Curtis PCGT4 & PCGT5 Service Manual

Introduction

This service manual provides detailed information for the Curtis PCGT4 and PCGT5 beverage dispensers. It is intended for authorized service technicians and covers installation, operation, programming, cleaning, and maintenance.

Models Included: PCGT4, PCGT5

Important Safeguards and Symbols

This appliance is designed for commercial use. Servicing other than routine maintenance should be performed by an authorized Wilbur Curtis Company service technician.

• ⚠️ DO NOT immerse the unit in water or any other liquid.
• ⚠️ To reduce the risk of fire or electric shock, DO NOT open service panels. There are no user-serviceable parts inside.
• ⚠️ Keep hands and other items away from hot areas of the unit during operation.
• ⚠️ Never clean with scouring powders or harsh chemicals.

Symbols

• WARNINGS: To help avoid personal injury.
• Important Notes/Cautions: Information from the factory.

Sanitation Requirements

Your Curtis G3 System is factory pre-set and ready to use. The following are the factory settings for the Primo Cappuccino Beverage System:

• Tank Temperature = 190°F
• Flavor Controls = Set at 60%
• Dispensing Mode = Set for Manual Dispensing

Generally, there is no need to change G3 programming. However, programming instructions are provided later in this manual for adjustments.

System Requirements:

• Water Source: 20 – 90 PSI (Minimum Flow Rate of 1 GPM)
• Electrical: Refer to the electrical schematic on page 7.

Setup Steps

⚠️ Follow this setup procedure before attempting to use this unit. Failure to follow these instructions can result in injury and/or void of warranty.

⚠️ DO NOT connect the unit to hot water. The inlet valve is not rated for hot water.

1. The unit should be level (left to right, front to back) on a secure surface.
2. Connect the water line to the water inlet fitting on the rear of the unit. Ensure consistent water volume to the machine. Use tubing sized sufficiently to provide a minimum flow rate of one gallon per minute.

Note: Some type of water filtration device must be used for trouble-free operation. In areas with extremely hard water, a sedimentary and taste & odor filter is suggested to prolong the life of the system and enhance beverage quality.

NSF International Requirements for Water Connection:

1. A quick disconnect or additional coiled tubing (at least 2x the depth of the unit) is required so the machine can be moved for cleaning.
2. This equipment must be installed with adequate backflow protection to comply with applicable federal, state, and local codes.
3. Water pipe connections and fixtures directly connected to a potable water supply must be sized, installed, and maintained in accordance with federal, state, and local codes.

3. Plug the power cord into an electrical outlet rated at 20A.
4. Turn on the power at the toggle switch located behind the unit. The display window and button lights will activate, and the heating tank will begin to fill.
5. Water in the heating tank requires approximately one hour to reach the operating temperature (factory setting of 190°F). The LCD will display "READY TO DISPENSE" when ready.
6. Remove and fill the canisters with powdered cappuccino product.

[NSF Certified] [cULus Certified]

ISO 9001:2008 Registered

Wilbur Curtis Co.
6913 Acco Street, Montebello, CA 90640-5403
For the latest information, visit: www.wilburcurtis.com
Tel: 800/421-6150 | Fax: 323/837-2410

Operating Instructions

1. Choose a flavor. Place your cup under the spout beneath the desired flavor.
2. Push and hold the dispensing button for the selected flavor.
3. Release the button when the cup is approximately ¼ full.

Fill Canisters Daily

1. Open the front door to access the product canisters.
2. Remove the canisters from the unit for filling. Turn the powder delivery elbows clockwise to point upward. Pull all canisters from the canister tray.
3. Refill the canisters. Small canisters hold five pounds of product; larger canisters hold ten pounds each. (Refer to Configuration of Canisters on page 6 for details.)
4. Reposition the canisters on the canister tray. Ensure the gear socket properly mates with the gear on the motor shaft when aligning. Turn the elbows clockwise to point downward.

Cleaning the Curtis Primo Cappuccino GT Beverage Dispenser

CAUTION: Do not use cleansers, liquid bleach, powders, or any substance containing chlorine. These products promote corrosion and will pit the stainless steel. Use of these products will void your warranty.

I. Every 3 - 4 Hours or More Often if Necessary

1. Ensure power is ON.
2. Place a container under the dispense spout to catch rinse water.
3. Locate the WASH button on the front control panel.
4. Rinse each flavor by pressing and holding the WASH button while simultaneously pressing one of the PUSH dispensing buttons.
5. Continue holding the WASH button until the water running from the spout runs clear.

II. Daily

1. Switch OFF the unit using the power toggle switch located behind the unit.
2. Wipe all exterior surfaces with a damp cloth, removing spills, residue, or dust.
3. Remove the drip drawer and louvered screen, then wash their contents. For hard-to-clean deposits, use a mild, nonabrasive detergent and rinse with water.
4. Wipe and clean the dispensing area with a mild detergent cleaner.

III. Weekly or More Often if Necessary

1. Clean the parts from the whipper assembly:
1. Remove the dispensing nozzle from the whipper chamber. Clean the inside using a narrow brush.
2. Remove the upper mixing cup: Pull the cup forward, twist to the left, and lift to separate it from the lower mixing cup.
3. To remove the lower mixing cup: Pull the mixing cup up and forward to free it from the hot water inlet fitting.
4. Remove the whipper chamber: Grasp the whipper chamber and turn it clockwise to detach it from the mounting plate.
5. Pull the whipper propeller from the motor shaft.
6. Wash, rinse, and sanitize using a 3-sink method. Air dry all parts.
7. Re-assemble cleaned parts onto the machine.

Diagram Description: Visuals show the process for cleaning the dispenser, including the use of detergent solution, rinse water, and sanitizer.

Important Note: When replacing the propeller, ensure it is properly aligned and seated on the motor shaft. The propeller has an embossed 'D' for correct alignment. Failure to properly seat the propeller may cause it to fuse with the whipper chamber, which is not covered under warranty.

6. Clean the mounting plate:
1. Clean the shaft with a cloth and mild detergent before removing the mounting plate.
2. Twist the mounting plate clockwise and pull it from the motor shaft.

Important: Do not remove pillars to take off the mounting plate.

6. Clean the mounting plate (continued):
1. Clean the area behind the mounting plate.
2. Clean the water inlet fitting.
3. Lubricate the center seal of the mounting plate before reinstalling.

Steps to Programming

Your Curtis Generation 3 cappuccino dispenser is factory pre-set for optimum performance. Programming for all models is identical, except where noted.

Entering the Programming Menus

Press and hold the [Stop/Wash Button] for approximately 10 seconds. The display will read "Program Menus". (Refer to illustration for button locations).

Manual Dispense (Factory Set to Manual Dispense)

Press the [Left Arrow] or [Right Arrow] to navigate to "Manual Dispense Select". Press the [Select Button] to go to "Manual Dispense Select Station". Choose the station and press the [Select Button]. The display will read "Saving Complete!". To select another station for manual dispense, press the [Left Arrow] to go to "Manual Dispense Select Station" or press the [Right Arrow] to continue to the next menu.

Dispense By Time (Factory Setting OFF)

The next screen is "Dispense By Time" (Press [Select Button] to select). Select a station. The screen will read "To Begin Press Push". Press the desired dispense button. Hot water will start to dispense, and the screen will display "To Finish Press Push". When the [Push Button] is pressed again, the time will be saved, and you will exit back to the "Dispense By Time" screen. Continue with additional selections or press the [Right Arrow] to continue to the next menu.

Temperature (Factory set at 190°F - Cold Cappuccino Units Set at 96°F)

Press the [Select Button]. The screen will show "Tank Temperature". Temperature is programmable from 80°F to 204°F in 2-degree increments. Press the [Left Arrow] or [Right Arrow] to adjust the temperature. Select the desired temperature and then press the [Select Button] to set. Press the [Right Arrow] to continue to the next menu.

Powder % Ratio (Factory set at 60%)

Press the [Select Button]. The screen will display "Powder % Ratio Select Station". Press the desired station. Powder ratio is programmable from 0% (Hot Water) to 100%, in 5% increments. Press the [Left Arrow] or [Right Arrow] to increase or decrease the ratio, then press the [Select Button] to set. Press the [Right Arrow] to continue to the next menu.

Important: Valves should not be field adjusted to change product strength. Product strength adjustments should be done through programming on the front panel only.

Service Call (Factory Set to 1-800-000-0000 x0000)

Press the [Select Button] to display the number. Press the [Select Button] to change the number or the [Right Arrow] to move between digits and [Exit Button] to exit when complete. This number will be displayed during a "Heating system SENSOR ERROR" or a "WATER ERROR". Press the [Right Arrow] to continue to the next menu.

Banner Name (Factory Set to Curtis)

Press the [Select Button] to display letters. Press the [Select Button] to change letters or the [Right Arrow] to move between positions and [Exit Button] to exit when complete. This feature allows up to 14 letters for a company name or regional name. Programming all blanks disables Banner Name. Press the [Right Arrow] to continue to the next menu.

Model Select

Press the [Select Button] to select. Press the [Left Arrow] or [Right Arrow] to select the desired model (PC-1, -2, -3, -4, -5). Press the [Select Button] to set and exit program mode.

Exit

Press the [Select Button] to select. This exits program mode and returns the unit to operation.

Diagram Description: The programming control buttons are illustrated, showing the function of the PUSH, SELECT, and STOP/WASH buttons.

Parts List

The following table lists the part numbers and descriptions for components of the PCGT4 and PCGT5 models.

Diagram Description: "Detail Bubbles" are provided in the original document to highlight specific components and their locations within the dispenser assembly.

Illustrated Parts

The "Illustrated Parts" sections provide exploded views of the dispenser, showing the arrangement and connection of various components. These diagrams aid in identifying parts and understanding assembly.

Diagram Description: Visuals show the exploded view of the PCGT unit, illustrating the placement of numerous parts. Another section details the application of flavor labels to the dispenser's front panel and presents a "Configuration of Canisters on PCGT Models" table, specifying canister types and quantities for PCGT4 and PCGT5.

Canister Configuration:

Electrical Diagram

The electrical diagram illustrates the wiring and connections within the PCGT4 and PCGT5 units. It includes a wiring connection assignment list and pin assignments for the Triac control board, essential for troubleshooting electrical issues.

Product Warranty Information

Wilbur Curtis Company certifies its products are free from defects in material and workmanship under normal use. The following limited warranties and conditions apply:

• 3 Years, Parts and Labor, on digital control boards.
• 2 Years, Parts, on all other electrical components, fittings, and tubing.
• 1 Year, Labor, on all electrical components, fittings, and tubing.

Additionally, Grinding Burrs are warranted for forty (40) months or 40,000 pounds of coffee, whichever comes first. Stainless Steel components are warranted for two (2) years against leaking or pitting. Replacement parts are warranted for ninety (90) days or the remainder of the equipment's limited warranty period.

All in-warranty service calls require prior authorization from the Technical Support Department at 1-800-995-0417. The effective date of this policy was April 1, 2003.

Conditions & Exceptions

The warranty covers original equipment only. Wilbur Curtis Company is not responsible for substitute replacement parts not purchased from them. The warranty is void under the following circumstances:

• Improper operation or installation.
• Improper voltage or water supply (pressure, flow rate).
• Owner's responsibility for adjustments, cleaning, and regular maintenance.
• Damage incurred in transit (claim with carrier).
• Abuse or neglect, including failure to clean or remove lime accumulations.
• Replacement of items subject to normal wear and tear (e.g., bulbs, gaskets, O-rings, seals).
• Repairs/replacements are subject to Wilbur Curtis's decision on faultiness. Overtime charges and costs due to delays are the owner's responsibility.

Wilbur Curtis Company allows up to 100 miles, round trip, per in-warranty service call.

Return Merchandise Authorization (RMA)

All warranty claims must be submitted to the Wilbur Curtis Company Technical Support Department prior to any repair work or equipment return. Returned equipment must be repackaged properly. No units or parts will be accepted without an RMA number clearly marked on the carton or shipping label. All in-warranty service calls must be performed by an authorized service agent.