Nespresso Le Cube EF 472 Service Manual

1 Preface

The purpose of this service manual is to provide service personnel all necessary information with regards to the correct handling, maintenance, and repair of the EF 472 coffee machine.

This manual should be used by technicians as a valuable aid to guarantee the permanent readiness of the machine. To upkeep the full advantages of all the functions, it is absolutely necessary to follow the instructions in this service manual.

Please print out this manual and keep it together with the corresponding service documentation. This way you are assured to have the necessary information.

The required utility software to read PDF files (Adobe Reader®) for PCs and MAC computers is included on the Le Cube Service CD-ROM, or can be downloaded for free from http://www.adobe.com.

2 Structure

2.1 Overview of the rating plates

This overview shows examples of various brands and is not complete.

The rating plate can be found on the underside of the coffee machine and may vary in design depending on the brand. It carries the following information:

• 1) Brand name
• 2) Voltage and power rating
• 3) Place of manufacture
• 4) Conformity with RoHS-guidelines (lead-free solder, etc.)
• 5) Barcode
• 6) Serial number
• 7) Machine type
• 8) Special disposal icon (do not dispose with ordinary waste)
• 9) Approval seal (CE, UL etc.)
• 10) Article number of the rating plate

Decoding the alphanumeric serial number

Example: 060 264 721 0000 68G OJ

• Checksum (if available)
• Color version
• Type of mains plug
• Mains voltage
• Distributing partner
• Incremental number per production day
• Manufacturing plant
• Manufacturer designation of the machine type (EF 472)
• 06026: Date of production (06 = year 2006, 026 = 26th day of the year)

By decoding the date of production and machine type, the coffee machine can be identified exactly.

2.2 Overview

An exploded view diagram shows the internal components of the coffee machine, labeled with numbers 1 through 22.

• 1) Closing handle
• 2) Cup cover, foldable
• 3) Warming plate or tray (depends on model)
• 4) Compact Brewing Unit (CBU)
• 5) Capsule inlet
• 6) Flow meter
• 7) "Small cup" button, back lighted
• 8) "Large cup" button, back lighted
• 9) Coffee outlet
• 10) Capsule container
• 11) Light guide to the capsule container
• 12) Cup tray, foldable
• 13) Drip tray
• 14) Thermoblock TB 2003
• 15) Mainboard with housing
• 16) Pump CP.04.098.0/ST/S/P
• 17) Water tank with valve, foldable
• 18) Connector (below the water tank)
• 19) Connector On/Off switch
• 20) Front cover
• 21) Support for compact brewing unit
• 22) Drip tray

2.3 Water circuit

A diagram illustrates the water circuit, showing the water tank (1), water tank valve and connector (2), flow meter (3), pump (4), thermoblock (5), compact brewing unit (6), and coffee outlet (7).

2.4 Technical data

3 Operations

3.1 Filling the water system

Diagrams show the steps for filling the water system:

1. Machine on, press "Large cup" button. The pump starts to work.
2. Open the closing handle, push it backwards to the stop and hold it in this position for approximately 3 seconds.
3. Check if any water leaks from the capsule inlet.
4. Close the handle immediately if a leakage is visible.
5. Press the "Large cup" button again to stop the pump. The coffee machine is now ready.

Notes:

• If the coffee machine cannot pump water although there is water in the tank, the water circuit may be empty (also refer to page 12).
• A small amount of steam may seep through the capsule bay.

3.2 Making a cup of coffee

Diagrams illustrate making coffee:

1. Open the closing handle.
2. Insert the capsule.
3. Close the handle and press it down all the way.
4. Place a cup under the coffee outlet.
5. Press the "Small cup" or "Large cup" button. Coffee preparation starts and stops automatically.
6. When the process is completed, briefly open the closing handle to eject the used capsule.

Should the cup start to overflow, press the same button again.

3.3 Programming the fill level

Diagrams show programming fill level:

1. Prepare coffee as usual (see "Making a cup of coffee" on page 10), but keep the coffee button pressed for at least three seconds in order to start programming mode.
2. Only release the button when the desired fill level is reached.

The procedure is the same for both cup sizes (fill level 10 - 750 ml).

The fill level of the cups has been preset by the manufacturer: Small cup 40ml, Large cup 110ml.

3.4 Resetting the fill level to the factory default

Diagrams show resetting fill level:

1. Switch off the coffee machine.
2. Press and hold the "Large cup" button.
3. Switch on the coffee machine.
4. Release the button.

3.5 Emptying the water system

Diagrams show emptying water system:

1. Switch off the coffee machine.
2. Pull out or remove the water tank.
3. Place a beaker under the coffee outlet.
4. Press and hold the "Small cup" button.
5. Switch the coffee machine on again.
6. Release the "Small cup" button. The pump drains the water system and stops automatically. The On/Off switch and the lights of the capsule container blink simultaneously.
7. Switch off the coffee machine.

Notes: After every operation, some water remains in the coffee machine. Therefore the water system must be emptied:

• if the coffee machine will not be used for a long time
• as antifreeze measure
• for repairs and shipment.

After this procedure, the coffee machine will not be ready for approx. 10 min (until the thermoblock cools to below 100 °C).

3.6 Light signals

The meaning of the symbols and indicators for different operating modes and errors are shown in the following tables.

Symbols for Illumination

Indicators

4 Troubleshooting

With an acceptance check in accordance with this checklist, errors are quickly found and corrected with the appropriate measure. Therefore, adhere to the sequence of the check list. Repair every occurring error and work the check list until it is completed.

4.1 Check list

5 Repairs

This section contains special safety and assembly notices. Disregarding them may lead to injuries and damages.

The components of the coffee machine are mostly connected with latches, meaning without screws. When loosening these connections, proceed with care and patience to avoid causing any damage.

Designation of spare parts

The components in the following illustrations are indexed with position numbers. The corresponding designation and spare part number are listed in section "Spare parts" on page 40.

5.1 Tools and accessories

With the following assortment of tools, all repairs described can be made:

• Oval-screwdriver
• TORX-screwdriver (TX6, TX10, TX20, TX25)
• Screwdriver with approx. 4 mm tool tip
• Hexagonal wrench SW 4
• Flat wrench SW 14, 10 mm AF
• Torque wrench
• Long-nosed pliers
• Beaker and towel to catch and wipe away leaking water

5.2 General disassembly

Notes:

• If necessary, empty the water system first (see page 12).
• Before disassembly, disconnect the mains plug - the coffee machine must be voltage free.

General disassembly gives access to the important machine components and is required for the following repair instructions. Depending on the repair done, the machine does not have to be fully disassembled.

Diagrams show general disassembly steps, illustrating the removal of components such as the water tank (21), drip tray (29), cup tray (28), capsule container (26), closing handle (56), coffee outlet (25), and front cover (30).

Further diagrams show the removal of the rear panel (47), cup covers (17), left (20) and right covers (36), detailing screw and latch removal.

Diagrams also illustrate the removal of the closing handle (56) and cover lid (57), coffee tap (24), compact brewing unit (58), drip tray (59), cup tray/heating plate (42), and side panels (39).

The following function test can now be done: "Pressure and leakage checks" on page 33.

Diagram shows the base of the machine with support (13) and housing (32), indicating screw (34) and latch (h) locations for removing the support.

5.3 Replacing the compact brewing unit

Diagram shows the compact brewing unit (58) and related parts like coffee tap (24) and O-ring (46).

Repair tips:

• Remove the drip tray (59): press and loosen the two locking latches on the side (i) of the capsule bay.
• In addition to the compact brewing unit (58), also replace: the coffee tap (24) and the O-ring (46) on the thermoblock-hose connection.
• The spare compact brewing unit (58) is used in the EF 470 and EF 471 coffee machines and therefore has a longer axis protruding from the side.
• Check the axial and parallel alignment of the closing handle (56) to the housing of the compact brewing unit (58). Should there be any deviations, tighten the mounting screws of the closing handle or replace a bent closing handle.

5.4 Replacing the thermoblock, NTC-temperature sensor and fine wire fuse(s)

Diagram shows thermoblock (5), NTC-temperature sensor (6), spring ring (7), safety clips (4), and fine wire fuse (900).

Repair tips for the thermoblock:

• When mounting the new thermoblock (5), align the positioning holes on the bottom to the damping element (8).

Repair tips for the NTC-temperature sensor:

• Do not twist the NTC-cable when plugging and unplugging the NTC-temperature sensor (6): unplug the NTC-plug from the main board.
• Tighten the new NTC-temperature sensor (6) and spring ring (7) with a torque wrench (90 - 110 Ncm).

Repair tips for the fine wire fuse(s):

• When mounting the safety clips (4), make sure that the housing of the fine wire fuse (900) is positioned exactly below the safety clips.
• To replace a defective fine wire fuse, the support (13) of the compact brewing unit must be removed from the floor (32).

Check if residual water leaks from the thermoblock.

Depending on the series, one or two fine wire fuses are mounted on the thermoblock (see "Wiring diagrams" on page 29).

5.5 Replacing the pump with the fine wire fuse

Diagram shows the fluid system support (11) and floor (32), indicating how to remove the support.

Repair tip for the fluid system support:

• Remove the fluid systems support (11) from the floor (32): insert the tip of the screwdriver into the slits in the housing base and press the locking latches to one side. Simultaneously lift the support (11). After loosening both locking latches, tilt up the support (11) and pull it out of the anchoring on the other side.

Diagram shows pump (48), thermoblock (5), angled hose connection (44), and fine wire fuse.

Repair tips for pump:

• Always replace a defective pump (48) together with the fine wire fuse.
• When installing a new pump, the angled hose connection (44) may have to be realigned: the white plastic lid on the pump is rotatable and has two flat surfaces onto which the flat wrench can be placed.

Mounting tip for the thermoblock:

• When mounting the thermoblock (5), align the positioning holes on the bottom to the damping element (8).

Check for water leaking from the pump.

5.6 Replacing the flow meter

Diagram shows flow meter (41) and hoses (40, 52) being removed from the base (32).

Repair tip for flow meters:

• Pull the flow meter (41) firmly upwards to remove it.

5.7 Replacing the mainboard with the button prints

Diagram shows mainboard (35) and related components like spring (14), and connectors (20, 15, 31).

Repair tips:

• Check the assembly position of the spring (14).
• A label on the housing of the mainboard (35) contains specifications on the hardware and software version.
• After assembly, check the plug arrangement of the mainboard (see "Wiring diagrams" on page 29).

When installing a new electronic component, the service technician must be earthed with a grounding band.

5.8 Replacing the on/off switch and/or the mains cable

Diagram shows on/off switch (62), insulation housing (23), mains cable (37, 38), and related components.

Repair tips:

• Check the assembly position of the spring (14).
• Remove the insulation housing (23): place screwdriver tip from below into the switch housing and force the switch out (62).
• The on-off switch (62) has no markings for the connections. Check its switch functions and wiring with a digital multimeter (j) and compare it with the diagram (see "Wiring diagrams" on page 29).
• The cable strain relief (37) is under tension. Therefore, hold the cable strain relief with your finger when unlatching it.

5.9 Wiring diagrams

Wiring diagrams are provided for different voltage and series configurations:

• Diagrams for 230 V - EU (first series)
• Diagrams for 230 V - EU (valid as of 01.01.2007)
• Diagram for 120 V - UL
• Wiring diagram for 100 V - Japan (first series)
• Wiring diagram for 100 V - Japan (valid as of 01.01.2007)

Component key for diagrams:

• 1) Print for button "On/off"
• 2) On/Off switch
• 3) Heating plate
• 4) Thermoblock (voltage varies by region)
• 5) Pump (voltage varies by region)
• 6) Flow meter
• 7) Mainboard (voltage varies by region)
• 8) Print for buttons "Coffee small/large"

6 Function tests

6.1 Measure flow rate

Diagrams show steps for measuring flow rate:

1. Fill the water tank.
2. Push the connector adapter into the capsule bay.
3. Carefully close the handle, until the adapter sits firmly in the capsule cage.
4. Pull out the mount. The adapter locks with the capsule cage.
5. Place a measuring cup under the drain hose of the pressure tester.
6. Switch on the coffee machine.
7. After heating up, press the "Small cup" button.
8. Open the valve until water begins to flow.
9. Close the valve until the pressure gauge indicates 12 bar. Constantly monitor the pressure gauge and if required readjust the valve. As the temperature increases, so does the pressure, readjust the pressure to 12 bar when required.
10. Carry out measurement for approx. 30 sec.
11. At least 60-120 ml of water must be in the measuring cup.

Notices:

• Should < 60 ml leak out, then the pump is defective or there is a leak in the water system.
• Large deviations in indicated pressure while measuring (± 4 bar) means that the pump is defective.

6.2 Pressure and leakage checks

Check the following parts of the coffee machine for leakages:

• Compact brewing unit
• Hose connections
• Thermoblock
• Pump

Warning: Dangerous mains voltages and hot parts under pressure inside the coffee machine! Do not touch any parts under voltage and or hot while checking for leakages! Always wear protective goggles.

Preparations

Diagrams show preparations for pressure and leakage checks:

1. Remove rear and side panels (the pump becomes visible, see "General disassembly" on page 16).
2. Push the connector adapter into the capsule bay.
3. Carefully close the handle, until the adapter sits firmly in the capsule cage.
4. Pull out the mount. The adapter locks with the capsule cage.

Test run

Diagrams show test run:

1. Place the measuring cup under the drain hose of the pressure tester.
2. Fill and insert the water tank.
3. Connect the mains cable.
4. Switch on the coffee machine.
5. After heating up, press the "Small cup" button.
6. Open the valve and let the water flow for approximately 10 sec. out of the drain hose.
7. Close the valve completely. The pressure stabilizes after increasing briefly between 16 - 19 bar (pressure check). The pressure increases slowly with increasing temperature. Should the pressure exceed 23 bar, switch off the coffee machine and release the pressure by opening the valve.
8. Check all connections under pressure for audible and visible leaks.
9. Switch off the coffee machine.
10. Open the valve and let water flow out of the pressure tester.

Warning: Do not run the pump for more than 50 sec. with the valve closed.

6.3 Measuring the coffee temperature

Diagrams show steps for measuring coffee temperature:

1. Press the on-off button.
2. Place a measuring cup under the coffee outlet.
3. After the heating up period, press the "Small cup" button and preheat the coffee outlet for approximately 10 sec. with hot water.
4. Insert capsule (Cosi is best suited).
5. Press the "Small cup" button.
6. Wait until the measuring cup contains 20 ml of coffee.
7. Then measure the coffee temperature approx. 5-10 mm under the coffee outlet.

The coffee temperature should be 86 °C ± 3 °C (187 °F ± 5.4 °F).

7 Maintenance

7.1 Descaling

Warning: Only use Nespresso decalcifiers - never use vinegar! Decalcifiers are aggressive to surfaces.

Step-by-step instructions for descaling:

1. Switch off the coffee machine.
2. Eject capsule. Insert the filter from the descaling set into the capsule bay and close the handle.
3. Remove the drip tray and capsule container and empty them.
4. Reinsert the drip tray and place a beaker on the cup support. Observe the safety instructions on the package of the decalcifier.
5. Fill the water tank with 0.1 l decalcifier and 0.5 l water and insert it into the coffee machine.
6. Switch on the coffee machine.
7. Press the "Small cup" and "Large cup" buttons simultaneously for at least 3 sec. The descaling mode is started (the buttons blink fast).
8. Press the "Large cup" button, the pump starts.
9. Let the entire descaling solution run through the system.
10. Pour the descaling solution back into the water tank.
11. Descale again: press the "Large cup" button and let the descaling solution run through the system again.
12. Empty the beaker.
13. Remove the filter from the capsule bay.
14. Thoroughly rinse the water tank and fill it with fresh water.
15. Place the beaker on the cup support.
16. Press the "Large cup" button - the pump starts. Let the entire solution in the tank run through the system.
17. Switch off the coffee machine. Descaling is completed.
18. Clean the coffee machine.

7.2 Daily maintenance, cleaning

Step-by-step instructions for daily maintenance and cleaning:

1. Eject capsule.
2. Empty the capsule container.
3. Empty the water tank and the drip tray.
4. Clean the water tank and the drip tray.
5. Fill the tank with fresh water.
6. Reassemble the coffee machine.
7. Press the "On/Off" button.
8. Press the "Large cup" button and rinse the coffee outlet for 10 sec.
9. Clean the coffee machine.

8 Spare parts

The following tables list the spare parts with their corresponding EFR numbers and designations.