Saeco Classic Service Manual
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Saeco Classic Service Manual

Coffee machine
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ROYAL CLASSIC
ROYAL EXCLUSIV
ROYAL DIGITAL
ROYAL DIGITAL REDESIGN
ROYAL DIGITAL PLUS
ROYAL PROFESSIONAL
ROYAL PROFESSIONAL REDESIGN
ROYAL CAPPUCCINO
ROYAL CAPPUCCINO REDESIGN
ROYAL COFFEEBAR
ROYAL OFFICE
SERVICE
MANUAL
Revision 4
Saeco International Group
All parts of the present service manual are the property of Saeco International Group. All rights reserved. The manufacturer
is not responsible for any errors or omissions in the present document. Any reproduction or unauthorised use of this manual
without the prior written permission of the manufacturer or by contractual agreement is prohibited.
Saeco
SEPT.: 2003

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  • Page 1 SEPT.: 2003 All parts of the present service manual are the property of Saeco International Group. All rights reserved. The manufacturer is not responsible for any errors or omissions in the present document. Any reproduction or unauthorised use of this manual...
  • Page 3 Table of contents Introduction Technical data Operation Functions and timing Service programme Faults Fault diagnosis Repairs / Service schedule Disassembly Circuit diagrams Saeco International Group REV.4 SEPT.2003...
  • Page 5 CHAPTER 1 INTRODUCTION Page 1. Documents required 2. Equipment 3. Material 4. Safety instructions 5. Overview of product range Saeco International Group REV.4 SEPT.2003...

  • Page 7: Introduction

    The machine must be disconnected from the main power supply before performing repair work. Switching the machine off is not an adequate measure. The Royal coffee machine is classified under Protection Class 1. Protective devices must be tested once the repair work has been completed. Saeco International Group REV.4 SEPT.2003 Page 1/2...

  • Page 8: Overview Of Product Range

    Pipe heater Office*** Note: * All machines, with the exception of the Royal Classic, are fitted with a powder coffee feed. ** The Royal Coffeebar has a fixed water connection (reversible). ***Royal Office – no steam function. Output capacity: Royal Series (Household): Maximum average daily output: 30 coffees...

  • Page 9: Technical Data

    Page 1. Technical Data Royal (Classic) 2. Technical Data Royal (Digital/Digital Redesign/Exclusive) 3. Technical Data Royal (Cappuccino/Professional Instant Steam/ Cappuccino Redesign) 4. Technical Data Royal (Professional-Rapid Steam/Prof. Redes. Digital Plus/Coffeebar) 5. Technical Data Royal (Office) Saeco International Group REV.4 SEPT.2003...
  • Page 11 ROYAL 2. TECHNICAL DATA 1. Technical data (Royal Classic) Royal Classic Technical data Power supply/output: 230V 50Hz 1250W Safety system: 170°C Safety thermostat for instantaneous water heater Temperature monitoring: KTY Temperature sensors transmit respective temperatures to electronic system Continuous flow thermoblock:...
  • Page 12 Initial grinding with completely empty machine: Approx. 15 sec. / subsequent grinding: approx. 5.5 sec. Time to make expresso: Approx. 28 sec. for 50 ml Time to make cup of coffee: Approx. 40 sec. for 100 ml Page 2/5 REV.4 SEPT.2003 Saeco International Group...
  • Page 13 Initial grinding with completely empty machine: Approx. 15 sec. / subsequent grinding: approx. 5.5 sec. Time to make expresso: Approx. 28 sec. for 50 ml Time to make cup of coffee: Approx. 40 sec. for 100 ml Saeco International Group REV.4 SEPT.2003 Page 3/5...
  • Page 14 Initial grinding with completely empty machine: Approx. 15 sec. / subsequent grinding: approx. 5.5 sec. Time to make expresso: Approx. 28 sec. for 50 ml Time to make cup of coffee: Approx. 40 sec. for 100 ml Page 4/5 REV.4 SEPT.2003 Saeco International Group...
  • Page 15 Initial grinding with completely empty machine: Approx. 15 sec. / subsequent grinding: approx. 5.5 sec. Time to make expresso: Approx. 28 sec. for 50 ml Time to make cup of coffee: Approx. 40 sec. for 100 ml Saeco International Group REV.4 SEPT.2003 Page 5/5...
  • Page 17 CHAPTER 3 OPERATION Page Operation (Royal Classic) 1.1. Operating instructions Operation (Royal Exclusive/Digital/Digital Redes.) 2.1. Operating instructions 2.2. User programme Operation (Profess. Instant Steam Cappuccino/ Cappuccino Redesign / Profess. Redesign) 7 3.1. Operating instructions 3.2. User programme Operation (Professional-Rapid Steam/Coffeebar/ Digital Plus) 4.1.

  • Page 19: Operation

    ROYAL 3. OPERATION 1. Operation (Royal Classic) 1.1. Operating instructions (quick reference) HS LED Temp. Steam Action Comments Getting started Unpack machine. Check for damage. Fill water tank Fill coffee beans container. Connect mains plug. Turn on main switch. Light on De-aerate water circuit.
  • Page 20 About every 3 months Do not use vinegar! (damages the pump) Descaling procedure: 1. Place Saeco descaler into fresh water tank. 2. Fill with about one litre of hot water. 3. Make 2-3 coffees to descale coffee circuit. 4. Remove the remaining descaler mixture in cupfuls via the HWS valve in intervals of about 5 –...

  • Page 21: Royal Digital/Exclusive/Digital Redesign

    To froth milk. Press steam button / deactivate Cooling stage (can be Overheating steam function. accelerated by de-aerating) De-aerate Hot water Overheating Ready (to make coffee) Ready for operation Descale: See Royal Cappuccino Saeco International Group REV.4 SEPT.2003 Page 3/25...
  • Page 22 Longer heating time or less hot water. The brewing unit is not in home Turn machine on, close The brewing unit cannot be position. service door and check dregs removed. drawer.(the brewing unit goes automat. to home position) 4/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 23 < 50°C) (not in Royal Exclusive). Water hardness 1 – 500 l Change in coffee quantity until descaling required (1-4). 2 – 300 l 3 – 150 l 4 – 80 l Saeco International Group REV.4 SEPT.2003 Page 5/25...
  • Page 24 Cleaning cycle Cleaning programme for brewing unit Factory Initialise standard settings settings (only for Royal Dig. Redesign) Exit: ESC button / Menu item - EXIT and ENTER (depending on programme). 6/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 25 Hot water quantity Keep the hot water button Hot water programming pressed for the desired time. Quantity (only when hot water The last programme entered is programme programme is activated in the saved user menu). Saeco International Group REV.4 SEPT.2003 Page 7/25...
  • Page 26 Clean filter Descale Depending on water hardness. 1. Place Saeco descaler into fresh water tank. Descale: 2. Fill with about one litre of hot water. 3. Remove about two to three cups via the brewing unit (cannot be poured).

  • Page 27: Troubleshooting

    The brewing unit is not in home Turn machine on, close The brewing unit cannot be position. service door and check removed. dregs drawer. (the brewing unit goes automatically to home position) Saeco International Group REV.4 SEPT.2003 Page 9/25...
  • Page 28 Setting/Indicator Standard Function Standby Standby Only for Redesign Series Language Country German Display language Rinse ON/OFF Rinses every time the machine is turned on (temp. of instantaneous water heater < 50°C) Not Roy. Cappuccino 10/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 29 Programming for the purposes of vending Cleaning cycle Not relevant in Austria Not Roy. Cappuccino Factory settings Reset standard values Not Roy. Cappuccino Exit Exit Not Roy. Redesign Exit: Exit – Enter / ESC depending on type Saeco International Group REV.4 SEPT.2003 Page 11/25...

  • Page 30: Professional Rapid Steam/Coffeebar/Digital Plus

    Hot water quantity Keep the hot water button Hot water programming pressed for the desired time. Quantity programme (only when hot water The last programme entered is programme is activated in the saved . user programme). 12/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 31 1 x per month grease filter. Descale According to indicator 1. Place Saeco descaler into fresh water tank. Descale: 2. Fill with about one litre of hot water. 3. Remove about two to three cups via the brewing unit. 4. Activate the Descale item in the user menu by selecting OK and open the HWS valve (place a sufficiently large container under the steam pipe).
  • Page 32 The brewing unit is not in home Turn machine on, close The brewing unit cannot be position. service door and check removed. dregs drawer. (the brewing unit goes automatically to home position) 14/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 33 (only when machine is cold). Water hardness 1 – 500 l Change in coffee quantity until descaling required (1-4). 2 – 300 l 3 – 150 l 4 – 80 l Saeco International Group REV.4 SEPT.2003 Page 15/25...
  • Page 34 Cleaning cycle YES/NO Activates the cleaning programme for the brewing unit. Factory YES/NO Activates fixed water connection. settings (only Roy. Digital+) Fixed water YES/NO Activates fixed water connection. (only Roy. Coffeebar/ Professional) Exit: ESC button 16/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 35 Change value: Arrow button Expresso lungo + arrow button Counter Number of coffees dispensed Reset: Expresso lungo + ESC Cycles Number since last reset Change value: Arrow button Expresso lungo + arrow button Saeco International Group REV.4 SEPT.2003 Page 17/25...
  • Page 36 If the programmed code is only used to read the counter reading, the code entry can also be • skipped. However, if an attempt is made to change the counter reading, the code request appears. Attention: If you forget the code, a new code must be requested from Saeco Austria! 18/25 REV.4 SEPT.2003...
  • Page 37 C + Espr. + Coffee Indicates the expressos and coffees dispensed Total Number Resettable (in vending menu) C + Hot water Indicates the hot water dispensed Hot water Total Number Resettable (in vending menu) Saeco International Group REV.4 SEPT.2003 Page 19/25...
  • Page 38 Clean filter Descale According to indicator 1. Place Saeco descaler into fresh water tank. Descale: 2. Fill with about one litre of hot water. 3. Remove about two to three cups via the brewing unit. 4. Confirm the Descale item in the user menu by pressing twice the E-button (place a sufficiently large container under the hot water pipe).
  • Page 39 The brewing unit is not in home Turn machine on, close The brewing unit cannot be position. service door and check dregs removed. drawer. (the brewing unit goes automatically to home position) Saeco International Group REV.4 SEPT.2003 Page 21/25...
  • Page 40 Function Code 111111 Programme protection If the code is entered five times incorrectly, the PUC code must be entered. Request from Saeco Austria. Vending The counter can be read and locking function activated via the vending menu. Language Country German...
  • Page 41 0-12.45 hours Machine switches to standby mode if not used within the programmed time. (Standby mode can also be activated at any time via the menu buttons.) Cleaning cycle No relevant in Austria Saeco International Group REV.4 SEPT.2003 Page 23/25...
  • Page 42 Enter and confirm with E-button. Code entry New code by: New code? Expresso button = 1 ****** Coffee button = 2 Hot water button = 3 C-button = 4 Enter and confirm with E-button. 24/25 REV.4 SEPT.2003 Saeco International Group...
  • Page 43 Use arrow button to select Yes New code = number Save Confirm code Press ENTER Code ****** Exit Press C-button twice Attention: If you forget the code, a new code must be requested from Saeco Austria! Saeco International Group REV.4 SEPT.2003 Page 25/25...

  • Page 45: Functions And Timing

    WSP (R. Cappuccino Redesign) 1.4. WSP (R. Coffeebar) 1.4. WSP (R..Office) 1.5. Electrical system 2.1.1. CPU – IN / OUT (R. Classic) 2.2.1. CPU – INPUT (Royal Digital/Exclusive) 2.2.2. Control panel (Royal Digital/Exclusive) 2.3.1. CPU – INPUT (Cappuccino/Professional Instant Steam) 15 2.3.2.
  • Page 47 ROYAL 4. FUNCTION/TIMING 1. Water system 1.1. Water system (Royal Classic / Digital / Exclusive / Digital Redesign) Boiler J Durchlauferhitzer Thermal sensor Temp.sensor Water tank Wassertank Float Schwimmer Water filter Wasserfilter Getriebevor Gear resistor -widerstand 2x Thermostat 2 Thermostate...
  • Page 48 Opens when brewing unit is aligned with water circuit to the unit itself. Steam valve For hot water and steam dispensing Elecrto-valve (hot water) Solenoid valve for water dispensing Elecrto-valve (for boiler filling) Solenoid valve for filling pipe heating system Page 2/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 49 Steam-valve For hot water and steam dispensing Electro-valve (for cappuccino maker) Solenoid valve/steam dispensing for cappuccino Electro-valve (water) Solenoid valve for water dispensing Electro-valve (steam) Solenoid valve for filling pipe heating system Saeco International Group REV.4 SEPT.2003 Page 3/22...
  • Page 50 Steam generation / Temperature approx. 130°C (steam) Sensor (KTY) Transmits current temperature value to electronic system System 1 (Water) Thermostat Alternates current supply for heating system in event of System 1 (Water) overheating. Page 4/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 51 Steam valve For steam dispensing Valve cappuccinatore Solenoid valve/steam dispensing for cappuccino (for cappuccino maker) Valve (water) Solenoid valve for water dispensing Valve (steam) Solenoid valve for steam dispensing (turbowater) Saeco International Group REV.4 SEPT.2003 Page 5/22...
  • Page 52 Pipe heating / Heating (steam) Steam generation / Temperature approx. 130°C Sensor (KTY) Transmits current temperature value to electronic System 1 (Water) system Thermostat Alternates current supply for heating system in event System 1 (Water) of overheating. Page 6/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 53 Solenoid valve EV3: Open Solenoid valve EV4: Closed Pump 2 functions to produce hot water. This ensures that both pumps are regularly flushed with water and no damage is caused by standing dry for too long. Saeco International Group REV.4 SEPT.2003 Page 7/22...
  • Page 54 EV1-2-3-4 are open to prevent an increased pressure in the water system caused by the descaling solution. All three processes are repeated several times automatically (about 45 minutes). A final rinse with no descaling solution must be performed. Page 8/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 55 Sensor (KTY) Transmits current temperature value to electronic Instantaneous water heater system Thermostat Alternates current supply for heating system in event Instantaneous water heater of overheating. Pipe heating Steam generation / Temperature approx. 130°C Saeco International Group REV.4 SEPT.2003 Page 9/22...
  • Page 56 The inlet valve is activated via the user programme (Chap. 3, Page 16). A pressure reducer installed at the inlet point maintains an almost pressureless operation before the pump. However, a separate flow meter is used to measure the flow rate. Page 10/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 57 Alternates current supply for heating system in event of overheating. Valve plug Opens when brewing unit is aligned with water circuit to the unit itself. Magnet valve (water) Solenoid valve for water dispensing Saeco International Group REV.4 SEPT.2003 Page 11/22...

  • Page 58: Electrical System

    4. FUNCTION/TIMING ROYAL 2. Electrical system 2.1. CPU – IN / OUT (Royal Classic) Filt Tür- Haupt- Door Main schalter schalter switch switch Grinder Mahlwerk- motor motor JP11 JP10 Dosier Dosing mag- magnet JP13 TSI- T-fuse Pump Pumpe Pumpe Boilerheiz.
  • Page 59 Gears in home position Microswitch MS2 15/5V = Gears in brewing position Microswitch MS3 15/5V = Brewing unit Microswitch MS4 15/5V = Doser Microswitch MS5 15/5V = HWS valve Microswitch MS6 15/5V = Dregs drawer Saeco International Group REV.4 SEPT.2003 Page 13/22...
  • Page 60 Pumpe- Pump T-fuse TSI-Pumpe System 1 Pump Approx. 190V~ Diode in pump Mains switch 230 V~ Door microswitch 230 V~ Doser coil 230 V~ / 300Ohm Microfuse F1 230 V~ / 8AT Page 14/22 REV.4 SEPT.2003 Saeco International Group...

  • Page 61: Cpu – Input

    Gears in home position Microswitch MS2 15/5V = Gears in brewing position Microswitch MS3 15/5V = Brewing unit Microswitch MS4 15/5V = Doser Microswitch MS5 15/5V = HWS valve Microswitch MS6 15/5V = Dregs drawer Saeco International Group REV.4 SEPT.2003 Page 15/22...

  • Page 62: Control Panel

    Thermostat Zusatzheiz. Suppl. heating Zusatzheiz. Zusatzheiz. Supplementary heating JP17 Microfuse F1 230 V~ / 32mAT Control Microfuse F2 230 V~ / 8AT Pipe heating Microfuse F3 230 V~ / 8AT Instantaneous water heater Page 16/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 63 Gears in home position Microswitch MS2 15/5V = Gears in brewing position Microswitch MS3 15/5V = Brewing unit Microswitch MS4 15/5V = Doser Microswitch MS5 15/5V = HWS valve Microswitch MS6 15/5V = Dregs drawer Saeco International Group REV.4 SEPT.2003 Page 17/22...
  • Page 64 Suppl. heating Suppl. heating Zusatzheiz. Zusatzheiz. Zusatzheiz. JP17 Supplementary heating Microfuse F1 230 V~ / 32mAT Control Microfuse F2 230 V~ / 8AT Pipe heating Microfuse F3 230 V~ / 8AT Instantaneous water heater Page 18/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 65 Firstly, the gearmotor is initialised. The gears move to MS1 (lower limit switch), change rotating direction, leave MS1 and move to the home position (about 2 mm after MS1). Exception: Royal Classic – process as for Vienna (moves to brewing position and back / see Vienna).
  • Page 66 If one of the thermal fuses is compromised or the heating plate is defective, the gearmotor also does not function. Exception: The Royal Office does not have a heating plate. The gear resistor is the small resistor on the instantaneous water heater. Page 20/22 REV.4 SEPT.2003 Saeco International Group...
  • Page 67 Cooling can be achieved by dispensing hot water. The pump functions at maximum output and the heating remains turned off as long as the temperature indicator flashes (R. Classic) / Overheating signal remains on (Royal Digital/Exclusive). These measures ensure that the cooling process is accelerated and the overheating signal will disappear after a few seconds (only in machines without Instant or Rapid Steam).
  • Page 68 If the dosing microswitch is not activated within 20 seconds from start of the grinder motor, the coffee beans low signal appears. The dosing quantity is set automatically by shifting the doser housing wall together with its microswitch. Page 22/22 REV.4 SEPT.2003 Saeco International Group...

  • Page 69: Service Programme

    CHAPTER 5 SERVICE PROGRAMME Page Service programme (R. Classic) 1.1. Test mode Service programme (Royal Digital/Exclusive/Digital Redes.) 2.1. Test mode 2.2. Diagnosis menu Service programme (Professional Instant Steam/Cappuccino/ Cappuccino Redesign) 3.1. Test mode 3.2. Diagnosis menu Service programme (R. Professional Rapid Steam/ Profess.
  • Page 71 ROYAL 5. SERVICE PROGRAMME 1. Service programme (Royal Classic): 1.1. Test mode Access the service mode by turning on the machine and simultaneously pressing the Access: Coffee and steam buttons. Press Coffee and Steam buttons. Various test functions can be activated in the service mode by activating either the coffee or steam buttons in conjunction with various coffee quantity settings.
  • Page 72 Coffee or scroll in menu and change value Expresso or exit menu Expresso lungo Selection of programming menu The various functions indicated in the table can be checked by pressing the button combinations listed below. Page 2/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 73 5 = Grinds container microswitch activated 7 = Menu 6 = Brewing unit microswitch activated 7 = Water tank filled (reed contact not activated) 8 = Flow meter pulses (indicator flashes when magnet passes Hall generator) Saeco International Group REV.4 SEPT.2003 Page 3/24...
  • Page 74 If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135. Exit: Switch the machine off from the main switch. Page 4/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 75 +/- 1 Used when dispensing the first ° C coffee after the machine has been turned on, to compensate for the high temperature loss due to the cold brewing unit and water pipes. Saeco International Group REV.4 SEPT.2003 Page 5/24...
  • Page 76 --SERVICE DATE-- 0 - 12 +/- 1 updated at each service. MONTH --SERVICE DATE-- 1996 - 2050 +/- 1 YEAR Exit: Switch the machine off at the main switch or by pressing ESC twice. Page 6/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 77 Coffee or scroll in menu and change value Expresso or exit menu Expresso lungo Selection of programming menu The various functions indicated in the table can be checked by pressing the button combinations listed below. Saeco International Group REV.4 SEPT.2003 Page 7/24...
  • Page 78 Pump System 1 + Magnet water valve Magnet valve By-Pass Pump System 2 + Magnet By-Pass valve Magnet valve steam Open steam valve! Pump System 2 + Magnet By-Pass valve Magnet water valve Page 8/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 79 If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135. Exit: Switch the machine off at the main switch. Saeco International Group REV.4 SEPT.2003 Page 9/24...
  • Page 80 3246Ω exceeds or falls short of the specified temperature value (96°C) by more than 1°C, the value indicated in test mode must be applied to adjust the sensor. No measuring resistance: Do not change! From 2003 version Page 10/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 81 Total water flow volume (in ml) / not resettable WATER DESCALING Pump system 1: Total water flow (in ml) since last (ml) descaling. Reset: Press cappuccino button for 5 sec. Redesign - Expresso lungo +ESC Saeco International Group REV.4 SEPT.2003 Page 11/24...
  • Page 82 From Version: 2003 deducted from the value. If a beverage is chosen for which the saved pulse number is higher than the remaining pulses, the message FILL WATER TANK appears. Page 12/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 83 --SERVICE DATE-- 0 - 12 +/- 1 updated at each service. MONTH --SERVICE DATE-- 1996 - 2050 +/- 1 YEAR Exit: Switch the machine off at the main switch. Saeco International Group REV.4 SEPT.2003 Page 13/24...
  • Page 84 Hot water Pre-select powder compartment or scroll in menu and change value Cappuccino or save value Coffee or scroll in menu and change value Expresso or exit menu Expresso lungo Selection of programming menu Page 14/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 85 S1 Water button Powder Standby Expresso Coffee Expresso Menu coffee lungo Unit up Unit down Grinder Heating plate Doser rinse Heating (System 1) Supplementary heating (System 1) Heating (System 2) Temperature indicator in °C Saeco International Group REV.4 SEPT.2003 Page 15/24...
  • Page 86 7 = Menu maker 6 = Brewing unit microswitch activated 7 = Water tank filled (reed contact not activated) 8 = Flow meter pulse system 1 (Water) (indicator flashes when magnet passes Hall generator) Page 16/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 87 If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135. Exit: Switch the machine off at the main switch. Saeco International Group REV.4 SEPT.2003 Page 17/24...
  • Page 88 3246Ω exceeds or falls short of the specified temperature value (96°C) by more than 1°C, the value indicated in test mode must be applied to adjust the sensor. No measuring resistance: Do not change! From 2003 version Page 18/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 89 Total water flow volume (in ml) / not resettable WATER DESCALING Pump system 1: Total water flow (in ml) since last (ml) descaling. Reset: Press cappuccino button for 5 sec. Redesign: Expresso lungo +ESC Saeco International Group REV.4 SEPT.2003 Page 19/24...
  • Page 90 --SERVICE DATE-- 0 - 12 +/- 1 updated at each service. MONTH --SERVICE DATE-- 1996 - 2050 +/- 1 YEAR Exit: Switch the machine off at the main switch. Page 20/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 91 5 = Grinds container microswitch activated 6 = Brewing unit microswitch activated 7 = Water tank full (reed contact not activated) 8 = Flow meter pulses (indicator appears as soon as the magnet passes the sensor) Saeco International Group REV.4 SEPT.2003 Page 21/24...
  • Page 92 If no button is activated, a number appears at the bottom right side referring to the grinder rate. This value must be between 125 - 135. Exit: Switch the machine off at the main switch. Page 22/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 93 TEMP. INCREASE 0-50°C +/-1 The boiler temperature is increased °C by a set value shortly before brewing in order to pre-heat the boiler. and compensate for the temperature drop during the first water flow. Saeco International Group REV.4 SEPT.2003 Page 23/24...
  • Page 94 ----------------- machine was manufactured. This ------ date cannot be changed. --DATE OF MANUF--- --------------------- ----------------- MONTH ------ --DATE OF MANUF--- --------------------- ----------------- YEAR ------ Exit: Switch the machine off at the main switch. Page 24/24 REV.4 SEPT.2003 Saeco International Group...
  • Page 95 CHAPTER 6 FAULTS Page 1. Faults Saeco International Group REV.4 SEPT.2003...
  • Page 97 Weak coffee Dose quantity too low Dose chamber - coffee residues Recurring indicator Doser switch does not work COFFEE BEANS LOW Doser flap does not close Brewing unit overfull Gearmotor obstructed Electronic system defective Saeco International Group REV.4 SEPT.2003 Page 1/3...
  • Page 98 Valve gasket calcified Water drips from steam pipe shaft Fracture in steam pipe Water leakage from HWS spout Defective O-ring Water leakage at joint Defective O-ring Hairline crack in HWS valve threaded joint Page 2/3 REV.4 SEPT.2003 Saeco International Group...
  • Page 99 Turbine calcified / other Water low indicator flashes deposits Hall sensor defective WATER LOW INDICATOR Float not watertight indicator Float jammed (water level over reserve) Magnet in float too weak Electronic system defective Reed sensor defective Saeco International Group REV.4 SEPT.2003 Page 3/3...

  • Page 101: Fault Diagnosis

    CHAPTER 7 FAULT DIAGNOSIS Page 1. Fault detection (Royal Classic) 1.1. Does not function 1.2. Machine does not function (red LED flashes) 1.3. Machine does not function (red LED lights up) 1.4. Water low 1.5. Brewing unit / Gearmotor obstructed 2.

  • Page 103: Machine Does Not Function

    ROYAL 7. FAULT DIAGNOSIS 1. Fault diagnosis (Royal Classic) 1.1 Machine does not function Machine does not function Is there current upstream Test mains fuse and machine from the mains filter? cable - Is there current downstream Replace - END...
  • Page 104 - Can dregs drawer be fitted? Check if brewing unit is blocked Is brewing unit installed? Can brewing unit be installed? Does brewing unit MS Replace MS function correctly? Replace MS Does dregs drawer MS function correctly? Page 2/12 REV.5 SEPT.2004 Saeco International Group...
  • Page 105 Does current reach grinding motor work after start button at a specific time? has been activated? Check cable / Replace Replace motor electronic system Does coffee dispensing stop after grinding (coffee beans low signal again)? Saeco International Group REV.5 SEPT.2004 Page3/12...
  • Page 106 Grinding can be made - Is coffee dispensing coarser complete? Test motor retainer - Does coffee have enough froth / Is grain size of dregs correct? Replace grinding disc Lock motor retainer into place - END Page 4/12 REV.5 SEPT.2004 Saeco International Group...
  • Page 107 Flow meter pulses for Flow meter calcified/ Replace hot water supply OK? Other dirt Check valve plugs Instantaneous water heater Calcified / Damaged calcified / Piping calcified - Check brewing unit END Descale / Replace Saeco International Group REV.5 SEPT.2004 Page5/12...
  • Page 108 Do gears move to home position in service mode? Is the gearmotor energised? Replace gearmotor Is current flow to cup warmer and Replace cup warmer / thermal fuse OK? thermal fuse Replace electronic system Page 6/12 REV.5 SEPT.2004 Saeco International Group...
  • Page 109 Does current flow to the door switch when the front Replace - END door is closed? Does the current flow Replace - END to the main switch? Replace - END KTY defective Electronic system Replace - END defective? Saeco International Group REV.5 SEPT.2004 Page7/12...
  • Page 110 MS function correctly? installed? Can grinds container Does indicator stop? be installed? Is the brewing unit in home position? Replace MS Does brewing unit microswitch function correctly? Check if brewing unit is blocked Page 8/12 REV.5 SEPT.2004 Saeco International Group...
  • Page 111 Fill water Water in tank? (over reserve) Replace / Has float sunk or is Remove jammed? Replace float Is magnet old? Is reed sensor Replace reed sensor defective? Electronic system Replace - END defective? Saeco International Group REV.5 SEPT.2004 Page9/12...
  • Page 112 Flow meter pulses for Replace Flow meter calcified/ hot water supply OK? Other dirt Check valve plugs Instantaneous water heater Calcified / Damaged calcified / Piping calcified - Check brewing unit END Descale / Replace Page 10/12 REV.5 SEPT.2004 Saeco International Group...

  • Page 113: Coffee Beans Low Indicator

    Grind can be made - Is coffee dispensing coarser complete? Does coffee have enough froth / Test motor retainer - Do dregs have correct consistency? Replace grinding disc Lock motor retainer into place - END Saeco International Group REV.5 SEPT.2004 Page11/12...
  • Page 114 Do gears move to home position in service mode? Replace gearmotor Is the gearmotor energised? Is current flow to cup warmer and Replace cup warmer / thermal fuse OK? thermal fuse Replace electronic system Page 12/12 REV.5 SEPT.2004 Saeco International Group...

  • Page 115: Service Schedule

    CHAPTER 8 REPAIRS / SERVICE SCHEDULE Page 1. Repairs schedule 2. Service schedule 3. Final test Saeco International Group REV.4 SEPT.2003...
  • Page 117 Vacuum cleaner / brush Doser Vacuum cleaner / brush Water circuit Descaler (Saeco) HWS valve VC / R Water outlet (valve plug) Grease solvent / brush O-ring (boiler connection / instantaneous water heater) Saeco International Group REV.4 SEPT.2003 Page 1/2...
  • Page 118 Grinds Container Remove grinds container Grinds Container Absent indicator Absent indicator Coffee Beans Start coffee programme - Coffee Beans Low Low indicator coffee bean container indicator empty Insulation test HG 701 Saeco International Group REV.4 SEPT.2003 Page 2/2...

  • Page 119: Disassembly

    6. Adjusting the grinder 7. Disassembling the grinder motor 8. Disassemble the instantaneous water heater 9. Disassembling the gears 10. Assembly/adjustment of instantaneous water heater 11. Disassembling the pump 12. Disassembling System 2 (Rapid steam) Saeco International Group REV.4 SEPT.2003...
  • Page 121 Remove the two screws (2) below the water tank (Torx/T10). Fig. 1 d) Remove the two bottom housing screws (1). Fig. 2 Saeco International Group REV.4 SEPT.2003 Seite 1/20...
  • Page 122 (2) carefully in order not to break the fixing hooks. Fig. 3 Lift the housing at the rear side and pull water hose off. Than remove the housing. When reassembling make sure, that the water hose is connected correctly! Seite 2/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 123 2. Disassembling the electronic system a) Number the connections on the control board and remove. Fig. 4 b) Unscrew the electronic system by removing the two fixing screws (1) and remove. Fig. 5 Saeco International Group REV.4 SEPT.2003 Seite 3/20...
  • Page 124 3. Disassembling the doser a) Unscrew the doser cover by removing the screw (1). Fig. 6 b) Using a screwdriver, release the fastening tab (1) and push dosing magnet out of its fitting. Fig. 7 Seite 4/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 125 ROYAL 9. DISASSEMBLY c) Using a screwdriver, first push the doser flap out of the open end (1). Than slide it out of the closed bearing (2) and remove. Fig. 8 Saeco International Group REV.4 SEPT.2003 Seite 5/20...
  • Page 126 (2). Carefully pull out the two rubber holders (3). Fig. 9 b) Disconnect the switch. Lift the doser switch using a screwdriver (1) and push it out of ist fitting (2). Fig. 10 Seite 6/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 127 Fig. 11 b) Remove the fixing screw (1) of the grinding cone (note: left thread). c) Carefully remove the grinding cone (2) (take care of balls and springs of friction clutch). Fig. 12 Saeco International Group REV.4 SEPT.2003 Seite 7/20...
  • Page 128 Carefully remove the clutch disc. Fig. 13 e) Remove: Balls, springs and rubber drivers. The sealing felt (1) can then be cleaned or exchanged. (Same steps have to be performed when exchanging the Grinder motor) Fig. 14 Seite 8/20 REV.4 SEPT.2003 Saeco International Group...

  • Page 129: Adjusting Grinder

    Install the grinding ring onto its fitting so that the marking (1) on the grinding adjustment ring and the ring fitting (2) are adjacent to one another. Fig. 15 b) Turn the grinding adjustment ring (1) clockwise until a certain friction can be felt. Fig. 16 Saeco International Group REV.4 SEPT.2003 Seite 9/20...
  • Page 130 Turn about 12-14 notches in an anti-clockwise direction and check the grind level by making a test coffee (Crema / dregs grain size). Adjust the grind level as required (max. 3-5 notches). Attach the housing and mount the lever in position 5. Seite 10/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 131 If the motor has to be exchanged perform according to description 6. Disassembling the grinder first. Remove the three fixing screws (1), and set the doser switch to max position. Fig. 17 b) Lift the motor and disconnect the connectors (1). Fig. 18 Saeco International Group REV.5 SEPT.2004 Seite 11/20...
  • Page 132 Remove the securing ring if there is one (not in all machines), unhook the three tabs and seperate the upper part from the motor/gear assy (the motor is alwasy delivered with the gear). Fig. 19 Fig. 20 Seite 12/20 REV.4 SEPT.2003 Saeco International Group...

  • Page 133: Disassembling Instantaneous Water Heater

    (2) and remove the Water hose. Fig. 21 b) Remove the two fixing screws (1) of the instantaneous water heater (new version / boiler J is fixed with 3 screws). Fig. 22 Saeco International Group REV.4 SEPT.2003 Seite 13/20...
  • Page 134 Attention: The metal cylinder (Fig. 24/1) of the thermal sensor (KTY) must be transferred from the old sensor to the new sensor when the sensor is replaced!. Fig. 24 e) When re-assembling ensure that sufficient heat conductive paste is used (Fig. 24/2). Seite 14/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 135 Remove the gear by lifting it a bit – pulling out the bottom side of the gear first, and thereafter the upper side. Unscrew the screws of the gear cover and remove the cover. Abb. 26 Fig. 26 Saeco International Group REV.4 SEPT.2003 Seite 15/20...
  • Page 136 - install brewing unit.) The small gear wheel can be assembled as required a) Micro switch brew position b) Micro switch home position c) Micro switch dreg drawer d) Micro switch brew unit Abb. 27 Seite 16/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 137 Fasten the lower fixing screw (1). Abb. 28 b) Drive the brew unit into home position, remove the brew unit and fasten the upper screw (1). (Attention: Boiler J is fixed with three screws) Abb. 29 Saeco International Group REV.4 SEPT.2003 Seite 17/20...
  • Page 138 Pull off the adapter angle (1) and pump holder (2). Abb. 30 Abb. 31 b) Remove the locking spring (1). c) Push down the fixing tab (2) and remove pump and holder (3). Abb. 32 Seite 18/20 REV.4 SEPT.2003 Saeco International Group...
  • Page 139 ROYAL 9. DEMONTAGE 12. Disassembly System 2 (Rapid steam) a) Loosen nut (1) and remove cappuccino valve. Abb. 1 b) Unscrew system two holding device, by removing the five screws (1). Abb. 2 Saeco International Group REV.4 SEPT.2003 Seite 19/20...
  • Page 140 Abb. 3 d) Remove the locking spring of the steam hose and remove the steam hose (1). Place the unit on the rim of the housing and change parts as necessary. Abb. 4 Seite 20/20 REV.4 SEPT.2003 Saeco International Group...

  • Page 141: Circuit Diagrams

    CHAPTER 10 CIRCUIT DIAGRAMS Saeco International Group REV.4 SEPT.2003...

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