Panel, Dispense Switch Cvr, 19 70635 TERMINAL, 1/4-032 X 45DEG TAB 8 61479 STRAIN RELIEF,HEYCO 20 63479 Switch Hot Water PIC5W 9 61303 Screw, #8 x 3/8 black trilobe 21 63481 Label "Hot Water" PIC5W 10 62889 Harness, Door PIC5/6 22 63480 Harness PIC5W Jumper 11 62937 Fixture,Circle Fluor w Lamp 22W 23 61451 Decal, Door Inner PIC 12 62973 Bulb Circle 22W Page 42 Bracket, Circle Lamp PIC5 manual -2.drw ECN2075, MJB, 5/25/06 Crathco® Powdered Beverage Dispensers PIC 5 Hopper Bracket Assembly (Part # 62850) 25 23 62850 - Hopper Brkt Asy PIC5 33 26 8 40 7 41 37 39 6 36 1 10 15 4 24 34 9 11 5 38 14 27 35 2 12 20 3 13 31 30 29 28 32 21 22 3 16 17 18 16 19 ITEM NO. PART NO. DESCRIPTION ITEM NO. PART NO. DESCRIPTION 1 62851 Bracket, Hopper PIC5 23 60381 Rivnut, 6-32 ALS4-632-80 2 61461 Button, Restrictor 24 61250 Washer, #8 Split Lock 3 61847 Switch,Toggle-Spst 25 61159-19-5 Seal, Closed Cell Foam 16.5" 4 61226 Funnel, Disconnect Funnel Whipper 26 61848 Decal, Do Not Pour 27 62825 Plenum, Steam PIC5 6 61255 SHROUD 28 71155-15-b Tubing, Silicone 5/16x1/2 7 62823 Plate, Cover Plenum, 29 71155-16-a Tubing, Silicone 5/16x1/2 8 61116-01-1 Motor, Whipper 120V 30 71155-16-b Tubing, Silicone, 5/16x1/2 9 61334 Washer, Slinger 31 71155-16-c Tubing, Silicone 5/16x1/2 Whipper Base Assy 32 71155-15-a Tubing, Silicone 5/16x1/2 11 60741 O-Ring,2-014 33 61618 Motor,24VDC,Auger,145 RPM 12 07023-04 Screw,6-32x1/4 PH BD M/S SS 34 61458 Blade, Whipper 13 61339 8-32 UNF S.S. ACORN NUT 35 61480 STRAIN RELIEF,HEYCO 14 62395 Chamber, Whipper 36 61353 Screw,8-32 X 1/4" PH PN 18-8 SS 15 61127 O-RING,.335 ID X .079 CS 37 61236 SCRW, 10-32X1/2 PH TR SS 16 61847-1 Nut, Switch, for 61847 38 63068 NUT, 10-32 ESNA SS 17 61242 Label, Flush On/Off 39 61228 Spacer, NYL HEY #334 SPU98 18 61247 Label, Power On Light PIC 40 86877 SCRW, #8X1/2 PH TR HD T/AB ZNC 19 61248 Label, Ready Light PIC 41 62891 Harness, Hopper Brkt PIC5/6 20 61889 Label, PWR ON/OFF PIC 43 61264 Plug, 3/16" Hole 21 63496 Lamp Red w/ Leads 22 63495 Lamp Green w/ Leads 5 61221 10 61523 Crathco® Powdered Beverage Dispensers Page 43 Page 44 Crathco® Powdered Beverage Dispensers PIC 5 Final Assembly 6 11 PIC5 - FINAL ASSEMBLY 28 40 1 28 9 25 22 5 14 24 17 7 20 18 13 30 23 3 21 34 10 19 40 35 28 2 16 31 15 16 8 4 39 16 12 ITEM NO. PART NO. DESCRIPTION ITEM NO. PART NO. DESCRIPTION 1 62813 Casing Assy,PIC 22 61237 Fitting,Assy,1/4 fL X 3/4 Hs, Brs 2 62819 Base Assy PIC6 23 61438 Panel,Steam Plenum-Black *IH* 3 63485 Hopper Brkt Asy PIC5 24 61423 Panel, Side Access DV 4 63060 Door Asy PIC5 25 61141 Plate,Back Access 5 62858 Tank Final Assy 26 61305 Screw, 8-32 x 5/8 black 6 62810 Lid Assy PIC6 27 71129 NUT, 8-32 KEPS SS 7 62830 Bracket, Tank Retaining, 28 61303 Screw, #8 x 3/8 black trilobe 8 62832 Splash Panel Plastic PIC 29 61304 Screw,6-32 x 1/2 PPH,SS 9 62974 Control Brkt Assy PIC6 30 60080 Clamp,5/8"Nylon **SC** 10 62831 Splash Panel, 31 62914 Button, Swch PIC5/6 w/ Art 11 62802 Blower Assembly 120V 32 61440 CAP, #8 SCREW SOFT 12 62833 Tray, Drain PIC5 33 61834 Decal, FLVR Strip PIC 13 62836 Tubing Asy,Drain,PIC5 34 100268 Decal,Caution,Behind Drip Tray 14 61372 Hopper Asy PIC Single Pinw 35 62981 Decal, Front Warning PIC 15 62921 Grid Drain PIC5 36 61146 Instr, Manual PIC Domestic 16 71256 Leg, 4" Plastic 37 00800 Label,Serial Number,Name Plate 17 71160 Clip,Syphon Hose w/Blk Adhsv 38 61463 Tag, Instalation 18 62835 Tee, 1.25" 39 62929 Decal, Cup PIC5/6 19 62845-2 TUBING, 1-1/4X14 LONG FLEX 40 62992 Mural Assy Side PIC5-6 20 62845-1 TUBING, 1-1/4X14 LONG FLEX 21 62845-3 TUBING, 1-1/4X14 LONG FLEX Crathco® Powdered Beverage Dispensers PIC5 manual -5 rev. C ECN2075, MJB, 5/25/06 Page 45 PIC 6 Casing Assembly (Part # 62872) 63493 PIC 6 Base Assembly (Part # 62876) Page 46 PIC 6 Lid Assembly (Part # 62874) Crathco® Powdered Beverage Dispensers PIC 5/6 Control Bracket Assembly (Part # 62848) 62848 - Control Bracket Assy PIC6 ITEM NO. 11 2 6 7 4 4 PART NO. DESCRIPTION 1 62849 Bracket, Control Mtg PIC5 No Display 2 61338 Terminal Board 3 61800 Controller,Pic 3 Portion 4 61131 Relay,12 vdc Coil 5 61481 Transformer,40VA 24/12S 6 61266 STANDOFF, RVRS EDGEMOUNT 7 10073 Label, Ground Symbol 8 60394 Bushing,Snap-7/8"OD x 3/4" 9 61303 10 61272 1 5 Screw, #8 x 3/8 black trilobe SCRW, #8X3/8 PH PN T/B ZNC/GN 11 62890 Harness, Chassis PIC5/6 12 62928 DECAL, CONTROLLER PIC5/6 12 3 3 3 PIC 6 Door Assembly (Part # 62875) 7 2 19 1 10 11 15 4 8 9 PIC6 Manual-2 rev. REL MJB, 1/14/04 ECN1888 Crathco® Powdered Beverage Dispensers 62875 - Door Assembly PIC6 ITEM NO. PART NO. DESCRIPTION CONFIG DESCR 1 62888 Door Brkt Wldmt, PIC 6 2 62916 Panel, Rear Door Cvr, PIC6 3 61479 STRAIN RELIEF,HEYCO 4 62915 Switch, Dispns PIC5/6 No Wafer 5 61303 Screw, #8 x 3/8 black trilobe 6 62910 Merchandiser PIC6 Plastic 7 62889 Harness, Door PIC5/6 8 62919 Graphic PIC6 9 62920 Graphic PIC6 10 62973 Bulb Circle 22W 11 62936 Bracket, Circle Lamp 12 61272 SCRW, #8X3/8 PH PN T/B ZNC/GN 13 61187 Washer, #8 Star Lock 14 70635 TERMINAL, 1/4-032 X 45DEG TAB 15 62856 Decal, 2/3 Full PIC5/6 16 60394 Bushing,Snap-7/8"OD x 3/4" 17 71129 NUT, 8-32 KEPS SS 18 70426 TERM, 1/4F INS QD 18-22 GA 19 62937 Fixture,Circle Fluor w Lamp 22W 20 61327 Decal, Light Replace Cover PIC6 Page 47 PIC 6 Hopper Bracket Assembly (Part # 62863) 26 1 31 30 7 29 35 34 36 6 37 8 9 4 32 5 10 13 25 11 15 3 28 14 2 22 33 20 21 3 19 18 Page 48 ITEM NO. PART NO. 1 62864 2 3 DESCRIPTION 17 62863, Hopper Brkt Assy PIC6 PIC6 Manual-3.drw ITEM NO. PART NO. Bracket, Hopper PIC6 24 61250 DESCRIPTION 61461 Button, Restrictor 25 62891 Harness, Hopper Brkt PIC5/6 61847 Switch,Toggle-Spst 26 61159-23.5 Seal, Closed Cell Foam 16.5" 4 61226 61848 Decal, Do Not Pour 61221 FTG, FUNNEL DISCONNECT Funnel Whipper 27 5 28 62865 Plenum, Steam PIC6 6 61255 SHROUD 29 71155-16-PIC6-2 Tubing, Silicone, 5/16x1/2 7 62879 Plate, Cover Plenum, 30 71155-16-PIC6-L Tubing, Silicone 5/16x1/2 8 61116-01-1 Motor, Whipper 120V 31 61618 MOTOR,24VDC, 145RPM 9 61334 Washer, Slinger 32 61458 Blade, Whipper 10 61523 Whipper Base Assy 33 61480 11 60741 O-Ring,2-014 34 71155-16-PIC6-3 Tubing, Silicone, 5/16x1/2 12 07023-04 Screw,6-32x1/4 PH BD M/S SS 35 71155-16-PIC6-4 Tubing, Silicone, 5/16x1/2 13 61339 8-32 UNF S.S. ACORN NUT 36 71155-16-PIC6-5 Tubing, Silicone, 5/16x1/2 14 62395 Chamber, Whipper 37 71155-16-PIC6-6 15 61127 O-RING,.335 ID X .079 CS 38 86877 16 61847-1 Nut, Switch, for 61847 39 61353 Screw,8-32 X 1/4" PH PN 18-8 SS 17 61242 Label, Flush On/Off 40 61228 Spacer, NYL HEY #334 SPU98 18 61247 Label, Power On Light PIC 41 61236 SCRW, 10-32X1/2 PH TR SS 19 61248 Label, Ready Light PIC 42 63068 NUT, 10-32 ESNA SS Washer, #8 Split Lock STRAIN RELIEF,HEYCO Tubing, Silicone, 5/16x1/2 SCRW, #8X3/8 PH PN T/B ZNC/GN 20 61889 Label, PWR ON/OFF PIC 43 61847-2 21 63496 Lamp Red w/ Leads 44 61452 Nut Round for Switch Decal, Cleaning Instr 5# HPR 22 63495 Lamp Green w/ Leads 45 61264 PLUG, 3/16 HOLE FAS 23 60381 Rivnut, 6-32 ALS4-632-80 Crathco® Powdered Beverage Dispensers PIC 6 Final Assembly 62917 62914 62981 62922 Drain Grid PIC6 62992 Crathco® Powdered Beverage Dispensers Page 49 PIC 1 120V and 120/240V “Q” Model Wiring Page 50 Crathco® Powdered Beverage Dispensers PIC 1 230V “E” Model Wiring Crathco® Powdered Beverage Dispensers Page 51 PIC1KE or PIC1KAE, 230V “E” Model Wiring Page 52 Crathco® Powdered Beverage Dispensers PIC1K or PIC1KA 120 & 120/240 “Q” Model Wiring Crathco® Powdered Beverage Dispensers Page 53 PIC1KAEW or PIC1KEW Wiring Page 54 Crathco® Powdered Beverage Dispensers CAP1AE or CAP1E 230V “E” Model Wiring Crathco® Powdered Beverage Dispensers Page 55 PIC 2/3 120 & 120/240V “Q” Model Wiring Page 56 Crathco® Powdered Beverage Dispensers Crathco® Powdered Beverage Dispensers Page 57 PIC33AE 230V “CE” Model Wiring with 3-Portion Touch Pads Page 58 Crathco® Powdered Beverage Dispensers PIC 2/3 100 & 200V “J” Model Wiring Crathco® Powdered Beverage Dispensers Page 59 PIC23A, PIC33A 100 & 200V “J” Model Wiring with 3-Portion Touch Pads Page 60 Crathco® Powdered Beverage Dispensers PIC3E or PIC3AE, 230/240VAC 50/60Hz Model Wiring with Remote Portion Control Crathco® Powdered Beverage Dispensers Page 61 PIC 4 Wiring Page 62 Crathco® Powdered Beverage Dispensers PIC43A 120V & PIC43AQ 120/240V Wiring Crathco® Powdered Beverage Dispensers Page 63 PIC43AZ and PIC43AWZ Model Wiring with 3-Portion Touchpad Page 64 Crathco® Powdered Beverage Dispensers PIC4Z, PIC4AZ, PIC4WZ, PIC4AWZ 240V Model Wiring Crathco® Powdered Beverage Dispensers Page 65 PIC 5/6 Wiring Page 66 Crathco® Powdered Beverage Dispensers Crathco® Powdered Beverage Dispensers Page 67 Grindmaster® Coffee Grinders and Brewers • PrecisionBrew™ Brewing Systems • Espressimo® Espresso Machines Crathco® Hot Beverage Dispensers • Crathco® Cold and Frozen Beverage Dispensers • AMW Coffee and Tea Systems Tel (502) 425-4776 • Fax (502) 425-4664 • 1-800-695-4500 (USA & Canada only) P.O. Box 35020 • Louisville, KY 40232 • USA www.grindmaster.com • email: [email protected] © Grindmaster Corporation™, 1996 0807 Form # CC-302-20 PRINTED IN USA Part # 62780
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