Cornelius Enduro 175 8 Valve User manual

ICE/BEVERAGE DISPENSER
MODEL: ENDURO-175 8 VALVE
OPERATOR’S MANUAL
Release Date: March 1, 2004
Publication Number: 620917901OPR
Revision Date: August 3, 2010
Revision: C
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possi-
ble contingency in the installation, operation or maintenance of this equipment. This manual assumes that the per-
son(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic,
and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and
construction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is sub-
ject to all of the restrictions and limitations contained in the Commercial Warranty.
Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained per-
sons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, oper-
ating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con-
tact:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
Printed in U.S.A.

Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Start-up and Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ice Drink Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLEANING AND MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Daily Cleaning:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Daily Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Weekly Cleaning: (In addition to daily procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Monthly Cleaning: (In addition to daily and weekly procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Yearly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning Interior Surfaces (Monthly Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cold Plate (Yearly Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dispensing Valves: ( Daily Cleaning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Tubing (Monthly Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sanitize Pre-Mix And Post–Mix Tank System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sanitize syrup lines, B-I-B Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replenishing CO2 Supply (As Required). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ice/BeverageDispenserOperator’sManual
© 2004-2010, IMI Cornelius Inc. - 1 - Publication Number: 620917901OPR
SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
Safety Overview
• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or
laminated cards).
• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before
operating this unit.
Recognition
DIFFERENT TYPES OF ALERTS
!
DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
!
WARNING:
Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment
damage.
CAUTION:
!
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment
damage.
SAFETY TIPS
• Carefully read and follow all safety messages in this manual and safety signs on the unit.
• Keep safety signs in good condition and replace missing or damaged items.
• Learn how to operate the unit and how to use the controls properly.
• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or
infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND
PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN
SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
!

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SAFETY PRECAUTIONS
This unit has been specifically designed to provide protection against personal injury. To ensure continued protection
observe the following:
!
WARNING:
Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify
all of the power is off to the unit before any work is performed.
Failure to disconnect the power could result in serious injury, death or equipment damage.
CAUTION:
!
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
CAUTION:
!
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained
from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.
CO2(CARBON DIOXIDE) WARNING
!
DANGER:
CO2displaces oxygen. Strict attention MUST be observed in the prevention of CO2gas leaks in the entire CO2and
soft drink system. If a CO2gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the
contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO2gas
experience tremors which are followed rapidly by loss of consciousness and DEATH.
MOUNTING IN OR ON ACOUNTER
!
WARNING:
When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 415 lbs. to
insure adequate support for the unit. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR
EQUIPMENT DAMAGE.
NOTE: Many units incorporate the use of additional equipment such as icemakers. When any addition
equipment is used you must check with the equipment manufacturer to determine the addi-
tional weight the counter will need to support to ensure a safe installation.

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© 2004-2010, IMI Cornelius Inc. - 3 - Publication Number: 620917901OPR
START-UP AND OPERATING INSTRUCTIONS
ICE DRINK DISPENSER
The ice drink dispenser shall be installed by qualified personnel following instruction given in the Installation manual
part number 620917901INS. Fill the hopper with ice. Dispense several large cups of ice (approximately 20 to 30
seconds total dispensing time) to allow ice to fill the cold plate cabinet. Add ice to the hopper as necessary to refill,
then replace the lid. Allow 10 to 15 minutes for the cold plate to cool down. Repeat this procedure whenever the
dispenser has run out of ice. Start up the beverage system and adjust faucets to the proper brix. Contact your local
syrup distributor for complete information on the beverage system.
The ice drink dispenser is designed to operate in ambient temperatures ranging from 40 to 105oF. Do not allow the
unit to be stored or operated in conditions below 32oF. This could cause damage to the unit.
CAUTION:
!
Dispenser cannot be used with crushed or flaked ice. Use of bagged ice which has frozen into large chunks can
void warranty. The dispenser agitator is not designed to be an ice crusher. Use of large chunks of ice which “jam
up” inside the hopper will cause failure if the agitator motor and damage to the hopper. If bagged ice is used, it
must be carefully and completely broken into small, cube-sized pieces and left to “temper” or warm up for a
minimum of 20 minutes in room temperature before loading into the dispenser hopper
In normal operation, pushing the ice dispenser mechanism will cause ice to flow from the ice chute. Ice flow will continue
until the dispenser mechanism is released. Dispensing of any faucet will provide beverage of the appropriate flavor.
!
WARNING:
Use caution to avoid spilling ice when filling dispenser. Clean up immediately any spilled ice from filling or operating
the unit. To prevent contamination of ice, the lid must be installed on the unit at all times. FAILURE TO CLEAN UP
SPILLS COULD RESULT IN SERIOUS INJURY OR DEATH
If the dispenser fails to dispense ice or beverage, refer to the troubleshooting section in the Installation Manual part
number 620917901INS.
NOTE: The dispenser is not designed for a wash-down environment and MUST NOT be placed in an
area where a water jet could be used.
NOTE: This appliance is not intended for use by personnel (including children) with reduced physical,
sensory or mental capabilities or lack of experience and knowledge, unless given supervision
or instruction concerning use of the appliance by a person responsible for safety.

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CLEANING AND MAINTENANCE INSTRUCTIONS
These instructions are used on all Cornelius ice drink dispensers. Some models may have additional cleaning
requirements. Those models will have addition procedures listed later in the manual.
!
WARNING:
Disconnect power to the unit before cleaning or servicing following all lock out / tag out procedures established by the
user. Verify all of the power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
CAUTION:
!
Do not use metal scrapers, sharp objects or abrasives on the ice storage hopper, top cover, agitator disc or exterior
surfaces as damage to the unit may result. Do not use solvents or other cleaning agents as they may attack the
material resulting in damage to the unit.
Soap solution – Use a mixture of mild detergent and warm (100° F ) potable water.
Sanitizing Solution – Dissolve 2 packets (4 oz) of Stera Sheen Green Label into 2 gallons of warm (80 – 100° F)
potable water to ensure 200 ppm of chlorine.
DAILY CLEANING:
1. Remove cup rest from drip tray and clean with warm soapy water, rinse with clean water and allow to air dry.
2. Wipe down the exterior of the unit with warm soapy water, rinse with clean water and allow to air dry.
3. Remove valve nozzles and diffusers and wash in warm soapy water, rinse in clean water and allow to air dry.
4. Clean the interior of the ice chute using the brush provided with the unit with warm soapy water, rinse with
clean water and allow to air dry.
5. Spray the ice chute inside and out with sanitizer and allow to air dry.
6. Pour warm soapy water down the drains to keep them clean and flowing smoothly.
7. Spray the nozzles and diffusers inside and outside with approved sanitizing solution, reinstall them on the
valves and allow to air dry.
8. Reinstall the cup rest into the drip tray.
9. Pour all remaining sanitizer solution down the drains to help keep the drain clear.
DAILY MAINTENANCE:
1. Check the temperature, smell and taste of the product.
2. Check the water pressure coming to the unit using the pressure gauges on the back room package.
3. Check carbonation of the drink.
4. Check level of CO2supply to the system.
5. Check the date on all of the BIB’s (bags in boxes).
WEEKLY CLEANING: (INADDITION TO DAILY PROCEDURES)
Remove the ice chute cover and clean it along with the back half with warm soapy using the brush provided with
the unit. Rinse with clean water and reinstall on the unit. Spray the ice chute assembly with approved sanitizer
allowing it to air dry.
MONTHLY CLEANING: (INADDITION TO DAILY AND WEEKLY PROCEDURES)
1. Flush and sanitize all syrup lines as well as all of the syrup connectors. (See the sanitize syrup lines section
shown later in this manual).

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2. Remove ice from hopper and clean and sanitize the hopper. (See the Cleaning the interior surfaces section
shown later in this manual).
3. While cleaning the hopper use the brush provided with the unit to clean the cold plate surface. To accom-
plish this, the brush needs to be extended through the opening in the bottom of the hopper.
YEARLY MAINTENANCE:
Have the water pump and check valve inspected and cleaned by a qualified service technician.
Have the CO2gas check valve inspected and cleaned by a qualified service technician.
Remove the unit’s splash and cold plate cover to clean and sanitize the cold plate surface. (See the cleaning the
cold plate section shown later in this manual).
Cleaning Interior Surfaces (Monthly Cleaning)
CAUTION:
!
When pouring liquid into the hopper, do not exceed the rate of 1/2 gallon per minute. Pouring more liquid into the
hopper could result in an overflow situation may result in injury or damage to the equipment.
1. Remove agitator assembly.
2. Using a nylon bristle brush or sponge, clean the interior of the hopper, top cover and agitator assembly with
soap solution. Thoroughly rinse the hopper, cover and agitator surfaces with clean potable water.
3. Reassemble agitator assembly. Take special care to ensure that the thumbscrew is tight.
4. Using a mechanical spray bottle filled with sanitizing solution, spray the entire interior and agitator assem-
bly. Allow to air dry.
5. Remove merchandiser and ice chute cover from unit.
6. With a nylon bristle brush or sponge, clean the inside of the ice chute, gasket, and cover with soap solution
and rinse thoroughly to remove all traces of detergent.
7. Reassemble ice chute assembly.
8. Using a mechanical spray bottle filled with sanitizing solution, spray the inside of the ice chute. Allow to air dry.
9. Reinstall merchandiser.
Cold Plate (Yearly Maintenance)
1. Remove splash panel.
2. Remove or move the plastic cold plate cover to expose the cold plate.
3. Locate and remove any debris from the drain trough. Check that the drain holes are not clogged.
4. Pour small amount of soap solution through cold plate openings in hopper.
5. Using a cloth, wash down the surfaces of the cold plate and plastic cover with soap solution.
6. Install and properly position the access covers on the cold plate.
7. Install the splash panel in the reverse order it was removed.
8. Rinse cold plate surface by pouring potable water through hopper openings.
Dispensing Valves: ( Daily Cleaning)
Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed on the unit.
Product Tubing (Monthly Cleaning)
IMPORTANT: Only trained and qualified persons should perform these cleaning and sanitizing procedures.
Sanitize Pre-Mix And Post–Mix Tank System
1. Remove all the quick disconnects from all the tanks. Fill a suitable pail or bucket with soap solution.

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2. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
3. Prepare sanitizing solution and using a mechanical spray bottle, spray the disconnects. Allow to air dry.
4. Using a clean, empty tank, prepare five (5) gallons of the sanitizing solution. Rinse the tank disconnects
with approximately 9 oz. of the sanitizing solution. Close the tank.
5. Prepare cleaning tank by filling clean five (5) gallon tank with a mixture of mild detergent and potable water
(120oF).
6. Connect a gas disconnect to the tank and then apply one of the product tubes to the cleaning tank. Oper-
ate the appropriate valve until liquid dispensed is free of any syrup.
7. Disconnect cleaning tank and hook up sanitizing tank to syrup line and CO2system.
8. Energize beverage faucet until chlorine sanitizing solution is dispensed through the faucet. Flush at least
two (2) cups of liquid to ensure that the sanitizing solution has filled the entire length of the syrup tubing.
9. Allow sanitizer to remain in lines for fifteen (15) minutes.
10. Repeat the step above, applying a different product tube each time until all tubes are filled with the sanitiz-
ing solution.
11. Remove the nozzle and syrup diffuser and clean them in a mild soap solution. Rinse with clean water and
reassemble the nozzle and syrup diffuser on the valve.
12. Rinse the parts in clean water, reassemble the valve and reconnect it to the dispenser.
13. Discard the tank of sanitizing solution and reconnect the product syrup tanks. Operate the valves until all
sanitizer has been flushed from the system and only product syrup is flowing.
Sanitize syrup lines, B-I-B Systems
1. Remove all the quick disconnects from all the B-I-B containers.
2. Fill a suitable pail or bucket with soap solution.
3. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
4. Using a plastic pail, prepare approximately five (5) gallons of sanitizing solution.
5. Rinse the B-I-B disconnects in the sanitizing solution.
6. Sanitizing fittings must be attached to each B-I-B disconnect. If these fittings are not available, the fittings
from empty B-I-B bags can be cut from the bags and used. These fittings open the disconnect so the sani-
tizing solution can be drawn through the disconnect.
7. Place all the B-I-B disconnects into the pail of sanitizing solution. Operate all the valves until the sanitizing
solution is flowing from the valve. Allow sanitizer to remain in lines for fifteen (15) minutes.
8. Remove the nozzle and syrup diffuser from each valve and clean them in a soap solution. Rinse with clean
water and reassemble the nozzle and syrup diffuser to the valve.
9. Remove the sanitizing fittings from the B-I-B disconnects and connect the disconnects to the appropriate 
B-I-B container. Operate the valves until all sanitizer has been flushed from the system and syrup is flowing
freely.
Replenishing CO2 Supply (As Required)
NOTE: When indicator on the 1800-psi gage is in the shaded (“change CO2cylinder”) portion of the
dial, CO2cylinder is almost empty and should be changed.
1. Fully close (clockwise) the CO2cylinder valve.
2. Slowly loosen the CO2regulator assembly coupling nut allowing CO2pressure to escape, then remove the
regulator assembly from the empty CO2cylinder.

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3. Unfasten safety chain and remove the empty CO2cylinder
!
WARNING:
To avoid personnel injury and/or property damage, always secure the CO2cylinder with a safety chain to prevent it
from falling over. Should the valve become accidently damaged or brokenoff, a CO2regulator can cause serious
personnel injury or death could occur.
4. Position the full CO2cylinder and secure with a safety chain.
5. Make sure gasket is in place inside the CO2regulator assembly coupling nut, then install the regulator
assembly on the CO2cylinder.
6. Open (counterclockwise) the CO2cylinder valve slightly to allow the lines to slowly fill with gas, then open
the valve fully to back-seat the valve (back-seating the valve prevents gas leakage around the valve shaft).
7. Check CO2connections for leaks. Tighten any loose connections.

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TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
!
WARNING:
If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve
the system pressure before proceeding. If repairs are to be made to theCO2 system, stop dispensing, shut off the
CO2supply, then relieve the system pressure before proceeding. If repairs are to be made to the refrigeration system,
make sure.
Should your unit fail to operate properly, check that there is power to the unit and that the hopper contains ice. If the
unit does not dispense, check the following chart under the appropriate symptoms to aid in locating the defect.
Trouble Probable Cause
BLOWN FUSE OR CIRCUIT BREAKER.
A. Short circuit in wiring.
B. Defective gate solenoid.
C. Defective agitator motor
GATE DOES NOT OPEN. AGITATOR DOES
NOT TURN.
A. No power.
B. Bent depressor plate (does not actuate switch).
C. Defective dispensing switch.
GATE DOES NOT OPEN OR IS SLUGGISH.
AGITATOR TURNS.
A. Defective gate solenoid
B. Excessive pressure against gate slide.
C. Defective rectifier
ICE DISPENSES CONTINUOUSLY.
A. Stuck or bent depressor plate (does not release switch).
B. Defective dispensing switch.
C. Improper switch installation.
SLUSHY ICE. WATER IN HOPPER.
A. Blocked drain.
B. Unit not level.
C. Poor ice quality due to water quality or ice maker problems.
D. Improper use of flaked ice.
BEVERAGES DO NOT DISPENSE. A. No 24 volt power to faucets.
B. No CO2 pressure.
BEVERAGES TOO SWEET.
A. Carbonator not working.
B. No CO2 pressure in carbonator.
C. Faucet brix requires adjusting.
BEVERAGES NOT SWEET ENOUGH. A. Empty syrup tank.
B. Faucet brix requires adjusting.
BEVERAGES NOT COLD (UNITS WITH BUILT-IN
COLD PLATE).
A. Unit standing with no ice in hopper -- no ice in cold plate cabinet.
FLAVOR SYRUPS DO NOT DISPENSE.
A. No 24 volt power to PC board.
B. No CO2 pressure.
C. Empty syrup tank.
D. Kinked tubing.
E. Clogged inner nozzle.
F. Defective PC board.
G. Defective harness from keypad.
H. Defective Flow control.
I. Defective solenoid harness.
J. Defective keypad

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© 2004-2010, IMI Cornelius Inc. - 9 - Publication Number: 620917901OPR
Contact your local syrup or beverage equipment distributor for additional information and troubleshooting of beverage
system.
FLAVOR DISPENSES FOR MORE THAN 1 SEC.
A. Dip switch settings on control board incorrect.
B. PC board defective.
C. Defective flow control.
FLAVOR DISPENSES MORE THAN .5 OZ.
A. Dip switch settings on control board incorrect.
B. Flow control incorrectly set.
C. PC board defective.
D. Defective flow control.

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IMI Cornelius Inc.
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