Bunn FMD 4 User Manual

®
BUNN  
FMD-4  
FMD-5  
RINSE  
E
IS 2/3 FULL, THEN RELEAS  
CUP  
ON UNTIL  
RINSE  
PUSH and HOLD BUTT  
PLACE  
HERE  
CUP  
RINSE  
RNING  
IS 2/3 FULL  
!
U
D
H
I IT  
L
PLACE  
HERE  
CUP  
ON WHEN CUP  
RELEASE BUTT  
PLACE  
HERE  
CUP  
IS 2/3 FULL, THEN RELEASE  
CUP  
ON UNTIL  
PLACE  
HERE  
CUP  
RINSE  
PUSH and HOLD BUTT  
NING  
PLACE  
HERE  
CUP  
IS 2/3 FULL  
W
!
H
I
I
T
D
L
ON WHEN CUP  
ELEASE BUTT  
PLACE  
HERE  
CUP  
PLACE  
HERE  
CUP  
OPERATING & SERVICE MANUAL  
BUNN-O-MATIC CORPORATION  
POST OFFICE BOX 3227  
SPRINGFIELD, ILLINOIS 62708-3227  
PHONE: (217) 529-6601 FAX: (217) 529-6644  
35135.0000 03/03 ©2003 Bunn-O-Matic Corporation  
USER NOTICES (Cont.)  
00656.0000  
00831.0000  
28368.0000  
FMD-4 28964.0004  
FMD-5 28964.0003  
35135 012103  
3
INITIAL SET-UP  
1. Locate the drip tray assembly inside the dispenser door.  
2. Remove the drip tray and the drip tray cover and set them aside.  
ELECTRICAL REQUIREMENTS  
CAUTION - The dispenser must be disconnected from the power source until specified in Initial Set-Up.  
The 120 volt version of this dispenser has an attached cordset and requires 2-wire, grounded service rated 120  
volts ac, 15 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-15R.  
The 120/208 and the 120/240 versions of this dispenser has an attched cordset. The mating connector must be  
a NEMA 14-20R.  
(Refer to the dispenser’s dataplate for exact voltage requirement.)  
ELECTRICAL HOOK-UP  
CAUTION – Improper electrical installation will damage electronic components.  
1. An electrician must provide electrical service as specified.  
2. Using a voltmeter, check the voltage and color coding of each conductor at the electrical source.  
3. Open the front door of the dispenser and place the heater switch in the “OFF” (upper position).  
4. Connect the dispenser to the power source.  
5. If plumbing is to be hooked-up later be sure the dispenser is disconnected from the power source. If plumb-  
ing has been hooked-up, the dispenser is ready for Initial Fill & Heat.  
PLUMBING REQUIREMENTS  
This dispenser must be connected to a cold water system with operating pressure between 20 and 100 psi  
(138 and 690 kPa). This water source must be capable of producing a minimum flow rate of 4.5 fluid ounces  
(133.1 ml) per second. A shut-off valve should be installed in the line before the dispenser. Install a regulator in  
the line when pressure is greater than 100 psi (690 kPa) to reduce it to 50 psi (345 kPa). The water inlet fitting  
is 38" flare.  
NOTE - At least 18 inches of an FDA approved flexible beverage tubing, such as reinforced braided polyethylene  
or silicone, before the dispenser will facilitate movement to clean the countertop. It can be purchased direct from  
Bunn-O-Matic (part number 00327-0000). Bunn-O-Matic does not recommend the use of a saddle valve to  
install the dispenser. The size and shape of the hole made in the supply line by this type of device may restrict  
water flow.  
This equipment must be installed to comply with the Basic Plumbing Code of the Building  
Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanita-  
tion Manual of the Food and Drug Administration (FDA).  
PLUMBING HOOK-UP  
1. Flush the water line and securely attach it to the flare fitting on the bottom of the dispenser.  
2. Turn-on the water supply.  
35135 012103  
4
INITIAL FILL & HEAT  
CAUTION - The dispenser must be disconnected from the power source throughout the initial set-up, except  
when specified in the instructions.  
1. Turn-on the water supply and connect the dispenser to the power source.  
2. Water will automatically flow into the tank to the proper level and then shut-off. This will take less than five  
minutes.  
3. When the tank is full of water, open the front door and place the heater switch in the “ON” (lower) position.  
A tank full of cold water will take approximately eighty minutes for the water to heat on 120 volt versions or  
forty minutes for 120/208 volt versions and 120/240 volt versions.  
During this waiting period, complete these dispenser set-up steps:  
a. Place the drip tray in front of the dispenser. Set the drip tray cover in place.  
b. Place a set of keyholes in the cup locator plate over the screws beneath the hopper access door and push down  
gently.  
c. Fill the hoppers with the dry product to be dispensed.  
LIQUID LEVEL CONTROL  
The system automatically maintains the hot water tank’s level by energizing the refill solenoid when the water  
leveldropsbelowtheliquidlevelprobe.Ifthesystemhasnotsuccessfullyrefilledin15minutes,arefillerroroccurs.  
When a refill error occurs, the refill solenoid is de-energized and the left rinse L.E.D. will flash about once every  
5 seconds. Once the cause of the refill error has been investigated (see the troubleshooting guide in the Operating  
and Service Manual) and cured, the system can be reset by placing the Rinse/Run switch in the programming  
(center) position, momentarily.  
RINSE TIMERS  
The dispenser is shipped from the factory with the rinse timers disabled. To enable the rinse timers, remove  
power from the dispenser, remove the lower access panel, and remove the jumper from J1 of the control boards.  
Replace the lower access panel, and return power to the dispenser. When enabled, the rinse timers automatically  
keep track of the time since the dispenser was last run through a rinse sequence. If the dispenser detects that a  
rinsesequencehasnotbeenrunfor8hours,theappropriaterinseL.E.D.willflashcontinually. If,afteranadditional  
4hours(12hourstotal), arinsesequencehasstillnotbeenrun, theappropriaterinseL.E.D. willlightcontinuously,  
and the appropriate hopper drives will be disabled until a rinse sequence has been run.  
RUNNING A RINSE SEQUENCE  
1. Place the rinse/run switch in the rinse position.  
2. Sequentially, or simultaneously, at each of the positions dispense for at least 10 seconds.  
3. After the rinse L.E.D. has extinguished, the rinse timer is reset.  
4. Return the rinse/run switch to the run position.  
DISPENSER USE  
1. Simply place a cup on the drip tray beneath the dispensing tip.  
2. Press the button and dispense the beverage.  
3. Release the button when the cup is approximately 2/3 full and allow the whipper chamber to drain.  
NOTE - The whipper chamber must drain at the end of each dispense.  
35135 012103  
5
COLD BEVERAGE SET-UP (OPTIONAL)  
Cold beverages may be dispensed from the left dispense position. Simply place the HOT/COLD switch near the left  
whipper chamber in the “COLD” (upper) position.  
CLEANING  
Refer to the decal on the rear of the dispenser door for cleaning recommendations and proccedures.  
Theuseofadampclothrinsedinanymild, non-abrasive, liquiddetergentisrecommendedforcleaningallsurfaces  
on Bunn-O-Matic equipment.  
ADJUSTMENTS  
The beverage solenoid is preset to dispense approximately 9/10 ounce per second. This amount can be adjusted:  
1. Disconnect the dispenser from the power source.  
2. Remove product hopper(s).  
3. Remove the hole plug(s) in the auger motor mounting panel.  
4. Rotatethecontrolatthebaseofthesolenoidclockwisetodecreaseorcounterclockwisetoincreasetheamount  
of water.  
5. Reinstall plug(s) and hopper(s).  
HOPPER MOTOR SPEED PROGRAMING  
The hopper dispense rate is preset at the factory. With 22 tooth gear and auger wire the preset dispense rate is  
approximately3to5gramspersecond.With30toothgearandaugerwirethepresetdispenserateisapproximately  
5 to 7 grams per second. The hopper dispense rate can be adjusted to produce a wide range of dispense rates as  
follows:  
1. Place the rinse/run switch in the center (program) position.  
2. Place the increase/decrease switch in the desired (increase or decrease) position.  
3. Press and release the dispense switch for the chamber you wish to adjust. Each time the dispense switch is  
pressed, the rinse L.E.D. will flash, and the motor speed for that hopper will be increased/decreased by  
approximately 2 1/2%.  
4. Return the rinse/run switch to the run position after hopper motor speed adjustments are complete.  
35135 012103  
6
DRAINING THE HOT WATER TANK  
CAUTION - The dispenser must be disconnected from the power source throughout these steps.  
1. Disconnect the dispenser from the power source.  
2. Place the tank heater switch in the “OFF” position.  
3. Shut-off and disconnect the incoming water supply.  
4. Remove the front, lower access panel.  
5. Pull out drain tube to empty into a sink or a container with a minimum of 6-1/2 gallon capacity.  
6. Make sure drain clamp is closed. Then, remove drain plug.  
7. Direct tube into sink or container and open drain clamp. Continue draining tank until ALL of the water is out.  
WARNING: Be very careful with the draining water because it can be very hot.  
8. Close drain clamp, insert drain plug, place drain tube back into machine, and replace lower access panel.  
NOTE - The dispenser must be refilled using the INITIAL FILL & HEAT steps before reconnecting to the power  
source.  
35135 012103  
7
TROUBLESHOOTING  
A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems  
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic  
Technical Service Department.  
Inspection, testing, andrepairofelectricalequipmentshouldbeperformedonlybyqualifiedservicepersonnel.  
All electronic components have 120 volt ac and low voltage dc potential on their terminals. Shorting of  
terminals or the application of external voltages may result in board failure.  
Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If an  
intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a  
terminal or crimp.  
Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are  
energized for more than ten minutes without a supply of water.  
Theuseoftwowrenchesisrecommendedwheneverplumbingfittingsaretightenedorloosened. Thiswillhelp  
to avoid twists and kinks in the tubing.  
Make certain that all plumbing connections are sealed and electrical connections tight and isolated.  
This unit is heated at all times. Keep away from combustibles.  
WARNING – • Exercise extreme caution when servicing electrical equipment.  
• Unplug the dispenser when servicing, except when electrical tests are specified.  
• Follow recommended service procedures  
• Replace all protective shields or safety notices  
REMEDY  
PROBLEM  
PROBABLE CAUSE  
Water lines and valves to the dis-  
penser must be open.  
Product will not dispense  
1. No water  
(A1) Check for 120 volts across the  
black and white wires on two wire  
120 volt dispensers.  
2. No power or incorrect voltage to  
the dispenser  
(A2) Check for 120 volts across the  
red and white wires and the black  
and white wires, 208 volts across  
the red and black wires on three wire  
120/208 volt dispensers and 240  
volts across the red and black wires  
on three wire 120/240 volt dispens-  
ers.  
(B) Check circuit breakers or fuses.  
Refer to Service - Dispense Switch  
for testing procedure. See page 23  
3. Dispense Switch  
RefertoService-DispenseSolenoid  
Valve for testing procedures. See  
page 35  
4. Dispense Solenoid Valve  
35135 012103  
8
TROUBLESHOOTING (cont.)  
PROBLEM  
Product will not dispense (cont.)  
PROBABLE CAUSE  
5. Solenoid Valve (Inlet)  
REMEDY  
Refer to Service - Solenoid Valve  
(Inlet) for testing procedures. See  
page 37  
6. Control Board #1 and Probe  
Refer to Service - Control Board and  
Probe for testing procedures. See  
page 20  
7. Auger Drive  
Refer to Service - Auger Drive. See  
page 13 & 15  
8. Water Strainer  
9. Lime build-up  
Remove the strainer and check for  
obstructions. Clear or replace.  
Inspectthetankassemblyforexces-  
CAUTION - Tank and tank compo- sive lime deposits. Delime as re-  
nents should be delimed regularly quired.  
dependingonlocalwaterconditions.  
Excessivemineralbuild-uponstain-  
lesssteelsurfacescaninitiatecorro-  
sive reactions resulting in serious  
leaks.  
10. Transformer  
Refer to Service - Transformer for  
testing procedures. See page 41  
1. Limit Thermostat  
CAUTION - Do not eliminate or by- for testing procedures. See page 31  
passlimitthermostat.UseonlyBOM  
Refer to Service - Limit Thermostat  
Water is not hot  
replacement part #29329.1000  
2. Control Thermostat  
Refer to Service - Control Thermo-  
statfortestingprocedures.Seepage  
19  
3. Tank Heater  
Refer to Service - Tank Heater for  
testing procedures. See page 38  
35135 012103  
9
TROUBLESHOOTING (cont.)  
PROBLEM  
PROBABLE CAUSE  
REMEDY  
Water is not hot (Cont.)  
4. Tank Heater Switch  
RefertoService -TankHeaterSwitch  
for testing procedures. See page 39  
5. Relay (120V versions only)  
Refer to Service - Relay for testing  
procedures. See page 40  
6. Control Board #2 (120V versions Refer to Service - Control Board #2  
only)  
for testing procedures. See page 22  
Spitting or excessive steaming  
1. Lime build-up  
Inspectthetankassemblyforexces-  
CAUTION - Tank and tank compo- sive lime deposits. Delime as re-  
nents should be delimed regularly quired.  
dependingonlocalwaterconditions.  
Excessivemineralbuild-uponstain-  
lesssteelsurfacescaninitiatecorro-  
sive reactions resulting in serious  
leaks.  
2. Control Thermostat  
Refer to Service - Control Thermo-  
stat for testing procedures. See  
page 19  
Dripping from dispense tip  
1. Lime build-up  
Inspectthetankassemblyforexces-  
CAUTION - Tank and tank compo- sive lime deposits. Delime as re-  
nents should be delimed regularly quired.  
dependingonlocalwaterconditions.  
Excessivemineralbuild-uponstain-  
lesssteelsurfacescaninitiatecorro-  
sive reactions resulting in serious  
leaks.  
2. Dispense Solenoid Valve  
Removethedispensesolenoidvalve  
and clear any obstructions. Rebuild  
orreplacethevalveifnecessary.See  
page 35  
Water flows into tank continuously  
1. Control Board #1 and Probe  
2. Solenoid Valve (Inlet)  
Refer to Service - Control Board and  
Probe for testing procedures. See  
page 20  
Refer to Service - Solenoid Valve  
(Inlet) for testing procedures. See  
page 37  
35135 012103  
10  
TROUBLESHOOTING (cont.)  
PROBLEM  
PROBABLE CAUSE  
REMEDY  
1. Dispense Switch  
Product overflows container  
Refer to Service - Dispense Switch  
for testing procedures. See page 23  
2. Dispense Solenoid Valve  
1. Water Temperature  
Removethesolenoidvalveandclear  
anyobstructions. Rebuildorreplace  
the valve if necessary. See page 35  
Weak product  
Place an empty container beneath  
the dispense tip. Initiate a dispense  
cycle and check the water tempera-  
tureimmediatelybelowthedispense  
tip with a thermometer. Reading  
should be 180°F to 200°F (see ther-  
mostat temperature settings decal  
in USER NOTICES on page 3.)  
2. Whipper Motor  
3. Frother  
RefertoService -WhipperMotorfor  
testing procedure. See page 27  
Refer to Service - Frother Compo-  
nents. See page 26  
4. Dispense Solenoid Valve  
RefertoService-DispenseSolenoid  
Valve for test procedures. See page  
35  
5. Auger Drive  
Refer to Service - Auger Drive Com-  
ponents. See page 13 & 15  
6. Auger Spring  
Refer to Service - Auger Drive Com-  
ponents. See page 13 & 15  
7. Auger Motor  
Refer to Service - Auger Drive Com-  
ponents. See page 13 & 15  
8. Rinse/Run Switch  
9. Rinse Timer  
Refer to Service - Rinse/Run Switch  
for test procedures. See page 32  
Refer to Operation - Rinse Timer.  
See Page 5  
10. Relay (120V versions only)  
Refer to Service - Relay for testing  
procedures. See page 40  
11.ControlBoard#2(120Vversions  
only)  
Refer to Service - Control Board #2  
for testing procedures. See page 22  
35135 012103  
11  
TROUBLESHOOTING (CONT.)  
PROBLEM  
PROBABLE CAUSE  
REMEDY  
1. Plumbing Lines  
Plumbing lines should not be rest-  
ing on the counter top.  
Dispenser is making unusual  
noises  
2. Water Supply  
(A)Thedispensermustbeconnected  
to a cold water line  
(B) Water pressure to the dispenser  
must not exceed 100 psi (690 kPa).  
Install a regulator if necessary to  
lower the working pressure to ap-  
proximately 50 psi (345 kPa).  
3. Tank Heater  
1. Fan  
Remove and clean lime off the tank  
heater. See page 38  
Refer to Service - Fan for testing  
procedures. See page 25  
Excess dust  
1. Lamp  
RefertoService- Lamp,seepage29  
for lamp replacement.  
Display not lit  
2. Lamp Holder  
3. Starter - Lamp  
4. Ballast  
Refer to Service - Lamp Holder for  
testing procedures. See page 29  
Refer to Service - Starter for testing  
procedures. See page 30  
Refer to Service - Ballast for testing  
procedures. See page 18  
35135 012103  
12  
AUGER DRIVE COMPONENTS FMD-4  
SERVICE  
This section provides procedures for testing and  
replacing various major components used in this  
dispenser should service become necessary. Refer to  
Troubleshooting for assistance in determining the  
cause of any problem.  
WARNING - Inspection, testing, and repair of electri-  
cal equipment should be performed only by qualified  
service personnel. The dispenser should be un-  
plugged when servicing, except when electrical tests  
are required and the test procedure specifically states  
to plug-in the dispenser.  
COMPONENT ACCESS  
WARNING-Disconnectthedispenser fromthepower  
source before the removal of any panel or the replace-  
ment of any component.  
J1  
J2  
J4  
All components are accessible by opening the  
door, removal of the door panels, dispenser top cov-  
ers, hopper(s), hopper support plate, splash guard,  
splash panel w/drip tray, lower front access panel and  
rear access cover.  
J3  
J1  
J2  
J4  
J3  
P2635  
Refer to the contents listing for component loca-  
tion.  
FIG. 1 AUGER DRIVE COMPONENTS  
Location  
Contents  
The auger components are located inside the  
bottom part of the hopper except for the auger drive  
bracket, spacer and retaining clip, which are located  
on the outside rear of the hopper base. The auger  
motor is located on the lower right rear of the motor  
mounting panel. Refer to Fig. 2 for disassembly and  
assembly.  
Auger Drive Components (FMD-4) .......................13  
Auger Drive Components (FMD-5) .......................15  
Ballast...................................................................18  
Control Thermostat...............................................19  
Control Board .......................................................20  
Dispense Switch ...................................................23  
Fan........................................................................25  
Frother ..................................................................26  
Increase/Decrease Switch.....................................28  
Lamp Holder .........................................................29  
Lamp ....................................................................29  
Lamp Starter and Socket ......................................30  
Limit Thermostat ..................................................31  
Rinse/Run Switch .................................................32  
Hot/Cold Switch-Optional .....................................33  
Solenoid (Cold Water - Optional) ..........................34  
Solenoid (Dispense) .............................................35  
Solenoid (Inlet) .....................................................37  
Tank Heater...........................................................38  
Tank Heater Switch ...............................................39  
Tank Heater Relay .................................................40  
Transformer ..........................................................41  
Whipper Motor .....................................................27  
Wiring Diagram .............................................. 42-45  
Test Procedures - Auger Motor  
1. Disconnect the dispenser from the power source.  
2. Disconnect the white/red wire and the white wire  
from the hopper speed control board.  
3. Check the voltage across the white/red wire and  
the white wire with a voltmeter. With the rinse/  
run switch in the run (lower) position, connect  
the dispenser to the power supply. The indica-  
tion must be :  
a) 120 volts ac for two wire 120 volt models.  
b) 120 volts ac for three wire 120/208 volt or  
120/240 volt models.  
4. Disconnect the dispenser from the power sup-  
ply.  
If voltage is present as described, proceed to #5.  
If voltage is not present as described, refer to the wir-  
ing diagram and check the dispenser wiring harness.  
35135 012103  
13  
SERVICE  
AUGER DRIVE COMPONENTS - FMD-4 (CONT.)  
1
2
5. Check the voltage across the positive (red wire)  
terminal and the negative (black wire) terminal on  
the auger motor with a voltmeter. With the rinse/  
run switch in the run (lower) position press and  
hold the dispense switch. Connect the dispenser  
to the power supply. After a .6 second delay the  
indication must be 4.0 to 24.5 volts dc.  
3
4
6
5
If voltage is present as described, the auger motor  
drive is operating properly. If auger does not turn,  
replace the auger motor.  
If voltage is not present as described, replace the  
auger hopper drive board.  
12  
13  
14  
7
8
9
10  
Removal, Cleaning and Replacement  
Hopper & Auger  
1. Open the dispenser door and raise the top front  
cover.  
15  
2. Lift the hopper assy (15) over the pins on hopper  
support plate (11) and slide hopper assembly out  
the front of the dispenser.  
3. Remove hopper lid (1) and empty product.  
4. Pull off the ejector elbow (14).  
5. Remove retainer clip (10) and washer (9) from the  
bottom of the hopper base (8).  
6. Remove whipper shaft (3), wiper blade (4) and  
wiper drive gear (5) from the hopper base (8).  
7. Remove auger wire (13) by pulling it out the front  
of the hopper base (8).  
8. Removeaugerdrivebracket(6)byunscrewingleft  
hand threads from auger drive shaft (12).  
9. Slide spacer (7) and auger drive shaft bracket (6)  
off of the auger drive shaft (12).  
16 17 18 19 11  
P2633  
FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY  
10. Remove auger drive shaft (12) from hopper base  
(8).  
1. Hopper Lid  
2. Hopper  
3. Wiper Shaft  
4. Wiper Blade  
5. Wiper Drive Gear  
6. Auger Drive Bracket  
7. Spacer  
8. Hopper Base  
9. Washer  
10. Retainer Clip  
11. Hopper Support Plate  
12. Auger Drive Shaft  
13. Auger Wire  
14. Ejector Elbow  
15. Hopper Assembly  
16. Auger Motor Bracket  
17. Auger Motor  
18. Dust Seal  
19. Auger Motor Mounting  
panel  
11. Washcomponentsinamildsolutionofdishdeter-  
gent using a bristle brush when needed.  
12. Rinse and dry each item thoroughly.  
13. Check for damaged or broken components, re-  
place any if necessary and reassemble hopper  
assembly.  
14. Installhopperassy(15)in thedispenserbysliding  
hopperassy onthehoppersupportplate(11)until  
the slot in the rear of the hopper base (8) seats  
against the pins in the hopper support plate (11).  
35135 012103  
14  
AUGER DRIVE COMPONENTS - FMD-4 & FMD-5  
SERVICE (cont.)  
AUGER DRIVE COMPONENTS - FMD-4 (cont.)  
Auger Drive Motor (Refer to Fig. 2)  
1. Remove hopper assy (15), and set aside for reas-  
sembly.  
2. Remove the four #8-32 screws securing the hop-  
per support plate (11), remove plate and set aside  
for reassembly.  
3. Remove the four #8-32 screws, located inside the  
dispenser housing on the lower right front of the  
auger motor mounting panel (19), securing auger  
motor mounting bracket (16) and auger motor  
(17) to the rear of the auger motor mounting panel  
(19).  
4. Disconnect the wires from the hopper drive board.  
5. Remove auger motor mounting bracket (16), au-  
ger motor (17) and dust seal (18) as an assembly.  
6. Remove dust seal (18) from auger motor (17).  
7. Disconnect the wires from the auger motor (17).  
8. Removethefour#8-32screwssecuringthe auger  
motor (17) to the auger motor mounting bracket  
(16).  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
9. Remove auger motor (17) and discard.  
10. Using four #8-32 screws install new auger motor  
(17) on mounting bracket (16).  
11. Install dust seal (18) on auger motor shaft and  
align notch in seal with motor casting.  
12. Reconnect the wires to the terminals on the hop-  
per drive board.  
13. Refer to Fig. 3 when reconnecting wires.  
14. Using four #8-32 locking screws install auger  
motor, dust seal and mounting bracket to the rear  
of the auger motor mounting panel (19).  
15. Install hopper assy (15).  
P2635  
FIG. 4 AUGER DRIVE COMPONENTS  
Location  
The auger components are located inside the  
bottom part of the hopper except for the auger drive  
bracket, washer and locknut, which are located on the  
outside bottom rear of the hopper. The auger motors  
are located on the rear of the auger motor mounting  
panel. Refer to Fig. 5 for disassembly and assembly.  
Test Procedures - Auger motors  
STATIONS 1 - 4  
1. Disconnect the dispenser from the power source.  
2. Disconnect the wires from the motor to be tested.  
3. Check the voltage across the positive (white/or-  
ange) wire for the right motor, or the positive  
(white/red) wire for the left motor and the negative  
(green) wire with a voltmeter. With the rinse/run  
switch in the run (lower) position press and hold  
the appropriate dispense switch. Connect the dis-  
penser to the power supply. After a .6 second  
delay the indication must be 4.0 to 24.5 volts dc.  
RED to BRN/WHI from  
Control Board #1 J3-3  
RED to WHI/RED from  
Control Board #1 J3-2  
RED to WHI/ORN from  
Control Board #1 J3-1  
RED to WHI/YEL from  
Control Board #2 J3-3  
BLK to GRN from  
Control Board J3-4  
P1639  
FIG. 3 AUGER MOTOR TERMINALS  
35135 012103  
15  
SERVICE (cont.)  
AUGER DRIVE COMPONENTS - FMD-4 & FMD-5  
(cont.)  
1
2
4. Disconnect the dispenser from the power supply.  
4
5
If voltage is present as described and the auger does  
not turn, replace the auger motor.  
If voltage is not present as described, refer to the wir-  
ing diagrams and check the dispenser wiring harness.  
3
8
7
6
9
10  
Removal, Cleaning and Replacement  
Hopper & Auger  
1. Open the dispenser door and raise the top front  
cover.  
2. Lift the front edge of hopper assy (20) over the  
tab on hopper support plate (19) and slide hop-  
per assembly out the front of the dispenser.  
3. Remove hopper lid (1) and empty product.  
4. Pull off the ejector elbow (13).  
11  
5. Remove agitator disc assy (2) by pulling agitator  
support rod (4) towards agitator disc assy and  
lifting agitator disc assy from hopper (10).  
6. Remove auger (12) by pulling it out the front of  
the hopper (10).  
7. Remove auger drive shaft (5) by removing the  
retaining clip (6) from auger drive shaft.  
8. Slide washer (8) and auger drive shaft bracket  
(7) off of the auger drive shaft (5).  
9. Slide auger drive shaft (5) from auger drive shaft  
bushing (3) and remove from hopper (10).  
10. Remove locknut (9) from auger drive shaft bush-  
ing (3) and remove auger drive shaft bushing  
from hopper (10).  
14 15 16 12 13  
P2634  
11. Wash components in a mild solution of dish de-  
tergent using a bristle brush when needed.  
12. Rinse and dry each item thoroughly.  
13. Check for damaged or broken components, re-  
place any if necessary and reassemble hopper  
assy.  
14. Installhopperassy(20)in thedispenserbysliding  
hopper assy in the guides on the hopper support  
plate (19) until the slot in the bottom rear the  
hopper seats against the pin (18) in the hopper  
support plate.  
FIG. 5 AUGER DRIVE & HOPPER DISASSEMBLY  
1. Hopper Lid  
2. Mixing Blade  
3. Agitator Disk  
4. Auger Drive Shaft  
Bushing  
5. Auger Drive Shaft  
6. Locknut  
9. Auger Wire  
10. Ejector Elbow  
11. Hopper Assy  
12. Auger Motor Mounting  
Panel  
13. Hopper Support Plate  
14. Auger Motor Bracket  
7. Auger Drive Bracket 15. Auger Motor  
8. Hopper  
16. Dust Seal  
35135 012103  
16  
SERVICE (cont.)  
AUGER DRIVE COMPONENTS - FMD-4 & FMD-5  
(cont.)  
STATIONS 1 - 5  
RED to BRN/WHI from  
Control Board #1 J3-3  
RED to WHI/RED from  
Control Board #1 J3-2  
RED to WHI/ORN from  
Control Board #1 J3-1  
RED to WHI/YEL from  
Control Board #2 J3-3  
RED to WHI/BLU from  
Control Board #2 J3-2  
Auger Drive Motor (Refer to Fig. 5)  
1. Remove all hopper assemblies (20) and set aside  
for reassembly.  
2. Remove the four #8-32 screws securing the hop-  
per support plate (19), remove plate and set aside  
for reassembly.  
3. Remove the four #8-32 locking screws, located  
inside the dispenser housing on the front of the  
auger motor mounting panel (14), securing auger  
motor mounting bracket (15) and auger motor  
(16) to the rear of the auger motor mounting panel  
(14).  
BLK to GRN from  
Control Board J3-4  
4. Disconnect the wires from the auger motor (16) to  
be removed.  
5. Remove auger motor mounting bracket (15), au-  
ger motor (16) and dust seal (17) as an assembly.  
6. Remove dust seal (17) from auger motor (16).  
7. Remove the four #8-32 screws securing the auger  
motor to the auger motor mounting bracket.  
8. Remove auger motor and discard.  
9. Using four #8-32 screws install new auger motor  
(16) on mounting bracket (15).  
P1639  
FIG. 6 AUGER MOTOR TERMINALS  
10. Install dust seal (17) on auger motor shaft.  
11. Using four #8-32 locking screws install auger  
motor, dust seal and mounting bracket to the rear  
of the auger motor mounting panel (14)  
12. Reconnect the wires to the terminals on the auger  
motor.  
13. Install hopper support plate (19) and all hopper  
assemblies (20).  
14. Refer to Fig. 6 when reconnecting wires.  
35135 012103  
17  
SERVICE (cont.)  
Removal and Replacement  
BALLASTS - FMD-4 & FMD-5  
1. Loosen the three #8-32 screws securing the com-  
ponent bracket to the dispenser housing base.  
2. Pull component bracket out the front of the dis-  
penser far enough so the leads on each ballast can  
bedisconnectedfromthemainwiringharnessand  
the door interconnect harness.  
3. Remove the two #8-32 screws securing each  
ballast to the rear of the component bracket.  
4. Remove and discard the ballast.  
5. Install new ballast on the rear of the component  
bracket and secure each with two #8-32 screws.  
6. Refer to Fig. 8 and reconnect the wires.  
7. Place the component bracket into position and  
tightenthetwo#8-32screwssecuringthecompo-  
nent bracket to the dispenser housing base.  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
BLK to BLK  
from Main  
Wiring Harness  
P2635  
BLK to RED from  
Main Harness  
FIG. 7 BALLASTS  
Location  
The front door lamp ballast is located behind the  
front access panel on the left front side of the compo-  
nent bracket.  
P1447  
FIG. 8 BALLAST TERMINALS  
Test Procedure  
1. Disconnect the dispenser from the power source.  
2. Disconnect the two black lead on the ballast from  
the main harness.  
3. Check for continuity between the two black leads  
on the ballast.  
If continuity is present as described the ballast is  
operating properly.  
If continuity is not present as described, replace the  
ballast.  
35135 012103  
18  
SERVICE (cont.)  
Removal and Replacement.  
CONTROL THERMOSTAT - FMD-4 & FMD-5  
1. Remove the thermostat capillary bulb by firmly  
pulling-up on the capillary at the tank lid. This will  
disengage the grommet from the tank lid.  
2. Loosen the two #6-32 screws securing the ther-  
mostat to the front tank mounting bracket.  
3. Disconnect the wires from the thermostat.  
4. Remove thermostat and remove the screws and  
spacers from the thermostat.  
5. Discard thermostat.  
6. Install two spacers and two #6-32 screws on the  
new thermostat.  
7. Position the thermostat on the botttom side of the  
front tank mounting bracket and tighten the two  
#6-32 screws.  
8. Slide the grommet to the line 4.5" above the bulb  
on the new capillary tube.  
J1  
J2  
P2635  
9. Insert the capillary bulb through the hole in the  
tank lid and press the grommet firmly and evenly  
so that the groove in the grommet fits into the tank  
lid.  
10. Carefully bend the capillary tube so that the tube  
and bulb inside the tank are in the vertical position  
and away from any electrical connections.  
11. Refer to Fig. 10 and reconnect the wires.  
NOTE - The capillary tube must be clear of any electri-  
cal termination and not kinked.  
FIG. 9 CONTROL THERMOSTAT  
Location  
The control thermostat is located at the upper left  
rear of the dispenser housing.  
Test Procedure  
1. Disconnect the dispenser from the power source.  
2. Disconnect the black wire of the control thermo-  
stat from the black lead from the limit thermostat.  
3. Remove bulb from the tank.  
4. Check the voltage across black wire on the control  
thermostat and the white or red wire on the tank  
heater with the tank heater switch in the “ON”  
lower position with a voltmeter. Connect the dis-  
penser to the power source. The indication must  
be:  
a) 120 volts ac for two wire 120 volt models.  
b)208voltsacforthreewire120/208volt models.  
c) 240 volts ac for three wire 120/240 volt models.  
5. Disconnect the dispenser from the power source.  
BLK from Limit  
Thermostat  
If voltage is present as described the control thermo-  
stat is operating properly. Reinstall bulb into the tank.  
If voltage is not present as described, replace the  
thermostat.  
BLK from Tank  
Heater Switch  
P1668  
FIG. 10 THERMOSTAT TERMINALS  
35135 012103  
19  
SERVICE (cont.)  
CONTROL BOARD  
5. Reconnect the six pin connector of the wiring  
harness to J3 of the control board.  
6. Disconnect the four pin connector from J4 of  
control board #1.  
7. Check the voltage across pins 1 & 4 of the four pin  
connector on the wiring harness with a voltmeter.  
Connect the dispenser to the power source. The  
indication must be 120 volts ac for two wire 120  
voltmodels, threewire120/208voltmodels, three  
wire 120/240 volt models.  
8. Disconnect the dispenser from the power source.  
If voltage is present as described, proceed to step 9.  
If voltage is not present as described, refer to the  
wiring diagram and check the dispenser wiring har-  
ness.  
J1  
J2  
9. Reconnect the four pin connector of the wiring  
harness to J4 of control board #1.  
J4  
J3  
J1  
J2  
J4  
J3  
10. Disconnect the ten pin connector from J2 of  
control board #1.  
#2  
11. Carefully connect a piece of insulated jumper wire  
to pin 10 (top right) of J2 on the control board.  
Keep the other end of this wire away from any  
metal surfaces of the dispenser.  
#1  
P2635  
FIG. 11 CONTROL BOARD  
12. Check the voltage across the terminals of the inlet  
solenoid valve with a voltmeter. Connect the dis-  
penser to the power source. The indication must  
be 120 volts ac for two wire 120 volt models, three  
wire 120/208 volt models, three wire 120/240 volt  
models after a delay of approximately 10 seconds.  
13. Touch the free end of the jumper wire to the  
dispenser housing. The indication must be 0.  
14. Move the jumper wire away from the housing. The  
indicationmust, again, be120voltsacfortwowire  
120 volt models, three wire 120/208 volt models,  
three wire 120/240 volt models after a delay of  
approximately 5 seconds.  
Location:  
The Control Boards are located behind the lower  
frontaccesscovermountedonthecomponentbracket.  
Test Procedure:  
Liquid Level Control Circuitry(Control Board #1):  
1. Disconnect the dispenser from the power source.  
2. Disconnect the six pin connector from J3 of the  
control board.  
3. Check the voltage across pins 5 & 6 of the six pin  
connector on the wiring harness with a voltmeter.  
Connect the dispenser to the power source. The  
indication must be 24 volts ac.  
15. Disconnect the dispenser from the power source  
and remove the jumper wire.  
4. Disconnect the dispenser from the power source.  
If voltage is present as described, proceed to step 5.  
If voltage is not present as described, refer to the  
wiring diagram and check the dispenser wiring har-  
ness.  
If voltage is present as described, proceed to step 16.  
If the voltage is not present as described, replace  
control board #1.  
35135 012103  
20  
SERVICE (cont.)  
CONTROL BOARD (CONT.)  
Hopper Motor Control Circuitry (Stations 1-3, Control  
Board #1 & Stations 4-5, Control Board #2):  
1. Disconnect the dispenser from the power source.  
2. Disconnect the six pin connector from J3 of the  
appropriate control board.  
3. Check the voltage across pins 5 & 6 of the six pin  
connector on the wiring harness with a voltmeter.  
Connect the dispenser to the power source. The  
indication must be 24 volts ac.  
16. Reconnect the ten pin connector of the wiring  
harness to J2 of control board #1.  
17. Gently pull the liquid level probe out of the tank lid  
and inspect for corrosion. Replace it if necessary.  
18. Place the probe so that neither end is in contact  
with any metal surface of the dispenser.  
19. Check the voltage across the terminals of the inlet  
solenoid valve with a voltmeter. Connect the dis-  
penser to the power source. The indication must  
be 120 volts ac for two wire 120 volt models, three  
wire 120/208 volt models, three wire 120/240 volt  
models afteradelayofapproximately10seconds.  
20. Move the probe’s flat end to the dispenser hous-  
ing. The indication must be 0.  
4. Disconnect the dispenser from the power source.  
If voltage is present as described, proceed to step 5.  
If voltage is not present as described, refer to the  
wiring diagram and check the dispenser wiring har-  
ness.  
21. Move the probe’s flat end away from the housing.  
The indication must, again, be 120 volts ac for two  
wire 120 volt models, three wire 120/208 volt  
models, three wire 120/240 volt models after a  
delay of approximately 5 seconds.  
5. Reconnect the six pin connector of the wiring  
harness to J3 of the control board.  
6. Check that the rinse/run switch is in the run  
position.  
7. Check the voltage across the red (+) terminal and  
the black (-) terminal of the auger motor with a  
voltmeter. Connect the dispenser to the power  
source. Press and hold the appropriate dispense  
switch. After a delay of about .6 seconds, the  
indication must be between +4.0 and +24.5 volts  
dc.  
22. Disconnect the dispenser from the power source.  
If the voltage is present as described, re-install the  
probe. The liquid level control circuitry is operating  
properly.  
If the voltage is not present as described, check the  
pink probe wire and green tank wire for continuity.  
If the voltage is present as described, the hopper  
motor control circuitry is operating properly.  
If the voltage is not present as described, replace the  
control circuit board.  
35135 012103  
21  
Tank Heater Relay Control Circuitry (Control Board  
#2)(120V dispensers only):  
1. Disconnect the dispenser from the power source.  
2. Disconnect the six pin connector from J3 of con-  
trol board #2.  
3. Check the voltage across pins 5 & 6 of the six pin  
connector on the wwiring harness with a voltme-  
ter. Connect the dispenser to the power source.  
the indication must be 24 volts ac.  
If voltage is absent as described, proceed to step 11.  
If voltage is present, replace the control circuit board  
#2.  
11. Placecontainersbelowanythreedispensernozzles.  
12. Simultaneously initiate dispenses at each of the  
selected dispense stations while monitoring the  
voltage across the coil terminals of the tank heater  
relay. The indication must be 120V ac.  
4. disconnect the dispenser from the power source.  
If voltage is present as described, the control board #2  
is functioning correctly.  
If voltage is not present as described, replace the  
control circuit board #2.  
If voltage is present as described, proceed to step 5.  
If voltage is not present as described, refer to the  
wiring diagram and check the dispenser wiring har-  
ness.  
Removal and Replacement:  
5. Reconnect the six-pin connector of the wiring  
harness to J3 of control board #2.  
6. Disconnect the four-pin connector from J4 of  
control board #2.  
7. Check the voltage across pins 1 & 4 of the four-pin  
connector on the wiring harness with a voltmeter.  
The indication must be 120 volts ac.  
1. Disconnect the three plugs on the main wiring  
harnessfromtheconnectorsonthecontrolboard.  
2. Remove the four #6-32 keps nuts securing the  
control board to the component bracket.  
3. Remove control board and discard.  
4. Installnewcontrolboardonthecomponentbracket  
using four #6-32 keps nuts.  
8. Disconnect the dispenser from the power source.  
5. Reconnect the three plugs on the main harness to  
the connectors on the control board.  
If voltage is present as described, proceed to step 9.  
If voltage is not present as described, refer to the  
wiring diagram and check the dispenser wiring har-  
ness.  
NOTE: J4 is not connected on Control Board #2 on  
120/208 - 240V dispensers.  
CONTROL BOARD #1  
J3 J1  
J3 J1  
9. Reconnect the four-pin connector of the wiring  
harness to J4 of control board #2.  
J1  
10. Check the voltage across the coil terminals of the  
tank heater relay with a voltmeter. Connect the  
dispenser to the power source. The indication  
must be 0 volts ac.  
J2  
J4  
J3  
J1  
J2  
J4  
J4  
J2  
J3  
CONTROL BOARD #2  
J4  
J2  
P2637  
FIG. 12 CONTROL BOARD CONNECTORS  
35135 012103  
22  
SERVICE (cont.)  
DISPENSE SWITCH(S) - FMD-4 & FMD-5  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Open the dispenser door and remove the bottom  
door cover.  
3. Disconnect the wires from the door interconnect  
wiringharnesstothedispenseswitchtobetested.  
4. Check for voltage across the black and red/white  
wires for the dispense switch to be teseted from  
the door interconnect wiring harness. Connect the  
dispenser to the power supply. The indication  
must be:  
RINSE  
a) 120 volts ac for two wire 120 volt models.  
b) 120 volts ac for three wire 120/208 volt or 120/  
240 volt models.  
E
IS 2/3 FULL,
CUP  
ON UNTIL  
RINSE  
PUSH and HOLD BUTT  
PLACE  
HERE  
CUP  
I
/3 FULL  
!
H
I
T
D
L
ON WHEN CUP  
LEASE BUTT  
PLACE  
HERE  
CUP  
PLACE  
HERE  
CUP  
5. Disconnect the dispenser from the power source.  
FMD-4  
If voltage is present as described, proceed to #6.  
If voltage is not present as described, refer to the wir-  
ing diagram and check the dispenser wiring harness.  
6. With a voltmeter, check the voltage across the  
remaining two wires of the dispense switch being  
tested from the door interconnect wiring harness.  
Connect the dispenser to the power source. The  
indication must be +5 volts dc.  
RINSE  
ELEASE  
LL, THEN  
R
IS 2/3 FU  
If voltage is present as described, proceed to #7.  
If voltage is not present as described, refer to the  
wiring diagram and check the dispenser wiring har-  
ness.  
CUP  
ON UNTIL  
RINSE  
PUSH and HOLD BUTT  
PLACE  
HERE  
CUP  
I
IS 2/3 FULL  
W
!
H
L
I OU IT  
PLACE  
HERE  
CUP  
ON WHEN CUP  
RELEASE BUTT  
PLACE  
HERE  
CUP  
PLACE  
HERE  
CUP  
FMD-5  
P2636  
FIG.13 DISPENSE SWITCHES  
Location:  
The dispense switches are located on the lower  
outside of the dispenser door.  
35135 012103  
23  
SERVICE (cont.)  
DISPENSE SWITCHES (cont.)  
7. Check for continuity across the terminals (top  
right to top left; bottom right to bottom left) of the  
dispense switch with the switch in the “ON” posi-  
tion. Continuity must not present when the switch  
is in the “OFF” released position.  
BLK  
RED/WHI  
STATIONS  
If continuity is present as described, reconnect the  
connector to the door interconnect wiring harness,  
the switch is operating properly.  
If continuity is not present as described, replace the  
switch.  
BLK/WHI -1- WHI/BLK  
RED -2- RED/BLK  
ORN -3- ORN/BLK  
GRN/WHI -4- GRN/BLK  
BLU -5- BLU/BLK  
Removal and Replacement  
P1449  
1. Open the dispenser door.  
2. Remove the six #8-32 screws securing the bot-  
tom door cover and remove cover.  
FIG. 14 DISPENSE SWITCH TERMINALS  
3. Disconnect the wires on the dispense switch from  
the door interconnect wiring harness.  
4. Compress the clips inside the door on the dis-  
pense switch and gently push the switch through  
the opening  
5. Push the new switch into the opening and spread  
the clips to hold the switch in the door.  
6. Reconnect the wires to the dispense switch from  
the door interconnect wiring harness.  
7. Reinstall the door bottom cover using six #8-32  
screws.  
8. Refer to Fig. 14 when reconnecting wires.  
35135 012103  
24  
SERVICE (cont.)  
FAN  
Removal and Replacement:  
1. Disconnect the vacuum hose from the fan.  
2. Remove the two #8-32 locking screws securing  
the fan to the dispenser housing base plate.  
3. Disconnect the wires from the fan terminals and  
discard the fan  
4. Refer to Fig. 16 and connect the wires to the new  
fan.  
5. Install new fan through the rear access hole and  
secure to the dispenser housing base plate using  
two #8-32 locking screws.  
6. Reconnect the vacuum hose to the fan.  
BLK from Main Harness  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
P2635  
FIG. 15 FAN  
WHI from Main Harness  
Location:  
P1507  
The fan is located inside the dispenser housing  
on the center rear of the dispenser base plate.  
FIG. 16 FAN TERMINALS  
Test Procedures:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the black and white wires from the fan  
terminals.  
3. Checkthevoltageacrosstheblackandwhitewires  
on the main harness with a voltmeter. Connect the  
dispenser to the power source. The indication  
must be:  
a) 120 volts ac for two wire 120 volts models.  
b) 120 volts ac for three wire 120/208 volt or 120/  
240 volt models.  
If voltage is present as described, replace the fan  
If voltage is not present as described, refer to wiring  
diagram and check the dispenser wiring harness.  
35135 012103  
25  
SERVICE (cont.)  
FROTHER AND WHIPPER MOTOR - FMD-4 (shown)  
& FMD-5  
4. Disconnect the dispenser from the power source.  
If voltage is present as described, replace the motor.  
If voltage is not present as described, refer to the wir-  
ing diagrams and check the dispenser wiring harness.  
10  
7
1
J1  
J2  
J4  
2
4
J3  
J1  
J2  
J4  
J3  
P2635  
3
9 8 6 5  
11 12  
13  
FIG. 17 FROTHER AND WHIPPER MOTOR  
P2628  
FIG. 18 MIXING/WHIPPER CHAMBER  
COMPONENTS  
Location:  
The frothers are located behind the dispenser door,  
mounted on the front panel inside the whipper cham-  
ber.  
The whipper motors are located on the back side  
of the whipper motor mounting panel.  
1. Steam Collector  
8. Nut  
2. Mixing Chamber  
3. Dispense Tip  
4. Whipper Chamber  
5. O-Ring  
9. Slinger  
10. Motor Assy.  
11. Fan  
12. Vacuum Hose  
13. Baffle  
Test Procedure:  
6. Frother  
1. Disconnect the dispenser from the power source.  
2. Disconnect the red and white wires (FMD-1 &  
FMD-2 left motor) or orange and white wires  
(FMD-2 right motor) of the main harness from the  
black leads of the motor.  
7. Receptacle w/Seal  
Removal, Cleaning & Replacement (Refer to Fig. 18):  
1. Open the dispenser door and raise the top front  
cover.  
3. Press and hold the dispense switch and check the  
voltage across the disconnected harness wires  
with a voltmeter. Connect the dispenser to the  
power source. The reading must be:  
2. Lift the front edge of the each hopper assembly  
over the tab on the hopper support panel and  
slide each hopper assembly out the front of the  
dispenser. Set aside for reassembly.  
a) 120 volts ac for two wire 120 volt models.  
b) 120 volts ac for three wire 120/208 volt or 120/  
240 volt models.  
3. Remove the four #8-32 screws securing the hop-  
per support panel to auger motor mounting panel  
and the whipper motor mounting panel. Set aside  
for reassembly.  
35135 012103  
26  
22. Pushfrother(6)ontothemotorshaft, makingsure  
theflatinthefrother(6)linesupwiththeflatonthe  
motor shaft.  
23. Install whipper chamber (4) on the whipper cham-  
ber receptacle (7) by twisting counterclockwise  
untilthetabsonthewhipperchamber(4)lockwith  
the tabs on the whipper chamber receptacle (7).  
Be sure dispense port is pointing down.  
24. Install dispense tip (3) into the bottom of the  
whipper chamber (4).  
25. Using two #4-40 screws secure the fan baffle to  
the whipper motor mounting panel.  
26. Install vacuum hose (12) on fan baffle (13).  
27. Install hopper support panel using four #8-32  
screws.  
28. Slip the mixing chamber (2) onto the mixing  
chamber water inlet tube far enough so the mixing  
chamber (2) will seat inside the whipper chamber  
(4).  
29. Install the steam collector (1) onto the mixing  
chamber (2) by pushing down and toward the  
dispenser while twisting until the flange on the  
steam collector lines-up with the slot in the front  
panel.  
30. Installhopperassemblyinthedispenserbysliding  
hopper assembly on the hopper support panel  
until the slot in the bottom rear of the hopper seats  
against the shoulder screw in the hopper support  
panel.  
SERVICE (cont.)  
FROTHER AND WHIPPER MOTOR - FMD-4  
(shown) & FMD-5 (cont.)  
4. Disconnect vacuum hose (12) from fan baffle (13).  
5. Remove the steam collector (1) by pulling it for-  
ward and at the same time twisting it clockwise.  
6. Pull the mixing chamber (2) out of the whipper  
chamber (4).  
7. Remove the two #4-40 x .25" screws securing the  
fan baffle (13) to the whipper motor mounting  
panel and remove fan baffle. Set aside for reas-  
sembly.  
8. Remove dispense tip (3) and twist the whipper  
chamber (4) clockwise and pull it off the whipper  
chamber receptacle (7).  
9. Pull the frother (6) off the motor shaft. Notice the  
flat side on the shaft and the matching flat inside  
the frother. It is important that these two flats are  
lined up when reassembling.  
10. Slip the O-ring (5) off the whipper chamber recep-  
tacle (7).  
11. Slide the receptacle w/seal off of the motor shaft.  
12. Slide the slinger (9) off of the motor shaft.  
13. Remove the two nuts (8) securing whipper cham-  
ber receptacle (7) and whipper motor (10) to the  
front panel.  
NOTE: To remove the receptacle only rotate clockwise  
until the receptacle clears the nuts (8) and slide off  
of the motor shaft.  
14. Disconnect the black leads on the motor (10) from  
the main wiring harness.  
15. Remove motor and discard.  
16. Install new motor (10) on rear of front panel and  
secure with two nuts (8) and connect black leads  
on the motor to the main wiring harness. Refer to  
Fig. 19 when reconnecting wires  
17. Slide slinger (9) onto the motor shaft flush against  
the front panel.  
BLK to Main Harness WHI  
BLK to Main Harness BRN Station #1  
BLK to Main Harness RED Station #2  
BLK to Main Harness ORN Station #3  
BLK to Main Harness YEL Station #4  
BLK to Main Harness BLU Station #5  
P1221  
18. Wash remaining components in a mild solution of  
dish detergent using a bristle brush.  
19. Rinse thoroughly and allow to dry before reinstall-  
ing in the dispenser.  
20. Slide whipper chamber receptacle w/seal (7) and  
O-ring (5) on to the motor shaft.  
21. Rotate the receptacle w/seal (7) counterclockwise  
until it snaps into place on the motor mounting  
nuts (8).  
FIG.19 WHIPPER MOTOR TERMINALS  
35135 012103  
27  
SERVICE (cont.)  
INCREASE/DECREASE SWITCH  
Removal and Replacement:  
1. Open the dispenser door.  
2. Remove the facenut securing the increase/de-  
crease switch to the whipper motor mounting  
panel.  
3. Remove switch with wires attached from the back  
side of the whipper motor mounting panel.  
4. Disconnect the wires from the switch and discard  
the switch.  
5. Refer to Fig. 21 when connecting the wires to the  
new switch.  
6. Install new switch with wires attached through the  
hole in the whipper mounting panel and secure  
with facenut.  
J1  
J2  
J4  
J3  
J1  
J2  
RED/BLK from Control  
Board J2-6  
J4  
J3  
GRN from Control  
Board J2-9  
WHI/VIO from Control  
Board J2-1  
P2635  
FIG. 20 INCREASE/DECREASE SWITCH  
Location:  
The increase/decrease switch is located on the  
lower left front of the whipper motor mounting panel.  
P1208  
FIG. 21 INCREASE/DECREASE SWITCH  
TERMINALS  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the wires from the switch terminals.  
3. Check for continuity between the center terminal  
and upper terminal with switch in the decrease  
position (lower). Check for continuity between the  
center terminal and the lower terminal with the  
switch in the increase position (upper).  
If continuity is present as described, the switch is  
operating properly.  
If continuity is not present as described, replace the  
switch.  
35135 012103  
28  
Removal and Replacement:  
1. Open dispenser door (1).  
SERVICE (cont.)  
LAMP HOLDERS  
2. Remove the six #8-32 screws securing lower door  
panel (5) to the door (1) and remove cover.  
3. Disconnect the door wiring harness from the door  
interconnect wiring harness.  
4. Remove three #8-32 screws securing the upper  
door panel (4) to the door.  
5. Remove the upper door cover (4), lamp (3), lamp  
holders (2) and door wiring harness as an assem-  
bly.  
6. Disconnect the wires from the lamp holder to be  
replaced from the door wiring harness.  
7. Rotate lamp (3) 90° and remove from lamp hold-  
ers (2).  
1
3
4
6
2
5
8. Removethe#6-32screwsecuringthelampholder  
(2) to be removed, remove lamp holder (2) and  
discard.  
RINSE  
9. Install new lamp holder (2) and secure with a #6-  
32 screw.  
IS 2/3 FULL, THEN RELEASE  
CUP  
ON UNTIL  
RINSE  
10. Connect the wires on the new lamp holder to the  
door wiring harness.  
PUSH and HOLD BUTT  
11. Install lamp (3) into lamp holders (2) and turn 90°  
until the pins snap in place.  
P2638  
12. Install upper door panel (4), lamp (3), lamp hold-  
ers (2) and door wiring harness as an assembly  
using three #8-32 screws.  
13. Reconnect the plug on the door wiring harness to  
the connector on the door interconnect wiring  
harness.  
FIG. 22 LAMP HOLDERS  
1. Door Assy  
4. Upper Panel  
5. Lower Panel  
6. Starter W/Socket  
2. Lamp Holders  
3. Lamp  
Location:  
The lamp holders are located on the front of the  
upper panel behind the display panel.  
14. Install the door lower panel (5) using six #8-32  
screws.  
LAMP REPLACEMENT (Refer to Fig. 22)  
1. Open dispenser door (1).  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Remove upper door panel (4) and disconnect the  
door wiring harness from the leads on the lamp  
holders.  
3. Remove lamp from lamp holders.  
4. Check for continuity on each lead of the lamp  
holders.  
2. Remove the six #8-32 screws securing lower door  
panel (5) to the door (1) and remove cover.  
3. Disconnect the door wiring harness from the door  
interconnect wiring harness.  
4. Remove three #8-32 screws securing the upper  
door panel (4) to the door.  
5. Remove the upper door cover (4), lamp (3), lamp  
holders (2) and door wiring harness as an assem-  
bly.  
6. Rotate lamp (3) 90° and remove from lamp hold-  
ers (2).  
If continuity is present as described, lamp holders are  
operating properly.  
If continuity is not present as described replace the  
lamp holder.  
7. Install lamp (3) into lamp holders (2) and turn 90°  
until the pins snap in place.  
8. Install upper door panel (4), lamp (3), lamp hold-  
ers (2) and door wiring harness as an assembly  
using three #8-32 screws.  
35135 012103  
29  
SERVICE (cont.)  
LAMP REPLACEMENT (Refer to Fig.22)(cont.)  
Removal and Replacement (Refer to Fig.22):  
1. Open dispenser door assy (1)  
2. Remove the four #8-32 screws securing the door  
lower panel (5) to the door assy (1).  
3. Disconnecttheleadsonthestartersocketfromthe  
door wiring harness.  
9. Reconnect the plug on the door wiring harness to  
the connector on the door interconnect wiring  
harness.  
10. Install the door lower panel (5) using six #8-32  
screws.  
4. Remove lower door panel (5) and starter w/socket  
(6) as assembly.  
LAMP STARTER and SOCKET (Refer to Fig. 22)  
Location:  
5. Compress the spring tabs on the socket and re-  
move socket from the door bottom cover (5).  
6. Rotate starter 90° and remove from the starter  
socket.  
7. Insertnewstarter(6)intosocketandturn90°until  
the pins snap in place.  
8. Install new socket by compressing spring tabs on  
the socket and pushing the socket up through the  
hole in the lower door panel (5) and releasing  
spring tabs.  
9. Connect the sockets leads to the door wiring  
harness.  
The lamp starter (6) is located inside the door assy  
(1) on the top of the door lower panel (5).  
Test Procedures:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the starter leads from the door wiring  
harness.  
3. Remove lamp starter from starter socket.  
4. Check for continuity on each lead of the starter  
socket.  
If continuity is present as described the starter socket  
is operating properly.  
If continuity is not present as described replace the  
starter socket.  
10. Installdoorlowerpanel (5)withstarterandstarter  
socket on door assy (1) using four #8-32 screws.  
5. Remove starter (6) from starter socket.  
6. Check for continuity across the pins on the bottom  
of the starter (6).  
Ifcontinuityispresentasdescribed,replacethestarter.  
If continuity is not present as described, starter is  
operating properly.  
Note: If continuity tests are both as described and  
lamp does not light, replace the starter.  
35135 012103  
30  
SERVICE (cont.)  
LIMIT THERMOSTAT  
Removal and Replacement:  
1. Remove all wires from the limit thermostat ter-  
minals.  
2. Carefully slide the limit thermostat out from un-  
der the retaining clip and remove the limit ther-  
mostat.  
3. Carefully slide the new limit thermostat into the  
retaining clip.  
4. Refer to Fig. 24 when reconnecting the wires.  
BLK to Tank Heater  
BLK to Control  
Thermostat  
P2635  
FIG. 23 LIMIT THERMOSTAT  
Location:  
The limit thermostat is located in the center of the  
tank lid.  
P1800  
FIG. 24 LIMIT THERMOSTAT TERMINALS  
Test Procedures:  
1. Disconnect the dispenser from the power source.  
2. Disconnect both black wires from the limit ther-  
mostat.  
3. Check for continuity across the limit thermostat  
terminals.  
If continuity is present as described, the limit thermo-  
stat is operating properly.  
If continuity is not present as described, replace the  
limit thermostat.  
35135 012103  
31  
SERVICE (cont.)  
RINSE/RUN SWITCH  
Removal and Replacement:  
1. Open the dispenser door.  
2. Remove the facenut securing the run/rinse switch  
to the whipper motor mounting panel.  
3. Remove switch with wires attached from the back  
side of the whipper motor mounting panel.  
4. Disconnect the wires from the switch and dis-  
card the switch.  
5. Refer to Fig. 26 when connecting the wires to  
the new switch.  
6. Install new switch with wires attached through  
the hole in the whipper motor mounting panel  
and secure with facenut.  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
GRY to Control  
Board J2-2  
BRN/BLK to  
Main Harness  
P2635  
GRN to Control  
Board J2-9  
FIG. 25 RINSE/RUN SWITCH  
Location:  
The rinse/run switch is located on the lower center  
of the whipper motor mounting panel.  
BLK from  
Main Harness  
Test Procedures:  
BRN/BLK to  
Main Harness  
1. Disconnect the dispenser from the power source.  
2. Check for continuity between the center left ter-  
minal and left bottom terminal, also between the  
center right terminal and the right bottom termi-  
nal with the switch in the rinse position (upper).  
Check for continuity across the center left termi-  
nal and the top left terminal, also between center  
right terminal and the top right terminal with the  
switch in the run position (lower). Continuity must  
not be present when the switch is in the center  
position.  
WHI/GRY to Control  
Board J2-3  
P1644  
FIG. 26 RINSE/RUN SWITCH TERMINALS  
If continuity is present as described, the switch is  
operating properly.  
If continuity is not present as described, replace the  
switch.  
35135 012103  
32  
If voltage is present as described, reconnect the four  
pin plugs and proceed to #5.  
If voltage is not present as described, refer to the  
Wiring Diagrams and check the main wiring harness.  
SERVICE (cont.)  
HOT/COLD SWITCH (Optional)  
5. Disconnect the wires from the switch terminals.  
6. With the switch in the “Cold” (upper) position  
check for continuity between the center terminal  
and the bottom terminal. With the switch in the  
“Hot” (lower) position check for continuity be-  
tween the center terminal and the upper terminal.  
If continuity is present as described, the hot/cold  
switch is operating properly.  
J1  
J2  
J4  
If continuity is not present as described, replace the  
switch.  
J3  
J1  
J2  
J4  
J3  
Removal and Replacement:  
P2635  
1. Remove all wires from the switch terminals.  
2. Remove the mounting nut on the front of the whip-  
per motor mounting panel.  
3. Remove the hot/cold switch from the rear of the  
front panel and discard.  
4. Reconnect the wires to the terminals on the rear  
of the new switch.  
5. Push new hot/cold switch through the hole on the  
left side of the whipper motor mounting panel and  
secure with mounting nut.  
FIG. 27 HOT/COLD SWITCH  
Location:  
The hot/cold switch is located on the left side of  
the whipper motor mounting panel.  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the four pin plug from the hot/cold  
switch and the four pin connector on the main  
wiring harness.  
6. Refer to Fig. 28 when reconnecting the wires.  
3. Press the left dispense switch on the door and,  
with a voltmeter, check the voltage across the  
white wire (pin 4) and red wire (pin 2) in the four  
pin connector on the main wiring harness. Con-  
nect the dispenser to the power source. The indi-  
cation must be:  
a) 120 volts ac for two wire 120 volt models, and  
three wire 120/208 volt and 120/240 volt models.  
b) 240 volts ac for two wire 240 volt models.  
4. Disconnect the dispenser from the power source.  
TAN to Main Harness  
RED to Main Harness  
WHI/YEL to Cold  
Solenoid  
P1208  
FIG. 28 HOT/COLD SWITCH TERMINALS  
35135 012103  
33  
6. Check the solenoid valve for coil action. Connect  
the dispenser to the power source. With "HOT/  
COLD" switch in the "COLD" (upper) position press  
the left dispense switch and listen carefully in the  
vicinity of the solenoid valve for a "clicking" sound  
as the coil magnet attracts.  
SERVICE (cont.)  
SOLENOID VALVE (COLD WATER - OPTIONAL)  
7. Disconnect the dispenser from the power source.  
If the sound is heard as described and water will not  
pass through the solenoid valve, there may be a block-  
age in the water line before the solenoid valve or, the  
solenoid valve may require inspection for wear, and  
removal of waterborne particles.  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
If the sound is not heard as described, replace the  
solenoid valve.  
P2635  
FIG. 29 COLD WATER SOLENOID VALVE  
Location:  
Removal and Replacement:  
1. Loosen the two screws securing the component  
bracket to the dispenser base. Lift the component  
bracket off of the base and move to the right.  
2. Remove the white and white/yellow wires from  
the solenoid valve.  
3. Turn off the water supply to the dispenser.  
4. Disconnect the water lines to and from the sole-  
noid valve.  
5. Loosen the two #8-32 screws and washers se-  
curing the solenoid mounting bracket to the base.  
Remove solenoid bracket and solenoid valve as  
an assembly.  
6. Remove the two #10-32 screws and lockwashers  
securing the solenoid valve to the solenoid bracket.  
7. Using two #10-32 screws and lockwashers install  
new solenoid valve on solenoid mounting bracket.  
8. Install the solenoid valve and bracket on the dis-  
penser base and tighten the two #8-32 screws.  
9. Securely fasten the water lines to and from the  
solenoid valve.  
The cold water solenoid valve is located on the  
left side of the dispenser base just behind the compo-  
nent bracket.  
Test Procedures:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the white and white/yellow wires from  
thesolenoidvalve.WiththeHOT/COLDswitchin  
the "COLD" (upper) position press the left dis-  
pense switch on front of the door.  
3. With a voltmeter, check the voltage across the  
white and white/yellow wires. Connect the dis-  
penser to the power source. The indication must  
be:  
a) 120 volts ac for two wire 120 volt models, three  
wire 120/208 volt, and 120/240 volt models.  
b) 240 volts ac for two wire 240 volt models.  
4. Disconnect the dispenser from the power source.  
If voltage is present as described, proceed to #5  
If voltage is not present as described, refer to Wiring  
Diagrams and check dispenser wiring harness.  
10. Refer to Fig. 30 when reconnecting the wires.  
WHI/YEL to Hot/  
Cold Switch  
WHI to Main Wiring  
Harness  
5. Check for continuity across the solenoid valve coil  
terminals.  
If continuity is present as described, reconnect the  
white and white/yellow wires to the solenoid.  
If continuity is not present as described, replace the  
solenoid valve.  
P1215  
FIG. 30 COLD WATER SOLENOID TERMINALS  
35135 012103  
34  
SERVICE (cont.)  
If voltage is present as described, proceed to #5  
If voltage is not present as described, refer to wiring  
diagram and check dispenser wiring harness.  
SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5  
5. Check for continuity across the solenoid valve  
coil terminals.  
If continuity is present as described, reconnect the  
wires to the solenoid (see Fig. 32), proceed to #6  
If continuity is not present as described, replace the  
solenoid valve.  
6. Check the solenoid valve for coil action. Connect  
the dispenser to the power source. With "RINSE/  
RUN” switch in the "RINSE" upper position press  
the dispense switch and listen carefully in the  
vicinity of the solenoid valve for a "clicking" sound  
as the coil magnet attracts.  
J1  
J2  
J4  
J3  
7. Disconnect the dispenser from the power source.  
J1  
J2  
J4  
J3  
If the sound is heard as described and water will not  
pass through the solenoid valve, there may be a block-  
age in the water outlet before the solenoid valve or,  
the solenoid valve may require inspection for wear,  
and removal of waterborne particles.  
P2635  
FIG. 31 DISPENSE SOLENOID VALVE  
Location:  
If the sound is not heard as described, replace the  
solenoid valve.  
The dispense solenoid is located on the upper left  
center of the tank.  
Test Procedures:  
1. Disconnectthedispenserfromthepowersource.  
2. Disconnectthetwowiresfromthesolenoidvalve  
thatisbeingtested.WiththeRINSE/RUNswitch  
inthe"RINSE"upper positionpressthe dispense  
switch on front of the door.  
3. Check the voltage across the two wires with a  
voltmeter. Connect the dispenser to the power  
source. The indication must be 120 volts ac for  
twowire120voltmodels,threewire120/208and  
120/240 volt models.  
4. Disconnectthedispenserfromthepowersource.  
35135 012103  
35  
SERVICE (cont.)  
SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5  
(cont.)  
Removal and Replacement:  
1. Remove the four #8-32 screws securing the side  
access panel to the housing. Remove panel and  
set aside.  
2. Remove the wires from the solenoid valve.  
3. Turn-off the water supply to the dispenser.  
4. Using the tank drain tube, drain enough water  
from the tank so the water level is below the  
dispense valve mounting hole.  
5. Disconnect the water line from the solenoid valve.  
6. Remove the #8-32 keps nut securing the solenoid  
valve bracket to side of the tank. Remove solenoid  
valve.  
7. Install new solenoid valve and o-ring on side of the  
tank and secure in place with valve mounting  
bracket and #8-32 keps nut.  
WHIto Main Harness  
TAN to Main Harness Station #1  
RED to Main Harness Station #2  
ORN to Main Harness Station #3  
YEL to Main Harness Station #4  
BLU to Main Harness Station #5  
P1672  
FIG. 32 DISPENSE SOLENOID VALVE  
TERMINALS  
8. Push the water line onto the tube on bottom of  
solenoid valve.  
9. Refer to Fig. 32 and reconnect the wires.  
10. Reinstall side access panels.  
35135 012103  
36  
6. Check the solenoid valve for coil action. Connect  
thedispensertothepowersource. Listencarefully  
in the vicinity of the solenoid valve for a "clicking"  
sound as the coil magnet attracts.  
SERVICE (cont.)  
SOLENOID VALVE (INLET)  
7. Disconnect the dispenser from the power source.  
If the sound is heard as described and water will not  
pass through the solenoid valve, there may be a  
blockage in the water line before the solenoid valve or,  
the solenoid valve may require inspection for wear,  
and removal of waterborne particles.  
If the sound is not heard as described, replace the  
solenoid valve.  
J1  
J2  
J4  
Removal and Replacement:  
J3  
J1  
J2  
J4  
1. Remove the white and violet wires from the sole-  
noid valve.  
J3  
2. Turn-off the water supply to the dispenser.  
3. Disconnect the water lines to and from the sole-  
noid valve.  
4. Remove the two #8-32 screws securing the sole-  
noid to the rear of the dispenser housing. Remove  
solenoid.  
P2635  
FIG. 33 INLET SOLENOID VALVE  
Location:  
The inlet solenoid is located on the lower left side  
near the rear panel.  
5. Remove the two #8-32 U-Type fasteners from the  
solenoid bracket.  
Test Procedures:  
6. Installthetwo#8-32U-Typefastenersandthetwo  
#8-32 screws on the new solenoid.  
7. Install new solenoid on rear of dispenser housing  
and tighten the two screws  
8. Securely fasten the water lines to and from the  
solenoid valve.  
1. Disconnect the dispenser from the power source.  
2. Disconnect the white and violet wires from the  
solenoid valve.  
3. Checkthevoltageacrossthewhiteandvioletwires  
with a voltmeter. Connect the dispenser to the  
power source. The indication must be 120 volts ac  
for two wire 120 volt models, three wire 120/208  
and 120/240 volt models.  
9. Refer to Fig. 34 and reconnect the wires.  
4. Disconnect the dispenser from the power source,  
If voltage is present as described, proceed to #5  
If voltage is not present as described, refer to the  
wiring diagram and check dispenser wiring harness.  
5. Check for continuity across the solenoid valve coil  
terminals.  
If continuity is present as described, reconnect the  
white and violet wires to the solenoid.  
If continuity is not present as described, replace the  
solenoid valve.  
WHI from Main Harness  
VIO from Main Harness  
P2641  
FIG. 34 INLET SOLENOID VALVE TERMINALS  
35135 012103  
37  
SERVICE (cont.)  
TANK HEATER  
Removal and Replacement:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the water supply tube on the tank lid.  
3. Disconnect the black wires on the limit thermstat.  
4. Disconnecttheblackwireandthewhiteorredwire  
from the tank heater terminals.  
5. Disconnect the pink wire from the liquid level  
probe and the green wire from the tank.  
6. Remove the thermostat capillary bulb by firmly  
pulling-up on the capillary at the tank lid. This will  
disengage the grommet from the tank lid.  
7. Remove the ten #8-32 nuts securing the tank lid to  
the tank.  
8. Remove tank lid with limit thermostat, liquid level  
probe and tank heater as an assembly.  
9. Remove the two hex nuts securing the tank heater  
to the tank lid. Remove tank heater with gaskets  
and discard.  
10. Install new tank heater with gaskets on the tank lid  
and secure with two hex nuts.  
P2635  
FIG. 35 TANK HEATER  
Location:  
The tank heater is located inside the tank and se-  
cured to the tank lid.  
11. Install tank lid with limit thermostat, liquid level  
probe and tank heater on the tank and secure with  
ten #8-32 hex nuts.  
12. Connect water inlet line to the tank lid.  
13. Reconnect the black wires to limit thermostat, the  
pink wire to the liquid level probe and the green  
wire to the tank. Refer to the limit thermostat and  
the liquid level board and probe sections in this  
manual when reconnecting wires.  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Checkthevoltageacrosstheblackandwhitewires  
120voltmodelsorblackandredwiresfor120/208  
volt modelsor120/240voltmodelswithavoltme-  
ter. Connect the dispenser to the power source.  
The indication must be:  
a) 120 volts ac for two wire 120 volt models;  
b) 208 volts ac for three wire 120/208 volt models.  
c) 240 volts ac for three wire 120/240 volt models.  
3. Disconnect the dispenser from the power source.  
14. RefertoFig. 36whenreconnectingthewirestothe  
tank heater.  
If voltage is present as described, proceed to #4.  
If voltage is not present as described, refer to the  
dispenser wiring diagram and check the wiring har-  
ness.  
BLK to Limit  
Thermostat  
WHI or RED to  
Main Harness  
4. Disconnect the black wire and the white or red  
wire from the tank heater terminals.  
5. Check for continuity across the tank heater termi-  
nals.  
If continuity is present as described, reconnect the  
wires, the tank heater is operating properly.  
If continuity is not present as described, replace the  
tank heater.  
NOTE - If the tank heater remains unable to heat,  
remove and inspect heater for cracks in the sheath.  
P1218  
FIG. 36 TANK HEATER TERMINALS  
35135 012103  
38  
SERVICE (cont.)  
TANK HEATER SWITCH  
Removal and Replacement:  
1. Remove the switch mounting nut on the front of  
the front panel.  
2. Remove switch with wires attached from the rear  
of the front panel.  
3. Remove the wires from the switch terminals and  
discard switch.  
4. Connect the wires to the new switch, refer to Fig.  
38.  
5. Push new switch through hole in the front panel  
and secure with facenut.  
BLK to Main  
Harnesss  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
BLK from Main  
Harness  
P2635  
FIG. 37 TANK HEATER SWITCH  
FIG. 38 TANK HEATER SWITCH TERMINALSP1219  
Location:  
The tank heater switch located inside the dispenser  
on the upper right of the front panel.  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the black wires from the main wiring  
harness.  
3. With the switch in the “ON” lower position check  
for continuity between the center and the upper  
terminal. With the switch in the “OFF” upper posi-  
tion no continuity should be present between  
center and upper terminals.  
If continuity is present as described, the tank heater  
“ON/OFF” switch is operating properly.  
If continuity is not present as described, replace the  
switch.  
35135 012103  
39  
6. With an ohmmeter, check for continuity between  
thenormallyclosed(NC-5)andcommon(COM-3)  
terminals of the relay.  
SERVICE (cont.)  
TANK HEATER RELAY (120V Dispensers only)  
7. Placecontainersbelowanythreedispensenozzles.  
8. Connect the dispenser to the power source.  
9. Simultaneously initiate dispenses at each of the  
selected dispense stations while monitorintg con-  
tinuity across the referenced terminals of the tank  
heater relay. The indication must be open circuit.  
If continuity is absent as described, the relay is func-  
tioning correctly.  
If continuity is present, replace the relay.  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
Removal and Replacement:  
J3  
1. Loosen the three #8-32 screws securing the com-  
ponent bracket to the dispenser housing base.  
2. Pull component bracket out the front of the dis-  
penser far enough so the tank heater relay can be  
disconnected from the main wiring harness.  
3 Disconnect the tank heater relay from the main  
wiring harness.  
4. Remove the two #8-32 screws securing the tank  
heater relay to the rear of the component bracket.  
5. Remove and discard the tank heater relay.  
6. Install new tank heater relay on the rear of the  
component bracket and secure with two #8-32  
screws.  
P2635  
FIG. 39 TANK HEATER RELAY  
Location:  
The tank heater relay is located behind the lower  
front access cover, mounted on the left rear side of the  
component bracket.  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Place the tank heater switch in the “OFF” (upper)  
position.  
3. With an ohmmeter, check for continuity between  
normally closed (NC-5) and common (COM-3)  
terminals of the relay. The indication must be less  
than 1 ohm.  
7. Connect the tank heater relay to the main wiring  
harness (see Fig. 40).  
8. Place the component bracket into position and  
tighten the three #8-32 screws.  
Ifcontinuityispresentasdescribed, proceedtostep4.  
If continuity is not present as described, replace the  
relay.  
BLK from  
Main Harness  
4. With an ohmmeter, check the resistance across  
the coil terminals (1 & 2) of the relay. The indica-  
tion must be approximately 4,000 ohms (4k).  
BRN/BLK from  
Main Harness  
WHI from  
Main Harness  
No Connection  
BLK from  
Main Harness  
If the resistance measures as described, proceed to  
step 5.  
P2639  
If the resistance does not measure as described,  
replace the relay.  
FIG. 40 TANK HEATER RELAY TERMINALS  
5. Disconnect the wires from the normally closed  
(NC-5) and common (COM-3) terminals of the  
relay.  
35135 012103  
40  
SERVICE (cont.)  
5. Check the voltage between J3-5 and J3-6 on the  
six pin connector at either control board. Connect  
the dispenser to the power source. The indication  
must be 24 volts ac.  
TRANSFORMER  
If voltage is present as described the transformer is  
operating properly.  
If voltage is not present as described, replace the  
transformer.  
Removal and Replacement:  
1. Loosen the three #8-32 screws securing the com-  
ponent bracket to the dispenser housing base.  
2. Pull component bracket out the front of the dis-  
penser far enough so the transformer can be  
disconnected from the main wiring harness.  
3 Disconnect the transformer from the main wiring  
harness.  
4. Remove the two #8-32 screws securing the trans-  
former to the rear of the component bracket.  
5. Remove and discard the transformer.  
6. Install new transformer on the rear of the compo-  
nent bracket and secure with two #8-32 screws.  
7. Connect the transformer to the main wiring har-  
ness (see Fig. 42).  
J1  
J2  
J4  
J3  
J1  
J2  
J4  
J3  
P2635  
FIG. 41 TRANSFORMER  
Location:  
The transformer is located behind the lower front  
access cover, mounted on the right rear side of the  
component bracket.  
Test Procedure:  
1. Disconnect the dispenser from the power source.  
2. Disconnect the four wires of the main harness  
from the transformer.  
8. Place the component bracket into position and  
tighten the three #8-32 screws.  
3 Check the voltage across black wire and the white  
wire on the main harness. Connect the dispenser  
to power source. The indication must be:  
a. 120 volts ac for two wire 120 volt models.  
b.120voltsforthreewire120/208voltmodelsand  
three wire 120/240 volt models.  
L I N E  
WHI from  
Main Harness  
BLK from  
Main Harness  
4. Disconnect the dispenser from the power source.  
WHI/GRN from  
Main Harness  
WHI/BLK from  
Main Harness  
If voltage is present as described reconnect the wires  
and proceed to #5.  
If voltage is not present as described, refer to the  
wiring diagrams and check the main wiring harness.  
P2640  
FIG. 42 TRANSFORMER TERMINALS  
35135 012103  
41  
SCHEMATIC WIRING DIAGRAM FMD-4  
L1  
N
GRN  
WHI  
BRN/BLK  
WHI  
J4-1  
J4-4  
CONTROL  
LIMIT  
TANK HEATER  
SWITCH  
C
O
N
T
THERMOSTAT  
THERMOSTAT  
K
TANK HEATER  
FAN  
BLK  
BLK-16  
BLK-16  
BLK-16  
BLK-16  
WHI-16  
BLK-16  
K
R
O
L
BLK  
WHI  
WHI  
BLK  
BLK  
M
C
I
J3-1  
LAMP #1  
BALLAST  
BLK  
BLK  
RED  
RED  
BLK  
BLK  
BLK  
BLK  
BLK  
LAMP #2  
BALLAST  
R
C
U
I
WHI/YEL  
GRN  
WHI/GRN  
WHI/BLK  
WHI  
J4-1  
J4-4  
VIO  
C
O
N
T
R
O
L
J3-5  
J2-1  
T
WHI  
WHI/VIO  
REFILL VALVE  
B
O
A
R
D
WHI/BLK  
LOAD  
WHI/GRN  
VIO  
WHI  
WHI  
WHI/VIO  
GRY  
WHI/GRY  
GRN  
OVERFLOW PROTECTION SWITCH  
RED RED  
SOL  
120V : 24V AC  
TRANSFORMER  
LINE  
WHI  
BLK  
WHI/VIO  
BLU/BLK  
RED/BLK  
WHI/YEL  
WHI/ORN  
GRN  
WHI/ORN  
WHI/RED  
BRN/WHI  
GRN  
WHI/GRN  
WHI/BLK  
J2-5  
C
I
J3-1  
#
2
R
C
U
I
J3-5  
J2-1  
J2-5  
WHI/BLK  
J2-10  
J1-1  
T
B
O
A
R
D
WHI/VIO  
GRY  
WHI/GRY  
WHI/RED  
TAN  
RED/BLK  
WHI/BLK  
WHI/ORN  
GRN  
WHI/RED  
J1-4  
#
1
PNK  
J2-10  
J1-1  
I
N
C
D
INCREASE/  
DECREASE  
SWITCH  
HOPPER #1  
HOPPER #2  
HOPPER #3  
HOPPER #4  
E
C
BRN/WHI  
RED  
BLK  
M
WHI/RED RED  
BLK  
WHI/ORN RED  
BLK  
WHI/YEL RED  
BLK  
M
M
M
J1-4  
GRN  
STATION #1  
WHIPPER  
STATION #2  
WHIPPER  
STATION #3  
WHIPPER  
STATION #4  
WHIPPER  
PROBE  
RINSE/PROGRAM/  
RUN SWITCH  
BLK  
BLK  
M
BLK  
BLK  
WHI  
BLK  
BLK  
WHI  
BLK  
YEL  
BLK  
M
M
M
WHI/GRY  
RINSE  
STATION #1  
DISPENSE  
VALVE  
STATION #2  
DISPENSE  
VALVE  
STATION #3  
DISPENSE  
VALVE  
STATION #4  
DISPENSE  
VALVE  
GRN  
BLK  
PGM  
GRY  
RUN  
BRN/BLK  
RINSE  
TAN  
WHI  
SOL  
RED  
ORN  
WHI  
PGM  
RUN  
SOL  
SOL  
SOL  
BRN/BLK  
COLD DRINK OPTION (LEFT ONLY)  
HOT/COLD SWITCH  
1
4
WHI/YEL  
BRN  
BRN  
TAN  
WHI  
RED  
RED  
TAN  
WHI  
COLD  
JUMPER PLUG MUST BE  
USED WHEN COLD  
DRINK FEATURE NOT  
INSTALLED  
RED  
RED  
RED  
SOL  
HOT  
PNK  
1
1
6
1
6
1
4
RED/WHI  
BLU/WHI  
GRY  
1
"RINSE" #1-3 L.E.D.  
PNK  
RED/GRN  
ORN/RED  
GRY  
1
"RINSE" #4 & 5 L.E.D.  
1
2
3
4
120 VOLTS AC - 2 WIRE  
SINGLE PHASE, 60HZ  
WHI/RED  
BLK  
WHI/RED  
BLK  
RED  
RED/BLK  
WHI/RED  
BLK  
WHI/RED  
BLK  
GRN/WHI  
GRN/BLK  
BLK/WHI  
WHI/BLK  
ORN  
ORN/BLK  
35135 012103  
42  
SCHEMATIC WIRING DIAGRAM FMD-4  
L1  
L2  
N
GRN  
J4-1  
J4-4  
CONTROL  
LIMIT  
TANK HEATER  
SWITCH  
C
O
N
T
THERMOSTAT  
THERMOSTAT  
TANK HEATER  
FAN  
BLK-16  
BLK-16  
BLK-16  
RED-16  
BLK-16  
R
O
L
BLK  
WHI  
BLK  
BLK  
M
C
I
J3-1  
LAMP #1  
BALLAST  
BLK  
BLK  
RED  
RED  
BLK  
BLK  
BLK  
BLK  
LAMP #2  
BALLAST  
R
C
U
I
WHI/YEL  
GRN  
WHI/GRN  
WHI/BLK  
WHI  
WHI  
J4-1  
J4-4  
VIO  
C
O
N
T
J3-5  
J2-1  
T
WHI  
WHI/VIO  
REFILL VALVE  
B
O
A
R
D
WHI/BLK  
LOAD  
WHI/GRN  
VIO  
WHI  
WHI  
WHI/VIO  
GRY  
WHI/GRY  
GRN  
OVERFLOW PROTECTION SWITCH  
RED RED  
SOL  
120V : 24V AC  
TRANSFORMER  
LINE  
WHI  
R
O
L
BLK  
WHI/VIO  
BLU/BLK  
RED/BLK  
WHI/YEL  
WHI/ORN  
GRN  
WHI/ORN  
WHI/RED  
BRN/WHI  
GRN  
WHI/GRN  
WHI/BLK  
J2-5  
C
I
J3-1  
#
2
R
C
U
I
J3-5  
J2-1  
J2-5  
WHI/BLK  
J2-10  
J1-1  
T
B
O
A
R
D
WHI/VIO  
GRY  
WHI/GRY  
WHI/RED  
TAN  
RED/BLK  
WHI/BLK  
WHI/ORN  
GRN  
WHI/RED  
J1-4  
#
1
PNK  
J2-10  
J1-1  
I
N
C
D
INCREASE/  
DECREASE  
SWITCH  
HOPPER #1  
HOPPER #2  
HOPPER #3  
HOPPER #4  
WHI/YEL RED  
M
E
C
BRN/WHI  
RED  
BLK  
M
WHI/RED RED  
BLK  
WHI/ORN RED  
BLK  
BLK  
M
M
J1-4  
GRN  
STATION #1  
WHIPPER  
STATION #2  
WHIPPER  
STATION #3  
WHIPPER  
STATION #4  
WHIPPER  
PROBE  
RINSE/PROGRAM/  
RUN SWITCH  
BLK  
BLK  
M
BLK  
BLK  
WHI  
BLK  
BLK  
WHI  
BLK  
YEL  
BLK  
M
M
M
WHI/GRY  
RINSE  
STATION #1  
DISPENSE  
VALVE  
STATION #2  
DISPENSE  
VALVE  
STATION #3  
DISPENSE  
VALVE  
STATION #4  
DISPENSE  
VALVE  
GRN  
BLK  
PGM  
GRY  
RUN  
BRN/BLK  
RINSE  
TAN  
WHI  
SOL  
RED  
ORN  
WHI  
PGM  
RUN  
SOL  
SOL  
SOL  
BRN/BLK  
COLD DRINK OPTION (LEFT ONLY)  
HOT/COLD SWITCH  
1
4
WHI/YEL  
BRN  
BRN  
TAN  
WHI  
RED  
RED  
TAN  
WHI  
COLD  
JUMPER PLUG MUST BE  
USED WHEN COLD  
DRINK FEATURE NOT  
INSTALLED  
RED  
RED  
RED  
SOL  
HOT  
PNK  
1
1
6
1
6
1
4
RED/WHI  
BLU/WHI  
GRY  
1
"RINSE" #1-3 L.E.D.  
PNK  
RED/GRN  
ORN/RED  
GRY  
1
"RINSE" #4 & 5 L.E.D.  
1
2
3
4
120/208-240 VOLTS AC - 3 WIRE  
SINGLE PHASE, 60HZ  
WHI/RED  
BLK  
WHI/RED  
BLK  
RED  
RED/BLK  
WHI/RED  
BLK  
WHI/RED  
BLK  
GRN/WHI  
GRN/BLK  
BLK/WHI  
WHI/BLK  
ORN  
ORN/BLK  
35135 012103  
43  
SCHEMATIC WIRING DIAGRAM FMD-5  
L1  
N
GRN  
WHI  
BRN/BLK  
WHI  
J4-1  
J4-4  
CONTROL  
LIMIT  
TANK HEATER  
SWITCH  
C
O
N
T
THERMOSTAT  
THERMOSTAT  
K
TANK HEATER  
FAN  
BLK  
BLK-16  
BLK-16  
BLK-16  
BLK-16  
WHI-16  
BLK-16  
K
R
O
L
BLK  
WHI  
WHI  
BLK  
BLK  
M
C
I
J3-1  
LAMP #1  
BALLAST  
BLK  
BLK  
RED  
RED  
BLK  
BLK  
BLK  
BLK  
BLK  
LAMP #2  
BALLAST  
WHI/BLU  
WHI/YEL  
GRN  
WHI/GRN  
WHI/BLK  
R
C
U
I
WHI  
J4-1  
J4-4  
VIO  
C
O
N
T
R
O
L
J3-5  
J2-1  
T
WHI  
WHI/VIO  
REFILL VALVE  
B
O
A
R
D
WHI/BLK  
LOAD  
WHI/GRN  
VIO  
WHI  
WHI  
WHI/VIO  
GRY  
OVERFLOW PROTECTION SWITCH  
RED RED  
SOL  
120V : 24V AC  
TRANSFORMER  
LINE  
WHI  
BLK  
WHI/VIO  
WHI/GRY  
WHI/BLU  
BLU/BLK  
RED/BLK  
WHI/YEL  
WHI/ORN  
WHI/ORN  
WHI/RED  
BRN/WHI  
GRN  
WHI/GRN  
WHI/BLK  
J2-5  
C
I
J3-1  
#
2
R
C
U
I
J3-5  
J2-1  
J2-5  
WHI/BLK  
J2-10  
J1-1  
T
B
O
A
R
D
WHI/VIO  
GRY  
WHI/GRY  
WHI/RED  
TAN  
RED/BLK  
WHI/BLK  
WHI/ORN  
GRN  
WHI/RED  
J1-4  
#
1
PNK  
J2-10  
J1-1  
I
N
C
D
INCREASE/  
DECREASE  
SWITCH  
HOPPER #1  
HOPPER #2  
HOPPER #3  
HOPPER #4  
HOPPER #5  
E
C
BRN/WHI  
RED  
BLK  
M
WHI/RED RED  
BLK  
WHI/ORN RED  
BLK  
WHI/YEL RED  
BLK  
WHI/BLU RED  
BLK  
M
M
M
M
J1-4  
GRN  
STATION #1  
WHIPPER  
STATION #2  
WHIPPER  
STATION #3  
WHIPPER  
STATION #4  
WHIPPER  
STATION #5  
WHIPPER  
PROBE  
RINSE/PROGRAM/  
RUN SWITCH  
BLK  
BLK  
M
BLK  
BLK  
WHI  
BLK  
BLK  
WHI  
BLK  
YEL  
BLK  
BLK  
BLU  
BLK  
M
M
M
M
WHI/GRY  
RINSE  
STATION #1  
DISPENSE  
VALVE  
STATION #2  
DISPENSE  
VALVE  
STATION #3  
DISPENSE  
VALVE  
STATION #4  
DISPENSE  
VALVE  
STATION #5  
DISPENSE  
VALVE  
GRN  
BLK  
PGM  
GRY  
RUN  
BRN/BLK  
RINSE  
TAN  
WHI  
SOL  
RED  
ORN  
WHI  
WHI  
PGM  
RUN  
SOL  
SOL  
SOL  
SOL  
BRN/BLK  
COLD DRINK OPTION (LEFT ONLY)  
HOT/COLD SWITCH  
1
4
WHI/YEL  
BRN  
BRN  
TAN  
WHI  
RED  
RED  
TAN  
WHI  
COLD  
JUMPER PLUG MUST BE  
USED WHEN COLD  
DRINK FEATURE NOT  
INSTALLED  
RED  
RED  
RED  
SOL  
HOT  
PNK  
1
1
6
1
6
1
4
RED/WHI  
BLU/WHI  
GRY  
1
"RINSE" #1-3 L.E.D.  
PNK  
RED/GRN  
ORN/RED  
GRY  
"RINSE" #4 & 5 L.E.D.  
1
1
2
3
4
5
120 VOLTS AC - 2 WIRE  
SINGLE PHASE, 60HZ  
WHI/RED  
BLK  
WHI/RED  
BLK  
RED  
RED/BLK  
WHI/RED  
BLK  
WHI/RED  
BLK  
GRN/WHI  
GRN/BLK  
WHI/RED  
BLK  
BLU  
BLU/BLK  
BLK/WHI  
WHI/BLK  
ORN  
ORN/BLK  
35135 012103  
44  
SCHEMATIC WIRING DIAGRAM FMD-5  
L1  
L2  
N
GRN  
J4-1  
J4-4  
CONTROL  
LIMIT  
TANK HEATER  
SWITCH  
C
O
N
T
THERMOSTAT  
THERMOSTAT  
TANK HEATER  
FAN  
BLK-16  
BLK-16  
BLK-16  
RED-16  
BLK-16  
R
O
L
BLK  
WHI  
BLK  
BLK  
M
C
I
J3-1  
LAMP #1  
BALLAST  
BLK  
BLK  
RED  
RED  
BLK  
BLK  
BLK  
BLK  
LAMP #2  
BALLAST  
WHI/BLU  
WHI/YEL  
GRN  
WHI/GRN  
WHI/BLK  
R
C
U
I
WHI  
WHI  
J4-1  
J4-4  
VIO  
C
O
N
T
R
O
L
J3-5  
J2-1  
T
WHI  
WHI/VIO  
REFILL VALVE  
B
O
A
R
D
WHI/BLK  
LOAD  
WHI/GRN  
VIO  
WHI  
WHI  
WHI/VIO  
GRY  
OVERFLOW PROTECTION SWITCH  
RED RED  
SOL  
120V : 24V AC  
TRANSFORMER  
LINE  
WHI  
BLK  
WHI/VIO  
WHI/GRY  
WHI/BLU  
BLU/BLK  
RED/BLK  
WHI/YEL  
WHI/ORN  
WHI/ORN  
WHI/RED  
BRN/WHI  
GRN  
WHI/GRN  
WHI/BLK  
J2-5  
C
I
J3-1  
#
2
R
C
U
I
J3-5  
J2-1  
J2-5  
WHI/BLK  
J2-10  
J1-1  
T
B
O
A
R
D
WHI/VIO  
GRY  
WHI/GRY  
WHI/RED  
TAN  
RED/BLK  
WHI/BLK  
WHI/ORN  
GRN  
WHI/RED  
J1-4  
#
1
PNK  
J2-10  
J1-1  
I
N
C
D
INCREASE/  
DECREASE  
SWITCH  
HOPPER #1  
HOPPER #2  
HOPPER #3  
HOPPER #4  
WHI/YEL RED  
M
HOPPER #5  
M
E
C
BRN/WHI  
RED  
BLK  
M
WHI/RED RED  
BLK  
WHI/ORN RED  
BLK  
BLK  
WHI/BLU RED  
BLK  
M
M
J1-4  
GRN  
STATION #1  
WHIPPER  
STATION #2  
WHIPPER  
STATION #3  
WHIPPER  
STATION #4  
WHIPPER  
STATION #5  
WHIPPER  
PROBE  
RINSE/PROGRAM/  
RUN SWITCH  
BLK  
BLK  
M
BLK  
BLK  
WHI  
BLK  
BLK  
WHI  
BLK  
YEL  
BLK  
BLK  
BLU  
BLK  
M
M
M
M
WHI/GRY  
RINSE  
STATION #1  
DISPENSE  
VALVE  
STATION #2  
DISPENSE  
VALVE  
STATION #3  
DISPENSE  
VALVE  
STATION #4  
DISPENSE  
VALVE  
STATION #5  
DISPENSE  
VALVE  
GRN  
BLK  
PGM  
GRY  
RUN  
BRN/BLK  
RINSE  
TAN  
WHI  
SOL  
RED  
ORN  
WHI  
WHI  
PGM  
RUN  
SOL  
SOL  
SOL  
SOL  
BRN/BLK  
COLD DRINK OPTION (LEFT ONLY)  
HOT/COLD SWITCH  
1
4
WHI/YEL  
BRN  
BRN  
TAN  
WHI  
RED  
RED  
TAN  
WHI  
COLD  
JUMPER PLUG MUST BE  
USED WHEN COLD  
DRINK FEATURE NOT  
INSTALLED  
RED  
RED  
RED  
SOL  
HOT  
PNK  
1
1
6
1
6
1
4
RED/WHI  
BLU/WHI  
1
GRY  
"RINSE" #1-3 L.E.D.  
PNK  
RED/GRN  
ORN/RED  
1
GRY  
"RINSE" #4 & 5 L.E.D.  
1
2
3
4
5
120/208-240 VOLTS AC - 3 WIRE  
SINGLE PHASE, 60HZ  
WHI/RED  
BLK  
WHI/RED  
BLK  
RED  
RED/BLK  
WHI/RED  
BLK  
WHI/RED  
BLK  
GRN/WHI  
GRN/BLK  
WHI/RED  
BLK  
BLU  
BLU/BLK  
BLK/WHI  
WHI/BLK  
ORN  
ORN/BLK  
35135 012103  
45  

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