Nescafe Dolce Gusto BEVERAGE CENTER GENIO 2 User manual

SERVICE MANUAL
BEVERAGE CENTER
GENIO 2
Version 1.1 en

Genio 2 service manual
2
CONTENTS
Main components.................................................................................................. 5
Overview of external parts............................................................................................ 5
Overview of internal parts............................................................................................. 6
Overview of rating plates.............................................................................................. 7
Krups rating plate ..................................................................................................... 7
De´Longhi rating plate .............................................................................................. 8
Breville rating plate (example).................................................................................. 9
Water circuit................................................................................................................ 10
Technical data ............................................................................................................. 11
Operating................................................................................................................ 14
Machine status ........................................................................................................... 14
Bargraph display ........................................................................................................ 15
Preparation, first use .................................................................................................. 16
Preparing a beverage................................................................................................. 18
Economy mode .......................................................................................................... 20
Empty fluid system for shipping.................................................................................. 20
Troubleshooting................................................................................................... 22
Checklist..................................................................................................................... 22
Repair....................................................................................................................... 26
General....................................................................................................................... 26
Safety information ...................................................................................................... 26
Tools and repair accessories...................................................................................... 27
Repair work without disassembling the machine ....................................................... 27
Removing / replacing needle plate, deblocking of needle ...................................... 27
General disassembly.................................................................................................. 30
Replacing water tank connector ................................................................................. 34
Assembly tip ........................................................................................................... 34
Replacing flowmeter................................................................................................... 35
Replacing pump ......................................................................................................... 36
Assembly tips ......................................................................................................... 39
Replacing NTC temperature sensor........................................................................... 41
Assembly tips ......................................................................................................... 42
Replacing power cord with thermo fuses ................................................................... 43
Assembly tips ......................................................................................................... 45
Replacing thermoblock............................................................................................... 46
Assembly tips ......................................................................................................... 47
Replacing electronic mainboard ................................................................................. 49
Assembly tips ......................................................................................................... 50
Replacing locking handle and control unit.................................................................. 51
Replacing electromagnet............................................................................................ 52
Assembly tip ........................................................................................................... 53
Replacing extraction head.......................................................................................... 54
Assembly tips ......................................................................................................... 55

Genio 2 service manual 3
Wiring diagram......................................................................................................56
Final testing............................................................................................................57
Test equipment............................................................................................................ 57
Heating up time........................................................................................................... 58
Flow rate (at 8 bar) / water temperature...................................................................... 58
Maximal pressure / leakage check.............................................................................. 60
Final inspections..................................................................................................61
General ....................................................................................................................... 61
Safety instructions....................................................................................................... 62
Protective earthing (PE) resistance test...................................................................... 62
Insulation resistance test............................................................................................. 63
Earth leakage current test ........................................................................................... 64
Leakage current test ................................................................................................... 65
Maintenance...........................................................................................................66
Descaling .................................................................................................................... 66
Daily care and final cleaning ....................................................................................... 70
Packing instructions .................................................................................................... 72
Krups spare parts ................................................................................................74
De´Longhi spare parts .......................................................................................78
NOTES ......................................................................................................................83

Genio 2 service manual
4
PREFACE
The purpose of this Service Manual is to provide the service personnel with all neces-
sary information with regards to correct handling, maintenance and repair of the Genio 2
beverage center W.I.K. model 9771.
This beverage center is a further development of the Genio beverage center W.I.K.
9747.12.
This Service Manual should be used by the technicians as a valuable aid to guarantee
the permanent readiness for use of the machine. In order to take full advantage of all the
functions, it is absolutely necessary to follow the instructions in this manual.
If you have any questions, please contact your country’s Nestlé hot line, listed in the user
manual.
For a quick information access, this service manual is also available in the internet as a
PDF file.
The required utility software to read PDF files (Adobe Reader®) for PCs and MAC
computers can be downloaded (under http://www.adobe.com) for free - please click the
logo:
Please keep this
manual together
with the corresponding
service documentation.
This way you are assured
to have the necessary
information.
If you display the
service manual on a
computer you can click
on the contents or on
page references to jump
to the required informa-
tion immediately.

Genio 2 service manual 5
MAIN COMPONENTS
MAIN COMPONENTS
Overview of external parts
This is the Krups
machine version
which is also shown in
the repair chapter.
1. Selection lever
2. Cold water setting
3. Hot water setting
4. Power button, illuminated (red, green)
5. Bargraph
(display of filling quantity)
6. Locking handle
7. Capsule holder
8. Drip grid
9. Drip tray
10. Capsule bin
11. Power cord (e.g. with Swiss power plug)
12. Cleaning needle
13. Water tank
7
11
12
13
6
8
9
10
23
4
5
1

Genio 2 service manual
6
MAIN COMPONENTS
Overview of internal parts
1. Needle plate
2. Reed sensor (capsule holder detection)
3. Electromagnet
4. Valve micro switch (selection lever setting)
5. Hot water pressure hose
6. Electronic main board with support
7. Cold water pressure hose
8. Main housing
9. NTC temperature sensor
10. Thermo fuses (2x)
11. Pump
12. Thermoblock
13. Flow meter
14. Water tank connector
1
2
3
4
6
7
5
9
8
11
12
13
14
10

Genio 2 service manual 7
MAIN COMPONENTS
Overview of rating plates
Krups rating plate
The rating plate
• can be found on the underside of the machine,
• carries the following information:
The rating plate is
laser-engraved.
www.krups.com
REF: KP160AAA /7Z0- WWYY R
TYPE KP160
220-240V~
50/60Hz
1340-1600W
Do not immerse in water
MADE IN CHINA
CCCCCCXYZ
Trade reference
WWYY = Fabrication date :
WW = Week / YY = Year
Commercial variant
Trade reference
Only if RoHS (Restriction of Hazardous
Substances) compliant
Fabrication origin code Technical variant
Origin variant if production transfer
Approval sign for European Union
Bar code label
CCCCCC = Serial number : 0 - 999999
X = Colour code : 6 = red, 9 = titanium,
8 = espresso red, 0 = piano black / matt
black, 2 = white / chocolate
Y = Country code: 0 = EU, 1 = CH, 2 = UK, 3 = US
4 = Brazil, 5 = Chile, 6 = Argentina, 7 = HK,
8 = Korea, J = Japan, M = Mexico,T = Taiwan
Z = Pump type : D = Defond, U = Ulka
Data Matrix code
Special disposal icon (do not dispose with
ordinary waste)
Technical variant
www.krups.com
REF: KP160AAA /7Z0- WWYY R
TYPE KP160
220-240V~
50/60Hz
1340-1600W
Do not immerse in water
MADE IN CHINA
CCCCCCXYZ

Genio 2 service manual
8
MAIN COMPONENTS
De´Longhi rating plate
The rating plate
• can be found on the underside of the machine,
• carries the following information:
The rating plate is
laser-engraved.
EDG = De´Longhi type reference
Type number for Genio : 465 / 466
Colour code: B =
piano black , S = silver
S = Work factory
FFFFFF = Supplier reference (e.g. 900202)
55132XXXXX = De´Longhi SKU reference
Y = Last digit of production year (e.g. 2013=3)
WW = Production week : 1 - 52
CC = Print date since year 1992
(e.g. 2013 - 1992 = 21 years)
Approval sign for European Union
Special disposal icon (do not dispose with
ordinary waste)
PL = Plug of power cord
XXX: 0 = EUR, 1= SEV, 2 = UK, 3 = US
Bar code reference
CCCCCC = Serial number : 0 - 999999
X = Colour code : 0 = piano black & anthracite,
1 = white & black, 2= white & red
Y = Country : 0 = EU, 1 = CH, 2 = UK,
3 = US, 4 = Brazil, 5 = Chile,
6 = Argentina, 7 = HK, 8 = Korea, J = Japan,
M = Mexiko, T = Taiwan, P = Phillipines,
S = Malaysia & Singapore, A = Australia
& New Zealand
Z = Pump type : D = Defond, U = Ulka
Data Matrix code

Genio 2 service manual 9
MAIN COMPONENTS
Breville rating plate (example)

Genio 2 service manual
10
MAIN COMPONENTS
Water circuit
1. Water tank with valve
2. Filter and connector
3. Flow meter
4. Pump
5. Thermoblock
6. Selection lever
7. F-connector
8. Capsule holder
9. Needle plate
10. Needle
1
2
4
5
6
8
9
10
7
3
7
9
1
2
4
5
3
6

Genio 2 service manual 11
MAIN COMPONENTS
Technical data
Mains voltage
Europe (UK, CH, DE, AT, FR, ES, PT, IT, NL, LU, BE, NO, SE, FI, DK,
GR, CZ, SK, PL, HU, RU, UA, LT, LV, EE, BG, RO, SI, BiH, SRB, HR)... 230 V / 50 Hz
USA / Canada ...........................................................................................120 V / 60 Hz
Japan ...................................................................................................100 V / 50/60 Hz
Mexico, Brazil............................................................................................ 127 V / 60 Hz
Approvals (country dependent) e.g.
Europe .......................................................................................................................CE
USA, Canada ......................................................................................... UL, C-UL, CSA
Japan ....................................................................................................................... JET
Russia ..................................................................................................................... PCT
Power consumption................................................................................max. 1’500 W
Thermoblock ..................................................................................................... 1’400 W
Pump...................................................................................................................... 41 W
Energy consumption (CECED / FEA 2009 method)
Energy efficiency class level ........................................................................................ A
Daily energy consumption.................................................................................... 90 Wh
Annual energy consumption............................................................................... 33 kWh
Preset water quantities (without capsule)
Bar graph segment 1 (bottom) ...............................................................................53 ml
Bar graph segment 2..............................................................................................68 ml
Bar graph segment 3..............................................................................................94 ml
Bar graph segment 4............................................................................................130 ml
Bar graph segment 5............................................................................................146 ml
Bar graph segment 6............................................................................................173 ml
Bar graph segment 7 (top) ...................................................................................230 ml
Bar graph segment 7 + XL ...................................................................................300 ml
Capacities
Water tank.......................................................................................................... max. 1 l
Drip tray.....................................................................................................approx. 70 ml
Environmental conditions
Operating temperature ................................5 °C up to + 45 °C (+ 41 °F up to + 113 °F)

Genio 2 service manual
12
MAIN COMPONENTS
Various data
Pre-heating time .....................................................................................approx. 30 sec.
Automatic shut off time (eco mode)........................................................................5 min
Hot beverage outlet temperature......................................85 °C ± 5 °C (185 °F ± 41 °F)
Descaling temperature ...............................................65 °C to 70 °C (149 °F to 158 °F)
Safety temperature for thermo block (thermal cut-off)........................... 133 °C (271 °F)
Safety temperature for pump (thermal cut-off) .......................................113 °C (235 °F)
Pump pressure ................................................................................ max. 13.5 ± 1.5 bar
Noise ....................................................................................................... max. 65 dB(A)
Dimensions [mm]
Dimensions (LxWxH)...........................................................................257 x 165 x 295 mm
Power cord length ........................................................................................ approx. 1 m
Weight of machine (without water) ........................................................... approx. 2.4 kg
295
257
165

Genio 2 service manual 13
MAIN COMPONENTS
Distance from drip grid to coffee outlet [mm]
Espresso ...............................................................................................................77 mm
Mug .....................................................................................................................120 mm
Tall glass .............................................................................................................150 mm
Higher cup (drip tray removed) ...........................................................................174 mm
120
77
150
174

Genio 2 service manual
14
OPERATING
OPERATING
Machine status
After switching on, an automatic self-test is performed to check if the
- capsule holder is inserted (with reed sensor)
- NTC is connected,
- NTC is not short circuited,
- the selection lever is in middle position,
- the thermoblock reaches the working temperature in about 30 seconds.
Operating modes and detected failures are indicated by LED signals of the power button
as listed in the following table:
Operating modes Power button Bar graph LED signals
Economy mode / Off —
Heating up / self-test red, blinking, approx.
30 sec.
Ready green, steady
After beverage preparation
(cool-down time)
red, blinking, approx.
5 sec.
Descaling ready and during
descaling cycle green, slow blinking
Error mode:
Hardware error
Pump switch-on time exceeds
10 min
Power button: red,
rapid blinking with
2.5 Hz
Error mode: No water flow
• Water tank or fluid system
empty
• Fluid system blocked
(calcified or needle
blocked)
Power button: alter-
nating red and green,
rapid blinking with
2.5 Hz
Bargraph display:
rapid blinking with
2.5 Hz
Error mode:
Selection lever / valve position
not detectable
Power button: red,
rapid blinking with
2.5 Hz
Bargraph: segment 1
rapid blinking with
2.5 Hz
XL
XL

Genio 2 service manual 15
OPERATING
Bargraph display
The bargraph display has 3 different functionalities:
1. Display of the filling quantity
2. Countdown timer
3. Flashlight signal
Error mode:
Thermoblock temperature over
115 °C (239°F)
Power button: red,
rapid blinking with
2.5 Hz
Bargraph: segment 7
rapid blinking with
2.5 Hz
Operating modes Power button Bar graph LED signals
XL
Each bargraph seg-
ment corresponds
to a certain water
volume. However some
of the suggested filling
quantities may not
correspond to the values
in millilitres exactly.
By pushing the selection lever up/down, the
bargraph display shows the according filling quan-
tity.
For easy operation, the suggested filling quantity is
printed as bargraph symbol on the capsule package
and on the cover of each capsule.
The bargraph display shows the remaining waiting time
during
- drink preparation
-rinsing
- descaling.
The bargraph display blinks
- during fill up mode (5 sec)
- after drink preparation (10 sec)
- if fluid system is empty or blocked.
173 ml
146 ml
130 ml
94 ml
68 ml
53 ml
230 ml /
300 ml (XL)
XL
XL
XL

Genio 2 service manual
16
OPERATING
Preparation, first use
The new machine has to be rinsed properly before first use according to the following
sequence:
The machine will
not work without a
capsule holder inserted.
The pre-heating
time is approx.
30 sec. The bargraph
display shows the
remaining time
(countdown).
If no water comes
out and machine
switches to error mode:
• Switch machine off
and on again.
• Check if water tank is
full and inserted
correctly.
• Move selection lever
again to the left to fill
the empty fluid
system.
1. Rinse water tank at first.
2. Fill water tank with fresh drinking
water.
3. Insert water tank into machine.
4. Remove drip tray
5. Open locking handle and insert
empty capsule holder. Then close
locking handle.
6. Place capsule bin (without insert)
under coffee outlet.
7. Connect power plug to mains power
socket.
8. Switch machine on.
9. Wait until power button light turns
steady green and machine is ready.
10. Push selection lever up to set the
bargraph display to maximum level.
11. Move selection lever to the left for
cold water rinsing.
12. Machine starts rinsing.
XL
XL
XL
ON
XL

Genio 2 service manual 17
OPERATING
13. Wait until countdown is finished and
machine stops.
14. Push selection lever up to set the
bargraph display to maximum level.
15. Move selection lever to the right for
hot water rinsing.
16. Machine starts rinsing.
17. Wait until countdown is finished and
machine stops.
18. Empty capsule bin.
19. Refill water tank with fresh drinking
water.
STOP
STOP
XL

Genio 2 service manual
18
OPERATING
Preparing a beverage
The drip tray is
height-adjustable in
3 levels.
Choose an
appropriate cup
size for beverage.
Users allergic to
dairy products:
clean capsule holder
under running water
before use.
For capsule prod-
uct range see user
manual or:
www.dolce-gusto.com
For filling
quantities see
bargraph symbol - on
capsule,
- or on product package,
- or in product overview
in user manual.
The flow speed
resp. preparation
time depends on the
used capsule.
Extraction can be
stopped manually
(e.g. cup overflows) by
moving the selection lever
back to the middle position.
1. Check if water tank is filled.
2. Check if machine is ON and ready.
3. Adjust drip tray according to chosen
beverage and cup size.
4. Place cup on drip tray.
5. Check sequence for beverages with
2 capsules.
6. Check bargraph symbol for setting of
filling quantity.
7. Open locking handle and pull out
capsule holder.
8. Insert a capsule in capsule holder
(e.g. Lungo).
9. Insert capsule holder in machine and
close locking handle.
10. Set bargraph display with selection
lever according to capsule’s
bargraph symbol or to your own
taste. Choose XL setting for an extra
large cup (see detail).
11. Push the selection lever to the right
for hot beverages or to the left for
cold beverages.
12. Beverage preparation starts and
bargraph display counts down
progressively until machine stops.
XL
XL
CAFFÉ LUNGO
XL
STOP

Genio 2 service manual 19
OPERATING
Danger of damage
and hot water /
product splashes.
Do not open locking
handle prematurely.
Risk of burning
from hot capsule.
Do not touch capsule
immediately after use.
13. Wait until the bargraph display stops
flashing and the power button stops
blinking red after about 10 seconds.
14. Take cup from drip tray.
15. Open the locking handle.
16. Pull out capsule holder and remove
used capsule.
17. Discard used capsule in capsule bin
or trash bin.
18. Rinse both sides of the capsule
holder with water and let dry.
19. Insert capsule holder into machine.
XL
XL
XL
XL

Genio 2 service manual
20
OPERATING
Economy mode
After 5 minutes without operation, the machine switches itself OFF automatically.
This feature helps to save electricity by reducing the amount of power the machine
draws while it is not in use and helps to protect the life of the machine.
To resume operation, simply press the power button.
Empty fluid system for shipping
It is not possible to
de-activate the
economy mode.
For shipping a
machine, it is
important to empty the
fluid system that can
contain up to 25 ml
water.
The machine will
not work without
inserted capsule holder.
Prolonged dry-
running can dam-
age the pump. Do not
push the selection lever
in the same direction
repeatedly.
1. Empty water tank and drip tray. 2. Check that capsule holder is empty.
3. Reinstall capsule holder.
4. Place capsule bin under outlet. 5. Set bargraph display to minimum
level with selection lever (if not
displayed already).
6. Push selection lever to the left (cold
water).