Bosch tca60f9 Repair Instruction

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Fully-automatic coffeemaker

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1 SAFETY........................................................3

1.1 Safety instructions..............................................................3

1.2 Repair instructions .............................................................3

2 INSTALLATION............................................4

2.1 Installation...........................................................................4

2.2 Scope of delivery................................................................4

3 OPERATION.................................................5

3.1 Switching on the appliance................................................5

3.2 Controls...............................................................................6

3.3 Preparation........................................................................11

3.4 Changing the standard settings ......................................12

3.5 Cleaning.............................................................................16

3.6 Descaling...........................................................................17

4 COMPONENTS...........................................21

4.1 Structure............................................................................21

4.2 Flowmeter..........................................................................22

4.3 Heater and NTC-sensor....................................................23

4.4 Control module and appliance software.........................25

4.5 Service door......................................................................26

4.6 Brewing unit......................................................................27

4.7 Gear unit............................................................................33

4.8 Ceramic valve (2-way valve).............................................37

4.9 Hot water / steam nozzle ..................................................39

4.10 Coffee outlet...................................................................... 40

4.11 Drip tray............................................................................. 42

4.12 Water filter......................................................................... 44

5 FUNCTIONS................................................45

5.1 The perfect espresso........................................................ 45

5.2 Operating principle........................................................... 45

5.3 Warming the cups............................................................. 45

5.4 Diaphragm regulator with blow-off valve ....................... 46

5.5 Reduction angle with blow-off valve (alternative).......... 46

5.6 Temperature...................................................................... 47

5.7 Overview of the symbols ................................................. 48

6 REPAIR.......................................................60

6.1 Replacing the brewing unit.............................................. 60

6.2 General disassembly........................................................ 64

6.3 Replacing the thermal fuse.............................................. 65

6.4 Removing the coffee outlet.............................................. 67

6.5 Remedial actions for “Error 8” - message...................... 70

7 FAULT DIAGNOSTICS...............................73

7.1 Malfunctions ..................................................................... 73

7.2 System and error messages............................................ 79

7.3 Incoming goods inspection............................................. 85

7.4 Service diagnosis............................................................. 86

7.5 Troubleshooting ............................................................... 92

7.6 Measuring the coffee temperature.................................. 98

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8 TECHNICAL SPECIFICATIONS ................99

8.1 Rating plate .......................................................................99

8.2 Power...............................................................................100

8.3 Temperatures ..................................................................100

8.4 Dimensions and weight..................................................101

8.5 Filling amounts ...............................................................101

8.6 Components....................................................................102

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1 SAFETY

1.1 Safety instructions

Danger!

► Repairs may be carried out by a qualified electrician only!

► The user may be put at considerable risk and injured by

improper repairs!

► Electric shock may occur if live components are touched

inside the appliance!

► Do not touch components in the appliance. Even the modules

can be live!

► Before commencing repairs, ALWAYS disconnect the

appliance from the power supply!

► If tests have to be conducted while the appliance is live,

ALWAYS use a residual-current-operated circuit-breaker!

► The protective conductor connection must not exceed the

standardised values! This is essential for personal safety and

appliance function!

► When repairs are complete, perform a test in accordance with

VDE 0701 or the corresponding national regulations!

► Following each repair, conduct a leak and performance test.

1.2 Repair instructions

Caution!

► NEVER attempt repairs by randomly replacing components!

► ALWAYS proceed systematically and comply with the

technical documentation for the appliance!

► Components become hot during operation. Before

commencing repairs, leave the appliance to cool down.

► As a rule, printed-circuit boards are not repaired but are

completely replaced with original spare parts. Exceptions are

documented separately.

Risk of scalding!

Hot water / steam nozzle or auto-cappuccinatore frothing-up

nozzle (optional) become very hot. Take hold of the nozzles

by the plastic parts only, not by the metal parts. Keep body

parts away from the nozzles and do not aim it to yourself or

anyone else.

When steam or hot water is released, the nozzles may initially

sputter!

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2 INSTALLATION

2.1 Installation

► The installation location must be level and dry.

► Protect the appliance from splash water.

► There must be a minimum filling height of 420 mm.

► Connect and operate the appliance only in accordance with

the specifications on the rating plate.

► Operate the appliance indoors and at room temperature only.

► Do not place the appliance on a hot surface (e.g. heating

plate) and never use it close to an open flame.

2.2 Scope of delivery

All appliances are supplied with the “Welcome pack” starter kit.

2.2.1 Welcome pack

The “Welcome pack” starter kit contains the parts required to start up

the appliance:

► 2 Detergent-tablets

► Test strip for determining the local water hardness

► 2 Descaler-tablets (for 1 descaling process)

► Scoop and screw-in aid for water filter (depending on model)

► Operating instructions in different languages as well as a

quick reference guide

Information on cleaning the appropriate milk-frothing aids (steam

nozzle or auto-cappuccinatore) is also enclosed.

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3 OPERATION

3.1 Switching on the appliance

WARNING

Risk of damage!

Do not use coffee beans which have been glazed,

caramelised or treated with other additives containing

sugar. These will damage the grinding unit!

Note:

When the appliance is used for the first time or if the

appliance has not been used for a prolonged period, the

first cup of coffee still does not have the full aroma and

should therefore not be drunk.

► Pull the mains plug out of the cord store at the rear

of the appliance and connect according to the

specifications on the rating plate.

► Remove the water tank and fill with fresh, cold

water. Observe the “max” mark. Re-attach the

water tank.

► Fill the bean container with fresh coffee beans.

Preferably use espresso beans or bean mixtures

for fully automatic machines.

► Set mains switch at the back of the appliance to I.

► Set function selector to coffee brewing process.

► Press Standby button.

The appliance conducts a self-

test, heats up and rinses.

► Heating up to standby

temperature

► Moving the brewing unit to the

upper end position

Pump starts, 50 ml of water are

conveyed through the coffee

outlet.

The system is rinsed and heated up.

► Brewing unit returns to basic position

The appliance is ready to use when the illuminated rings around the

standby button and the coffee dispensing button are lit green and a

coffee symbol is displayed.

3.1.1 Filling the pipe-system

If the appliance is completely drained and steamed out, the water

line system must be filled when the appliance is switched on for the

first time:

Rinse symbol lights up.

► Press the coffee

dispensing buton

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3.2 Controls

3.2.1 Mains switch

The mains switch on the rear of

the appliance switches the power

supply on or off.

When the mains switch is switched

on, the illuminated ring on the

standby button lights up green.

The appliance is in stand-by mode.

If the appliance is isolated from the

mains with the mains switch, the

next time the appliance is switched

on, a self-test is run and the

brewing module is re-initialised.

Warning:

Do not actuate the mains switch during the brewing

process. When the appliance is switched on again,

malfunctions and damage may occur.

Do not switch off the appliance with the mains switch

until the appliance has been switched to stand-by

mode with the standby button.

3.2.2 Standby button

The Stand-by button switches on and starts the

appliance or switches it from brewing mode to stand-by.

When the standby button has been pressed, the

appliance heats up and is then rinsed. The illuminated

ring around the button flashes during this process.

During the coffee brewing process the standby button is

assigned a Stop function. Press this button to end the

current brewing process at any time.

3.2.2.1 Switching on a cold appliance:

When the standby button has been pressed, the

appliance heats up and is then rinsed. The illuminated

ring around this button flashes. Coffee cannot be

brewed until the illuminated ring stops flashing.

3.2.2.2 Switching on a warm appliance:

The illuminated ring around the standby button is lit

constantly. Coffee can be brewed.

3.2.2.3 The appliance is not rinsed if:

► it was still warm when switched on

or

► there was no coffee from the last brew before

the appliance was switched off.

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3.2.3 Function selector

DANGER

Risk of scalding!

When steam or hot water is released, the nozzles

may initially sputter!

Rotate the function selector to

draw coffee, hot water or steam:

1. Drawing hot water –

via hot water/ steam pipe.

2. Drawing coffee –

via brewing unit to the coffee

outlet.

3. Drawing steam –

via hot water/ steam pipe.

Steam can be drawn after the

appliance has heated up to steam

temperature.

After steam has been drawn,

coffee can be brewed again

immediately.

3.2.4 Coffee dispensing button

► Press the coffee dispensing button to start the

coffee brewing process.

During the brewing process the green illuminated ring

flashes.

► If the coffee dispensing button is pressed again,

the coffee brewing process ends early.

(The grinding process is ended, the brewing process is

stopped, and the brewing unit is emptied.)

Ready to use mode is indicated by the illuminated ring

which is lit constantly.

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3.2.5 Filling quantity selector

This rotary knob is used to select the amount of liquid which is

required.

Single cups Double cups

Small espresso approx. 25ml 2 small espresso approx. 50ml

Espresso approx. 40ml 2 espresso approx. 80ml

Small coffee approx. 80ml 2 small coffees approx. 160ml

Coffee approx. 125ml 2 coffees approx. 250ml

Large coffee approx. 160ml 2 large coffees approx. 300ml

XXL coffee approx. 220ml 2 XXL coffees approx. 360ml

Note:

The permitted filling quantity tolerance is +/– 5 ml.

The filling quantities for 2 large coffees and 2 XXL

coffees are not the same as the double filling quantity fo

r

corresponding single cups. Therefore aromatic coffee can

still be brewed even when there is the maximum amount

of liquid selected.

3.2.6 Coffee strength selector

The amount of coffee to be ground can be changed by rotating the

coffee strength selector.

This setting affects the aroma and flavour, the caffeine and acid

content as well as the formation of the crema.

Amount of coffee powder can be selected between “very mild” 7 g and

“extra strong” 14 g.

very mild approx. 7 g

mild approx. 8 g

normal approx. 9 g

normal plus approx. 10 g

strong approx. 12 g

extra strong approx. 14 g

The amount of ground coffee powder is monitored in the brewing unit

and corrected by compensation of the grinding unit running time.

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3.2.7 Cleaning button

When the red illuminated ring lights up around the

cleaning button clean, the appliance must be cleaned.

Coffee can still be brewed.

To start the cleaning cycle, press the clean button for

approx. 3 sec.

► Use cleaning tablets Mat.-no. 31 0575!

3.2.8 Descaling button

When the red illuminated ring lights up around the

descaling button calc, the appliance must be descaled.

Coffee can still be brewed.

To start the descaling cycle, press the calc button for

approx. 3 sec.

► Use liquid descaling agent Mat.-no. 31 0451!

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3.2.9 Adjusting the grinding unit

Dependent on the roasting degree and on the oil rate of the used

coffee beans the grinder setting must be changed

► Bright roasting, low oil rate - adjust finer

► Dark roasting, high oil rate - adjust more coarsely

The correct grinding unit adjustment is crucial for the coffee taste, the

strength and the flavour of the coffee.

Note:

A

very fine grinding unit setting in combination with a

very high amount of ground coffee can cause

malfunctions especially by using dark roasted coffee

beans with high oil rate.

Risk of damage:

Adjust the grinding unit only while the grinding

unit is running! Otherwise the appliance may be

damaged.

► Open right cover of the

appliance.

► Press the coffee dispensing

button to start a brewing

cycle.

► While the grinding unit is

running, turn the knob to

select the degree of grinding:

The smaller the dots the finer the

ground coffee.

The new setting will not become apparent until the second or third cup

of coffee.

3.2.9.1 Service-Sticker

To make sure that the grinding unit will be adjusted correctly a sticker

is added on the right cover of the appliance.

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3.3 Preparation

General: Prewarm cups on the cup shelf or fill with hot water and

rinse out.

3.3.1 Using coffee beans

This coffee machine grinds fresh coffee beans for each brewing

process.

► Turn function selector to coffee position.

► Select the desired amount of coffee and numbers of cups with

the rotary knob.

► Select the preferred coffee strength with rotary knob.

► Place a cup under the outlet. If required adjust the height of

the outlet.

► Press the coffee dispensing button. The brewing cycle runs

automatically.

Note:

If ADD BEANS is displayed despite a full beans

container, the grinding unit might be empty and must still

be filled up with ground coffee.

Therefore press the coffee dispensing button again to

make sure that there is enough ground coffee filled in

the brewing unit.

3.3.2 Using preground coffee

WARNING

Risk of damage!

Do not add whole coffee beans or instant coffee!

Add a maximum two scoops of pre-ground coffee.

A second type of coffee can be used. Pre-ground coffee can be filled

into the brewing unit via the coffee duct.

► Open the right cover of the

appliance.

► Open ground coffee duct flap

(A).

► Add one or two level scoops of

medium-fine ground coffee to

the ground coffee duct.

► Close the ground coffee duct

flap and the right cover of the

appliance.

► Press the coffee dispensing

button.

If coffee is not brewed within 90 seconds, the brewing chamber is

emptied automatically in order to prevent overfilling. The appliance is

rinsed.

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3.4 Changing the standard settings

The appliance has been set at the factory so that coffee can be

brewed without any additional programming.

The following settings can be changed:

► Water hardness

► Water filter

3.4.1 Setting the water hardness

It is important for the descaling programme that the

water hardness is set correctly. If external wate

r

softeners are used in the domestic water system or i

f

filtered water is used, select water hardness 1

Water hardness 4 is preset

► Determine the water hardness with the enclosed test strip or ask

your local water supplier.

Test strip for determining the water hardness, mat. no.: 05 6317

Hardness 1

Descale alarm after 220 litres

Hardness 2

Descale alarm after 100 litres

Hardness 3

Descale alarm after 70 litres

Hardness 4

Descale alarm after 40 litres

3.4.1.1 Degrees of water hardness

Setting German French

1 1 – 7 1 - 13

2 8 – 15 14 - 27

3 16 – 23 28 – 42

4 24 – 30 43 - 54

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3.4.1.2 Change setting

The appliance must be in stand-by mode. Only the illuminated ring

around the stand-by button is lit.

► Simultaneously press and hold down the calc and clean buttons

for at least 3 sec.

The display changes to:

The number of the illuminated

rings around the control buttons

symbolise the selected water

hardness.

Hardness 1 Hardness 2 Hardness 3 Hardness 4

► Press calc descaling button until the illuminated rings for the

desired water hardness light up.

If the illuminated ring around the cafe button flashes, the filter can be

set.

► Press cafe button once.

The selected water hardness is saved.

Note:

The appliance now switches on automatically.

As soon as the illuminated rings around the stand-by

and cafe buttons as well as the coffee cup sign in the

display are lit, the appliance is ready for use again.

If you do not press the calc descaling button for 90 seconds, the

appliance returns to coffee dispensing mode without saving any

settings.

The previously set water hardness is retained.

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3.4.2 Water filter

A water filter available as an accessory (mat. no.: 46 1732) can be

inserted in the water tank.

When approx. 50 l of water have run through (corresponds to approx.

400 brews) or after 2 months at the latest, the effect of the filter is

depleted. The filter must then be replaced. (Risk of bacteria!)

Insert filter into the water tank, then change the appliance settings

according to instructions enclosed with the filter.

Note:

► Do not insert the filter if the red illuminated ring

around the calc button on the appliance is lit.

The appliance must be descaled first.

► Before descaling the appliance, take the

inserted water filter out of the water tank.

► If softened water from a domestic softening

system is used, a water filter is not required.

► If the change filter system message is

displayed, immediately replace or remove used

water filters. If no new water filter is inserted,

adjust the water hardness.

To activate the filter and ensure correct function, the

inserted filter must be rinsed. Observe the following

points.

3.4.2.1 Inserting the water filter

► The appliance must be in

stand-by mode.

► Place a vessel with a

capacity of at least 500 ml

under the hot water nozzle.

► Insert the water filter

according to instructions

enclosed with the filter.

► Simultaneously hold down the calc and clean buttons for at

least 3 sec.

The display changes to:

► Keep pressing the calc button until the filter symbol lights up.

► Acknowledge by pressing the cafe button.

► Rotate function selector to draw hot water.

The appliance rinses the filter automatically. Water is conveyed into

the collecting vessel (approx. 2 minutes). The water may be a little

cloudy, do not drink it!

► If the turn on coffee system message is displayed, turn

function selector back to brew coffee.

The appliance is ready for use again.

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3.4.2.2 Changing the water filter

► Switch the appliance to

stand-by mode.

► Place a vessel with a

capacity of at least 500 ml

under the hot water nozzle.

► Using the screwing aid,

unscrew the water filter in

an anti-clockwise direction.

► Screw in a new water filter.

► Simultaneously hold down the calc and clean buttons for at

least 3 sec.

► Acknowledge by pressing the cafe button.

► Rotate function selector to draw hot water.

The appliance rinses the filter automatically. Water is conveyed into

the collecting vessel (approx. 2 minutes). The water may be a little

cloudy, do not drink it!

► If the turn on coffee system message is displayed, turn

function selector back to brew coffee.

The appliance is ready for use again.

3.4.2.3 Removing the water filter

► Switch the appliance to stand-by mode.

► Using the screwing aid, unscrew the water filter in an anti-

clockwise direction.

► Simultaneously hold down the calc and clean buttons for at least 3

sec.

► Press calc descaling button until the illuminated rings for the

desired water hardness light up. (The number of the illuminated

rings around the control buttons symbolise the selected water

hardness).

► Acknowledge by pressing the cafe button.

The appliance is ready for use again.

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3.5 Cleaning

DANGER

Risk of electric shock

► Before cleaning the appliance, pull out the mains

plug!

► Never immerse the appliance in water!

► Do not use a steam cleaner!

WARNING

Risk of damage!

► Do not use any scouring agents!

3.5.1 Daily cleaning of the appliance

► Wipe the outside of the appliance with a damp cloth.

► Remove water tank, rinse out and fill with fresh water.

► Pull drip tray forwards and remove. Empty drip tray (1) and

dregs drawer (2) and clean with mild detergent solution.

Only degs drawer (2) can be cleaned in the dishwasher!

► Thoroughly clean drawer contacts (3) on all sides and dry.

Note!

Coffee or water residue between the drawer contacts

may result in error messages.

► Extract or wipe out the appliance interior.

If the appliance is cold when switched on, the appliance is rinsed

automatically.

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3.6 Descaling

The lime content in drinking water causes calcification of the thermal

block, the hose system and the valves in the appliance. This affects

the flavour of the coffee and reduces the service life of the appliance.

To ensure optimum quality, descale the appliance regularly.

If the illuminated ring around the calc descaling button

lights up red when the appliance is switched on and

the request to descale the appliance is indicated on the

display, the appliance must be descaled immediately.

Descale the appliance according to the following instructions,

otherwise the appliance may be damaged.

WARNING

► Never descale the appliance with vinegar or

vinegar-based substances.

► Do not interrupt the descaling programme.

► Never drink the liquid.

3.6.1 Descaling alarm

The correct setting of the water hardness is important for the

descaling indicator.

Test strip for determining the water hardness, mat. no.: 05 6317

Hardness 1 220 litres

Hardness 2 100 litres

Hardness 3 70 litres

Hardness 4 40 litres

If water hardness 1 is set, the request to descale the appliance is

indicated after 220 l of water. (1° – 7° dH)

If water hardness 2 is set, the request to descale the appliance is

indicated after 100 l of water. (8° – 15° dH)

If water hardness 3 is set, the request to descale the appliance is

indicated after 70 l of water. (16° – 23° dH)

If water hardness 4 is set, the request to descale the appliance is

indicated after 40 l of water. (24° – 30° dH)

3.6.1.1 Degrees of water hardness

Setting German French

1 1–7 1–13

2 8–15 14–27

3 16–23 28–42

4 24–30 43–54

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3.6.2 Descaling programme

Warning!

Never descale with water filter inserted!

The descaling programme starts only if the FILTER

programming is not active.

Take the filter out of the water tank

and set the water hardness.

The descaling programme lasts

approx. 35 minutes. While the des-

caling programme is running, pro-

cesses and handling modes are

displayed.

3.6.2.1 Starting the descaling programme

1.

► To start the descaling

programme, hold down the

calc button for at least 3

seconds.

► Pull drip tray out of the

appliance. Empty and re-

insert drip tray and dregs

drawer.

2.

This display is indicated irrespective

of the actual filling of the trays and

ensures that the descaling cycle is

not interrupted.

3.

► Fill water tank up to the

mark (0.5 l) with warm

water and add descaling

agent

or

► Fill water tank with 0.5 l of

ready mixed descaling

solution.

If using descaling tablets, add two tablets. Observe the

dissolving time of the tablets (approx. 4–6 minutes)!

4.

► Place an appropriately large

collecting vessel under the

steam nozzle.

► Rotate function selector to

draw hot water.

5.

The illuminated ring around the calc

descaling button flashes.

The appliance is descaled

automatically. Descaling solution

(approx. 250 ml) is conveyed in

intervals into the collecting vessel.

► Wait for the next display.

(approx. 10 minutes)

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3.6.2.2 Descaling programme

6.

► Rotate function selector to

coffee brewing process.

The appliance is descaled

automatically. Descaling solution

(approx. 250 ml) is conveyed in

intervals into the drip tray via the

drainage valve.

7.

In doing so, the water tank is

completely drained.

► Wait for the next display

(approx. 10 minutes)

8.

► Pull drip tray out of the

appliance, empty and re-

insert.

9.

► Remove water tank, rinse

out, fill with fresh water and

re-insert.

► Empty collecting vessel and

place back under the steam

nozzle.

10.

► Rotate function selector to

draw hot water.

The appliance is rinsed auto-

matically. Water (approx. 150 ml) is

conveyed in intervals into the

collecting vessel.

11.

Wait for the next display. (approx.

4 minutes)

► Rotate function selector to

coffee brewing process.

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3.6.2.3 Descaling programme

12.

The appliance is rinsed auto-

matically. Water (approx. 300 ml) is

conveyed in intervals into the drip

tray via the drainage valve.

► Wait for the next display.

(approx. 4 minutes)

13.

► Pull drip tray out of the

appliance and empty.

► Carefully clean contacts of

the drip tray on all sides

and dry.

Ensure that there is no ground

coffee residue or water droplets

between the tray contacts.

► Re-insert drip tray and

dregs drawer.

14.

The appliance is rinsed auto-

matically.

The descaling process is complete.

The illuminated ring around the

calc descaling button goes out.

The appliance is ready for use

again.

If the descaling process is termi-

nated prematurely, the descaling

alarm is not cancelled.

3.6.2.4 The descaling programme does not start:

The descaling programme starts only

if the FILTER programming is not

active.

► Take the filter out of the water

tank and set the water

hardness.

WARNING!

Never descale the appliance with the filter inserted!

The descaling programme does not

start if the temperature of the heater is

too high.

Symbol flashes 5 x.

► Cool down the system by

drawing off approx. 1 cup of

hot water.

When the required temperature has

been reached, the descaling process

can be started.

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Bosch tca60f9 Repair Instruction

Bosch tca60f9 Repair Instruction

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