QUEST ELITE 4000 Service Manual Release Date: December 18, 2010 Publication Number: 620048956SER Revision Date: January 6, 2015 Revision: G Visit the Cornelius web site at www.cornelius.com for all your Literature needs.
The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment.
TABLE OF CONTENTS Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Chassis Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Check and Top-Off Water Ice Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replace Pump Tubing and Clean Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quest Elite 4000 Service Manual SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards). • Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit. Recognition Recognize Safety Alerts ! This is the safety alert symbol.
Quest Elite 4000 Service Manual • Keep your unit in proper working condition and do not allow unauthorized modifications to the unit. QUALIFIED SERVICE PERSONNEL ! WARNING: Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
Quest Elite 4000 Service Manual MOUNTING IN OR ON A COUNTER ! WARNING: When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 189 lbs. (85.7 kg.) to insure adequate support for the unit. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE. © 2010-2015, Cornelius Inc.
Quest Elite 4000 Service Manual UNIT SPECIFICATIONS Figure 1. Unit Dimensions Nameplate Data Model QST ELITE 4000, 115 VAC, 5 amps, 1 phase 60 hertz, 6.34 – 6.41 oz. (180182) R-134a refrigerant. Test press: High side 400 psi (2757.9 kilopascals), (27.6 bar). Low side 88 psi (606.7 kilopascals), (6.1 bar). Model Quest ELITE 4000, 230 VAC, 2 amps, 1 phase 50 hertz, 6.34 - 6.41 oz. (180-182g) R-134a refrigerant. Test press: High side 400 psi (2757.9 kilopascals) (27.6 bar). Low side 88 psi (606.
Quest Elite 4000 Service Manual Recommended Clearance 12” (30.48 cm) on top and 4” (10.16 cm) required in back for air circulation and 4” at the sides of the unit. Electrical Connection 6 ft. long (1.83 m) power cord with 3-prong plug attached to dispenser. Export models are shipped with a European plug. ! CAUTION: ONLY trained and certified electrical technicians should replace the power cord or the unit should be returned to an Authorized Service Center for power cord replacement.
Quest Elite 4000 Service Manual Water Connection 3/8 in. (0.95 cm) SAE male flare fitting on dispenser. Water Supply Requirements 60 psi (413.7 kilopascals) (4.1 bar) maximum static pressure. 30 psi (206.8 kilopascals) (2.1 bar) minimum dynamic pressure; i.e., flowing pressure measured at dispenser water inlet with 3 OZ (88.7 ml) per second water flow. Optimum recommended pressure 50 psi (344.7 kilopascals) (3.5 bar) dynamic pressure. Ice Bank/Pull Down Weight 14-16 lbs. (6.35-7.25 kg.). Pull Down: 3.
Quest Elite 4000 Service Manual APPLICATIONS This appliance is intended to be used in household and similar applications such as the following: • Staff kitchen areas in shops, offices and other working environments.
Quest Elite 4000 Service Manual CONCENTRATE HANDLING AND LOADING It is recommended that the concentrate be thawed in a refrigerated 35°F to 40°F (1.6°C to 4.4°C) compartment for a minimum of 48 hours prior to loading it into the Quest Juice Dispenser. ! WARNING: Concentrate must be completely thawed and within the temperature range of 35°F to 40°F (1.6°C to 4.4°C) prior to loading. Failing to supply concentrate inside the recommended temperature range, especially below 35°F (1.
Quest Elite 4000 Service Manual CHANGING CONCENTRATE CONTAINERS 1. Open the cabinet door and move the valve handle from the Dispense to Flush position, see Figure 3. Dispense/Flush Levers Figure 3. Dispense/Flush Lever Location 2. Close the door. Depress and hold the dispense button (Figure 4) until clear water flows from the dispense nozzle. Figure 4. Dispense Buttons 3. Open the cabinet door and return the handle to the Dispense position. 4. Depress and hold the dispense button for 1-2 seconds.
Quest Elite 4000 Service Manual BRIXING PROCEDURE NOTE: If concentrate is not properly thawed, it will adversely affect the amount of concentrate dispensed. Thawed product should be between 35°F/1.6°C to 40°F/4.4°C. SUPPLIES • 1 - Small 12 oz. cup (354.8 ml) • 1 - Large 21 oz. cup (621.1 ml) • 1 - Straw • Paper Towels • 1 - Thermometer • 1 - Refractometer • 1 - Flat Bladed Screwdriver NOTE: The refractometer shown is P/N 511004000, and is available through your local Cornelius Distributor.
Quest Elite 4000 Service Manual Table 1. Flavor Ratio BRIX Lemonade 5+1 10.5 Tropical Punch 5+1 11.8 Sweetened Ice Tea 7+1 6.0 Pineapple Juice 4+1 12.8 Prune Juice 2+1 16.0 5. To change the BRIX setting, simply readjust the water flow rate. Located on each of the valve assemblies inside the refrigerated compartment are the adjusting screws for the water flow rate (one per valve). If the BRIX reading is too high or low, rotate the appropriate water flow control according to Figure 6.
Quest Elite 4000 Service Manual PLANNED MAINTENANCE SCHEDULE DAILY Flush System 1. Move all of the Dispense/Flush levers (located on the platform assembly in the refrigerated cabinet) to the Flush position. Place an empty cup on the drip tray below each dispense nozzle (Figure 7). Dispense/Flush Levers Mixing Chambers Figure 7. Platform Assembly with Dispense/Flush Levers 2. Close the door and depress each dispense button for 2-3 seconds or until clear water flows from each dispense nozzle. Figure 8.
Quest Elite 4000 Service Manual Clean Splash Zones & Dispense Nozzles 1. On a daily basis, clean the external cabinet and splash areas using a clean damp cloth. Remove and wash the cup rest and drip tray using mild dish soap. 2. Remove the dispense nozzles and static mixers by rotating each 90° and pulling down. Remove the mixing chambers by pulling straight forward. Wash using mild dish soap. IMPORTANT: DO NOT wash nozzles, static mixers, or mixing chambers in a dish washer.
Quest Elite 4000 Service Manual Sanitize Pump System 1. Fill a clean concentrate container with 2 quarts (1.9L) of fresh sanitizing solution. 2. Place Dispense/Flush levers (located on the platform assembly in the refrigerated cabinet) to the Dispense position.and close the door. Dispense/Flush Levers Mixing Chambers Figure 9. Dispense/Flush Levers 3. Press and hold the dispense button for 90 seconds then release. Allow sanitizing solution to remain in the lines for 5 minutes. Figure 10.
Quest Elite 4000 Service Manual SEMI ANNUALLY ! CAUTION: The following procedures require removal of the dispenser side panel(s). Disconnect the power cord (See Figure 11.) from the receptacle prior to proceeding. Figure 11. Pull AC Plug from Wall Outlet Clean Water Inlet Strainer 1. Remove the right side panel from the dispenser. 2. Turn off the water supply to the dispenser. 3. Remove the access port from the “Y” shaped water inlet solenoid located on the right side of the dispenser. (See Figure 12) 4.
Quest Elite 4000 Service Manual Check and Top-Off Water Ice Bath 1. Remove the drip tray and lower splash panel. Lower Splash Panel Cup Rest Drip Tray Figure 13. Drip Tray and Cup Rest If the Ice bath level is below the Full indicator, top it off with water. Refer to the Filling the Ice Bath procedure in the Installation manual (P/N 620048956INS). ANNUALLY Replace Pump Tubing and Clean Cabinet A replacement pump tubing kit, part # 45098, is available.
Quest Elite 4000 Service Manual Bottle Adapter Juice Inlet Concentrate Delivery Tubes Water Inlet Quick Connector Pump Body Screws Water Manifold BRIX Adjustment Screw Pump Motor Locking Latch Water Solenoid Front & Rear Pump Halves Figure 14. Interior Details 5. Slide the locking latch forward. Lift the platform slightly and pull forward to gain access to the electrical connector (see Figure 14). 6.
Quest Elite 4000 Service Manual 1 4 2 3 Figure 15. Pump Body Screws 3. Remove ONLY the rear pump body half to reveal the pump tubing and rollers (See Figure 16). 4. Remove the old pump tubing from the pump body. If the roller assembly comes out with the tubing, place it back into the pump housing. Make sure to align the roller assembly shaft keyway to the motor shaft so that the two interlock. 5.
Quest Elite 4000 Service Manual Cleaning the Cabinet The cabinet bottom surface and walls should be inspected and cleaned annually according to the following steps: 1. Remove natural rubber nozzle bushing gasket (see Figure 17) and inspect it and silicone RTV. If cracked, clean off RTV, and re-apply using kit P/N 729011013 per instructions provided with kit. 2. Re-apply nozzle bushing gasket so that the edges lie flat on the floor of the cabinet. Figure 17.
Quest Elite 4000 Service Manual TROUBLESHOOTING GUIDE The following tables contain trouble-shooting information intended to aid an experienced service person in diagnosing operational problems that may occur. For further assistance, contact the Cornelius Customer Services department at 800283-3600 between the hours of 7:30A.M. and 5:00P.M. Central Standard Time. You must have the model and serial number (Located on the right side of the dispenser) when calling.
Quest Elite 4000 Service Manual Table 2 Symptom No water dispensed, concentrate only Probable Cause Remedy A. No water in dispenser. A. Restore water. B. Water supply line inside refrigerated cabinet disconnected from pump platform. B. Reconnect C. Water solenoid located on pump platform clogged or defective. C. Disassemble & clean solenoid. Replace if necessary. D. Main water solenoid/strainer located at D. Remove & clean strainer.
Quest Elite 4000 Service Manual Table 2 Symptom Probable Cause Remedy A. Ambient air around dispenser is too warm. A. Relocate dispenser. B. Excessive demand on dispenser. B. Add water pre-cooler or second dispenser C. Dirty condenser coil. C. Clean condenser coil. D. Inoperative condenser fan. D. Replace condenser fan motor. E. Defective Ice Bank Control. E. Test & replace if necessary. F. Loss of refrigerant charge due to leak in system. F. Repair leak and recharge system.
Quest Elite 4000 Service Manual ASSEMBLY DRAWINGS Figure 18. System Wiring Diagram Quest Elite 4 FL © 2010-2015, Cornelius Inc.
Quest Elite 4000 Service Manual Figure 19. Main Electrical Box Wiring Diagram Quest Elite 4 FL Publication Number: 620048956SER - 24 - © 2010-2014, Cornelius Inc.
Quest Elite 4000 Service Manual CORNELIUS STANDARD SERVICE CALL GUIDE The parts warranty referenced in the Certificate of Warranty in this manual applies to the replacement of the defective part. Cornelius Inc. will not accept parts warranty claims for water leaks applicable to the installation, clogged drains, adjustments of any kind including regulators, pumps, thermostats, ratio, or brix settings, stratification issues, preventative maintenance, sanitizing, etc. Cornelius Inc.
Quest Elite 4000 Service Manual Publication Number: 620048956SER - 26 - © 2010-2014, Cornelius Inc.
Cornelius Inc. www.cornelius.
