Kalerm KLM1602 User manual

KLM1602
Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602-SM-EN V002

English
KLM1602
Service Manual
Intelligent Fresh Ground
Coffee Machine

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Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602
Contents
1. Introduction 4
6
2. Structure
15
3. Troubleshooting
32
4. Repair
2.1 Overview
2.2 Description of internal components
2.3 Water circuit
2.4 Schematic circuit diagram
2.5 Technical data
General warnings
Symbol description
4
5
6
9
10
10
11
12
13
14
3.1 Troubleshooting check list
3.2 Check list for minor failure
15
28
2.3.1 Overview of water circuit
2.3.2 Water circuit for making coffee
2.3.3 Water circuit for making hot water
4.1 Tools preparation
4.2 General disassembly
4.2.1 Disassemble exterior parts
4.2.2 Disassemble power cord
4.2.3 Disassemble brew unit
4.2.4 Disassemble valve support group
4.2.5 Disassemble flowmeter
4.2.6 Disassemble grinder group
4.2.7 Disassemble control panel group
4.2.8 Disassemble drainage valve group
4.2.9 Disassemble solenoid valve group
4.2.10 Disassemble pump group
4.2.11 Disassemble PCBA
4.2.12 Disassemble dispenser valve 2W
4.2.13 Disassemble thermoblock group
4.2.14 Disassemble drive motor group
Contents

5. Function test and maintenance 63
6. Explosive view 68
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49
51
54
63
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63
64
65
Contents
4.3 Precautions for maintenance and installation
Precautions for assembling
4.3.1 Brew unit group
4.3.2 Grinder group
4.3.3 Control panel group
5.1 Function test and test standards
5.2 Coffee machine maintenance
5.2.1 Coffee machine decalcifying
5.2.2 Rinse the brew unit
5.2.3 Wipe the coffee machine

1. Introduction
The manufacturer reserves the right to make product improvements. We guarantee that this manual respects the
technological status at the time the machine is supplied.
We are open to any suggestions from technicians which may improve the product and the manual.
General warnings
Once the packaging has been removed make sure the appliance is in good condition; if you have any doubts,
check the fault and contact the retailer or manufacturer directly.
Packaging must not be left where children can reach it as it is a potential hazard source.
The appliance must be installed in compliance with the safety standards in force in the country of use.
This appliance is completely safe only when it is connected to an effective earthing system that complies with
the safety standards. Make sure that the mains power is sufficient for the energy required for the machine.
It is unadvisable to use extension leads or electrical adaptors for multiple sockets. If it is essential to use them, use
only single adaptors or leads that comply with the current safety standards. Never exceed the capacity
indicated on the adaptor or leads, or the maximum power indicated on the adaptor.
This appliance should only be used for what it has been designed. Any other use is considered improper and
consequently dangerous. The manufacturer cannot be held responsible for any damages caused due to an
erroneous or irrational use. The technician must remind the user about the safety standards to ensure correct
operation of the appliance.
The use of an electrical appliance is subject to the safety standards.
If the customer decides not going to use the appliance for a long time, the power cable must be disconnected
from the mains and empty the water container.
To guarantee that the coffee-maker works properly and efficiently, it is essential to follow the manufacturer’s
instructions, and carrying out periodical maintenance and check of all the safety devices.
Always make sure that hands, or other parts of the body, never come within the range of the coffee dispensing
spouts or those of steam and hot water so as not to be scalded.
The maintenance technician must inform the retailer or manufacturer promptly of any problems when installing
or using the appliance.
The coffee machine must be used at the temperature between 5℃and 40℃.
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Introduction
4Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602

Introduction
5
Symbol description
Non-compliance with the operation, may cause electric
shock, and threat to life.
Non-compliance with the operation may cause coffee
machine damaged, or personal injury.
Non-compliance with the operation, may cause scalded or
burned.
This symbol, if prompted, please carefully read information
with it.
This symbol, if prompted, represents recycle.

2. Structure
2.1 Overview
Structure
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Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602
Drip tray decoration cover
Top cover
Cup support
Front cover right
Drip tray cover
Drip tray
Bean container lid
Water tank cover
Water tank ornament cover
Water tank
Front cover left
Export decorative cover

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15
Structure
7
14
16
17
13
16
17
Bean container
Grinder adjustment
knob
Ground coffee
container lid
13
14
15
Hot water export
Coffee export
Back cover
Logo
Right side section
18
19
20

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25
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27
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29
30
23
24 25 26 27 28 29
30
21
22
Left side section
Power line
21
22
Power switch
Americano button
Espresso button
Coffee button
Double cup
Coffee strength button
Setting button
Screen
Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602
Structure

2.2 Description of internal components
1
2
3
5
6
7
8
9
10
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17
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9
15
4
Thermoblock
Solenoid valve 2W
Geared motor
Dispenser valve 2W
Support
PCBA
Pump
Drainage valve
Line pencil connector
Transformer
Base
Brew unit
Drip tray microswitch
Reed sensor
Flowmeter
Valve support
Control panel
Grinder group
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3
4
5
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Structure

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10 Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602
Structure
2.3.1 Overview of water circuit
2.3 Water circuit
Water tank
Sieve
Flowmeter
Pump
Pressure maintaining valve
Coffee thermoblock
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2
3
4
5
6
Dispenser valve 2W
Drainage valve
Brew unit
Solenoid valve 2W
Beverage export
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9
10
11

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2
3
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2.3.2 Water circuit for making coffee
Structure
Water tank
Sieve
Flowmeter
Pump
Pressure maintaining valve
Coffee thermoblock
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2
3
4
5
6
Dispenser valve 2W
Drainage valve
Brew unit
Beverage export
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10

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3
4
5
6
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7
2.3.3 Water circuit for making water
Structure
Water tank
Sieve
Flowmeter
Pump
Pressure maintaining valve
Coffee thermoblock
1
2
3
4
5
6
Solenoid valve 2W
Beverage export
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Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602

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25
Structure
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3
4
5
6
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10
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Power switch
Data interface
LCD screen
HMI
Flowmeter
Drip tray microswitch
Reed sensor
LED light
Thermoblock
NTC
Feedback device
Solenoid valve 2W
Stepper motor
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Drive motor
Transformer
Thermoblock fused-cord
Solenoid valve fused-cord
Pump
Filter
Terminal
Power line
Grinder motor
Microswitch
Communication cable
Power PCBA
2.4 Schematic circuit diagram

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Structure
Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602
2.5 Technical data
Total voltage/power
China
Europe
220V/50HZ 1200W
230V/50HZ 1400W
Approvals CCC,CB,CE
Power ratings
Thermoblock
Pump
Solenoid valve 2W
Grinder motor
Drive motor
Dispenser valve motor
220V 1200W
230V/50HZ 48W ULKA EP4
230V/50Hz 9-12VA
DC 220V
DC 24V
DC 24V
Capacities
Water tank
Coffee grounds container
Coffee bean container
Coffee powder volume for brew unit
1.8L
15 Pieces
250g
MIN 5g; MAX 14g
Various data
Dimensions（length×width×height）
Cable Length
Net weight
450×302×370 mm
approx 1.5 m
approx 11.5kg

Troubleshooting
15
3. Troubleshooting check list
3.1
3.2
3.1.1
3.2.1.1
3.2.1.2
3.2.1.3
3.1.2
3.2.1
3.2.2
3.1 Troubleshooting check list
Item Confirmation No. No. Cause Remedy RemarksProblem Prob-
ability
Examine
external
damage
of coffee
machine
Examine
the
external
moving
parts
External
parts are
broken or
damaged
Power cord
damaged
Drip tray
can not be
installed in
place
Drip tray
can not be
taken out
YES - If necessary - replace the
external parts
NO - continue to 3.1.2
YES - replace powder cord
Disassemble the
external parts
according to 4.2.1
Disassemble the powder
cord according to 4.2.2
Data interface
cover on the front
panel shedding
YES - Reassemble the data
interface cover fitted to the
front panel group,item: 73000202
NO - continue to point 3. 2.2.2
Replace or repair the
damaged components
according to the front
panel group explosive
view 8810102001
Much coffee
powder left on
the base
Brew unit doesnot
reset
YES - take out the drip tray,
observe if there are lots of coffee
powder on the base, clean the
rest coffee powder
NO - continue to 3.2.1.3
YES - 1. Take away the coffee
ground container 2. Insert the
drip tray into the coffee machine
3. Press ON/OFF 4. Take out the
drip tray after the coffee
machine reset and the screen
appears ""HEATING"" 5. Put the
coffee groud container on the
drip tray and insert them into the
coffee machine again
NO - continue to 3.2.1.4
Drip tray group
components
damaged
YES - replace the components
Replace or repair the
damaged components
according to the drip
tray explosive view
8810102001
3.2.1.4
3.2.2.1
3.2.2.2
Export blocked
the drip tray
Brew unit does not
reset, abnormal
power off
YES - move the export up
NO - continue to 3.2.2.2
YES - take the drip tray out when
the machine in READY state
NO - continue to 3.2.2.3
Restart more times if
once is not enough
3.2.2.3
Brew unit is stucked
by slag box coffee
grounds
YES - Take out the drip tray, then
remove the grounds container
capacity, and clean up the
coffee grounds inside
3.2.3.1
3.2.3.2
The following should be repaired or replaced water tank group
3.2.3
Replace or repair
damaged components
according to water
tank explosive view
8810101020
YES - move valve body in order to
make it reset
NO - continue to 3.2.3.2
YES - replace components
Valve body is
stucked, can not
be reset
Components
damaged
Water
leakage
from the
bottom
when
taking out
water tank
or filling in
water tank
3.2.4 3.2.4.1 YES - clean the coffee powder
NO- continue to 3.2.4.1
Powder
container
cover can
not be
covered
tightly
Lots of coffee
powder left below
the powder
container cover

3.2 3.2.4.2
3.3.1.1
3.3.1.2
3.3.1.3
3.3.1.4
3.3.1
3.3
16
3.2.4
3.3.1.5
3.3.1.6
3.3.1.7
3.3.1.9
3.3.1.8
3.3.2.1
3.3.2.2
3.3.2.3
3.3.2
Examine
the
external
moving
parts
Powder
container
cover can
not be
covered
tightly
Replace or repair
damaged components
according to bean
container explosive
view 8810101019
YES - replace powder container
cover 79000123
Powder container
cover deformed
Machine
can not be
powered
on
Press
On/Off to
AUTO
CHECKIN
G and
then to
READY
YES - use proper voltage for the
machine
NO - continue to 3.3.1.2
YES - replug the powder cord to
the powder socket
NO - continue to 3.3.1.3
Improper voltage
for the machine
Confirm if the
powder cord
connected
correct
The following should be repaired by dismatling the machine
Disassemble and
replace components
according to 4.2.2
1. Disassemble control
panel according to
4.2.8;
2. Disassemble
microswitch and
replace according to
4.3.4
YES - replacepowder cord
NO - continue to 3.3.1.4
YES - replace microswitch
73000051(item X4G303K1BB)
NO - continue to 3.3.1.5
Powder cord
damaged
Powder switch
damaged
The connector
between PCB and
powder switch
does not work
YES - connect or repair power
switch connector
NO - continue to 3.3.1.6
1. Disassemble control
panel according to
4.2.7;
2. Disassemble control
panel,repair connection
line according to 4.3.3
Disassemble right side
section according to
4.2.1
Disassemble back cover
according to 4.2.1
YES - connct or repair the
transformer connector
NO - continue to 3.3.1.7
YES - replace the fuse inside the
line pencil connector
NO - continue to 3.3.1.8
Transformer
connector fell off
or damaged
Fuse inside the line
pencil connetor is
damaged
Fuse on the PCBA
is damaged
YES - replace the fuse on the
PCBA
NO - continue to 3.3.1.9
Disassemble right side
section according to
4.2.1
Disassemble PCBA,
replace and repair
according to 4.2.11
YES - replace or repair PCBA,
item: 78000056
PCBA damaged
Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602
FILL WATER
TANK on
screen
YES - fill in the water tank
NO - continue to 3.3.2.2
YES - place the water tank again
NO - continue to 3.3.2.3
YES - clean water tank, knock the
place near the ball in order to
make the ball move inside water
tank
NO - continue to 3.3.2.4
No water in the
water tank
The water tank
does not install in
place
The ball inside the
water tank is
sticked
The following should be replaced or repaired the water tank group
Item Confirmation No. No. Cause Remedy RemarksProblem Prob-
ability
Troubleshooting

3.3.2.4
3.3.2.5
3.3.2.6
3.3.2.7
3.3
3.3.2
17
HMI damaged
3.3.3
3.3.3.1
3.3.3.2
3.3.3.3
3.3.3.4
3.3.3.5
3.3.3.6
3.3.4.2
3.3.2.8
3.3.4
3.3.4.1
Troubleshooting
Item Confirmation No. No. Cause Remedy RemarksProblem Prob-
ability
Press
On/Off to
AUTO
CHECKIN
G and
then to
READY
FILL WATER
TANK on
screen
YES - replace water tank group,
item: 8810101020
NO - continue to 3.3.2.5
YES - replace water tank group,
item: 8810101020
NO - continue to 3.3.2.6
The ball is fell off
Ball damaged
The following should be repaired by dismatling the machine
YES - replace reed sensor,
item: 73000095
NO - continue to 3.3.2.7
YES - connect or repair power
switch connector
NO - continue to 3.3.2.8
Reed sensor
damaged
Connector
damaged
PCBA damaged
Disassemble PCBA,
replace and repair
according to 4.2.11
YES - replace or repair PCBA,
item: 78000056
INSTALL
TRAY on
screen
YES - clean rest coffee powder
NO - continue to 3.3.3.2
YES - take out coffee grounds
container, reinstall drip tray
NO - continue to 3.3.3.3
Lots of coffee
powder left on the
base
Brew unit does not
reset
The following should be repaired by disassembling or changing proper parts
YES - replace coffee grounds
container frame item: 79000113
NO - continue to 3.3.3.4
YES - replace microswitch,
item: 73000088 (X3C306N2LB)
NO - continue to 3.3.3.5
YES - connect or repair
microswitch connector,
item: 78000022
NO - continue to 3.3.3.6
Replace or repair
damaged components
according to drip tray
explosive view
8810102001
Coffee grounds
container frame
damaged
Drip tray
microswitch
damaged
Drip tray
microswitch
connector does
not work
YES - replace or repair HMI,
item: 78000055
1. Disassemble control
panel according to
4.2.7;
EMPTY TRAY
on screen
YES - clean up the terminal
NO - continue to 3.3.4.2
YES - clean up the terminal
NO - continue to 3.3.4.3
Disassemble back
cover according to
4.2.1
Drip tray terminal
is wet
Base terminal is
wet

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3.3
3.3.4
3.3.5
3.3.4.3
3.3.5.1
3.3.5.2
3.3.5.3
3.3.5.4
3.3.6.1
3.3.6.2
3.3.6.3
3.3.6
Troubleshooting
Item Confirmation No. No. Cause Remedy RemarksProblem Prob-
ability
YES - replace or repair PCBA,
item: 78000056
Disassemble PCBA,
replace and repair
according to 4.2.11
PCBA damaged
The following should be repaired by dismatling the machine
Press
On/Off to
AUTO
CHECKIN
G and
then to
READY
EMPTY TRAY
on screen
No water
comes from
coffee
export
when
CLEANING
YES - power off the machine,
restart (drainage will be reset
when power on the machine)
NO - continue to 3.3.5.2
Stepper motor in
drainage valve
does not reset(
stepper motor still
in the drainage
position when
making coffee)
The following should be repaired by dismatling the machine
Inside pipe
connector
damaged- water
leakage(lots of
water on the
table)
YES - repair damaged pipe or
connector
NO - continue to 3.3.5.3
1. Disassemble
drainage valve group
according to 4.2.8;
2. Replace or repair
damaged components
according to drainage
valve group explosive
view 8810101006
YES - replace drainage valve
group
NO - continue to 3.3.5.4
Drainage valve
group damaged
1. Dismantle brew unit
according to 4.2.3;
2. Replace or repair
damaged components
according to brew unit
explosive view
8810101016
YES - replace contropistone seal,
item: 73000065
NO - continue to 3.3.5.5
Contropistone
seal damaged
YES - replace brew unit coffee
brewing unit,item: 881010032
NO - continue to 3.3.5.6
YES - replace brew unit seal,
item: 73000035
Brew unit piston
seal damaged
Brew unit waterseal
damaged
3.3.5.5
3.3.5.6
A little
water drops
from coffee
export
when
CLEANING (
normal
volume
should be
more than
35ml)
After cleaning,when
drainage starts,if the
noise is very loud, it
means brew unit filter
screen get clogged
YES - enter
menu-MAINTAINCE-CLEAN
NO - continue to 3.3.6.2
Brew unit filter
screen clogged
The following should be repaired by dismatling the machine
1. Disassemble
drainage valve group
according to 4.2.10;
2. Replace or repair
damaged components
according to drainage
valve group explosive
view 8810101006
YES - repair damaged pipe or
connector
NO - continue to 3.3.6.3
YES - replace drainage valve
group
NO - continue to 3.3.6.4
Inside pipe
connector
damaged-water
leakage(lots of
water on the
table)
Drainage valve
group damaged
Service Manual
Intelligent Fresh Ground Coffee Machine
KLM1602