GAGGIA rera Service Manual

SERVICE
MANUAL

Revision 00

All parts of this document are the property of Saeco International Group.

All rights reserved. This document and all the information herein is provided without liability deriving
from any errors or omissions. Furthermore, no part may be reproduced, used or collected, except where
express authorisation has been provided in writing or through a contractual agreement.

Rev. 00 / OCTOBER 2009

Page

Table of contents

1. Introduction

1.1 Documentation required 1

1.2 Tools and equipment required 1

1.3 Material 1

1.4 Safety warnings 1

1.5 Brera range 2

1.6.1 External machine parts 3

1.6.2 Internal machine parts 4

2. Technical specications

2.1 Technical specications 1

2.2 Machine parameters and performance 1

3. Brief instructions

3.1 Customer and programming menu 1

3.2 Operation, cleaning and maintenance 3

4. Operating logic

4.1. Water circuit 1

4.2 Control ringnut and valve 2

4.3 Coffee cycle operating diagram 3

4.4 Single microswitch 4

4.5 Temperature sensor 4

4.6 Coffee grinder operation 5

4.7 Detection of low bean level, dose adjustment, 5
coffee grinder blockage

4.8 Dose self-learning 6

Rev. 00 OCTOBER 2009

Table of contents

Page

5. Service mode

5.1. Test mode 1

6. Servicing & Maintenance

6.1 Repair schedule 1

6.2 Service schedule 1

6.3 Final test 2

7. Disassembly

7.1 Outer elements disassembly 1

7.2 Dispensing spout disassembly 1

7.3 Keypad card and valve card disassembly 2

7.4 Power/CPU card disassembly 3

7.5 Gearmotor disassembly 3

7.6 Boiler disassembly 4

7.7 Valve disassembly 4

7.8 Pump and turbine disassembly 5

7.9 OETIKER clamps assembly and disassembly 6

7.10 Coffee grinder disassembly 7

7.11 Grinder adjustment / assembly and disassembly 8

Rev. 00 OCTOBER 2009

8. Notes

9. Water circuit diagram

9.1. Water circuit diagram

10. Electrical diagram

10.1

Wiring diagram

GAGGIA

1.1 Documentation required

The following documentation is needed for repair procedures:

• Instruction booklet for specic model

• Technical documentation for specic model (diagrams, exploded drawings)

1.2 Tools and equipment required

As well as the standard equipment, the following is required:

Qty. Description Notes

1 Screwdriver Torx T 10
1 Pliers for Oetiker clamps
1 CC -A - Vdc tester

01 INTRODUCTION

1 Digital thermometer Scale limit > 150°C
1 SSC (Saeco Service Center) Programmer

1.3 Material

Description Notes

Thermal paste Heating element > 200°C
Descaler Saeco Entkalker
Grease solvent Personal preference
Silicone grease Safe to use with food

1.4 Safety warnings

We recommend you consult the technical manual of the machine before performing any mainte­nance work.
Observe all applicable standards relating to the repair of electrical appliances.

Always disconnect the power plug from the mains before beginning repair work.

Simply turning off the main machine power switch is not an adequate safety precaution.

This domestic appliance is rated as insulation class I.
On completion of the repair work, insulation and dielectric rigidity tests must be performed.

Rev. 00 OCTOBER 2009 Page / 04

01

GAGGIA

1.5. Brera range

01 INTRODUCTION

Led interface X

Painted details X

Water/steam valve X

Alarm LED X

Automatic rinse X

Automatic dosage X

Pannarello (frother) X

Dispensed coffee memory capacity X
Automatic shutdown

X

(after 60' inactivity)

Rev. 00 OCTOBER 2009 Page / 04

02

GAGGIA

1.6.1 External machine parts

Grinder adjustment knob

Cup stacking surface

Control panel

Dispensing spout

01 INTRODUCTION

compartment

Cup holder grill

Full drip tray indicator

Wand protective gripper

Hot water/steam wand

Drip tray

ON-OFF power button

Brew group

Service door

Water tank

LED display

Power cord

STAND-BY Button

selector switch

Hot water/steam selector switch

Rev. 00 OCTOBER 2009 Page / 04

03

GAGGIA

1.6.2 Internal machine parts

Side door
microswitch

01 INTRODUCTION

Coffee grinder

Coffee grinder
motor

Card ­PWR/CPU

boiler

Pump

Temperature sensor

Turbine

Rev. 00 OCTOBER 2009 Page / 04

04

TECHNICAL SPECIFICATIONS

CHAPTER 2

Rev. 00 OCTOBER 2009

GAGGIA

2.1. Technical specications

Power supply and output: 240 V~ 50 Hz 1400 W - 230 V~ 50/60 Hz 1400 W -

120 V~ 60 Hz 1500 W - 100 V~ 50/60 Hz 1300 W

Temperature monitoring: Variable heating element sensor (NTC) - transmits the value

to the electronic card

Safety system: 2 manual reset or one-shot thermostats (175°C)

02 TECHNICAL SPECIFICATIONS

Coffee heat exchanger output:
Stainless steel

Gearmotor: 33VC with 2 rotation directions; power supply 24VC

Pump: Ulka with reciprocating piston and 120°C cutout 48 W, 230V,

Overpressure valve: Opens at approx. 16-18 bar
Water lter: In tank
Coffee grinder: Direct current motor with at ceramic grinder blades
Hot water/steam valve Presblock
Automatic dosage Dose adjustment controlled by the electronic system
Power consumption: During the heating phase - approx. 5,6 A
Dimensions: W x H x D in mm: 256x315x410
Weight: 9 kg
Water tank capacity: 1l.
Coffee bean hopper capacity 200 gr. coffee beans
Dreg drawer capacity 8
Heat exchanger capacity: Approx. 10 cc
Water circuit lling time: Approx. 15 seconds for rst lling cycle
Heating time: Approx. 45 seconds
Dispensing temperature: Approx. 84°± 4°
Grinding time: Approx. 8-10 seconds

(230/120 V~) 1300 W - (100 V~) 1100W
for coffee, hot water and steam dispensing

50 Hz, Type EP5 approx. 13-15 bar 120V, 60Hz 100V, 50/60 Hz

2.2. Machine parameters and performance

AMOUNT

OF PRODUCT

Espresso 70 165 600 Yes No

Medium coffee

Long coffee 70 440 600 Yes No

Pre-ground Yes

Hot water Continues until the water supply has been exhausted (capacitive sensor)

Steam pannarello

(frother)

Rev. 00 OCTOBER 2009 Page / 04

Minimum

amount

(Puls.)

No No No No No

Continues until the water supply has been exhausted (capacitive sensor)

Default

amount

(Puls.)

Maximum

amount

(Puls.)

Programm.
by the user

Programm. by

Production/Service

department

01

GAGGIA

02 TECHNICAL SPECIFICATIONS

RINSE Initial rinse Final rinse

When performed When the machine is

switched on and the boiler

temperature is ≤ 50°C

No. of pulses 180 80

Stopping option Yes, by pressing any key Yes, by pressing any key

User disable option No No

Disabling by

Production/Service department

No. of pulses user adjustment

option

No. of pulses adjustable by

Production/Service department

Pulse range

(Min. - Max.)

WATER HARDNESS CANNOT BE SET

No No

No No

No No

No No

When the machine is switched

off electronically, manually or

automatically after 60’, after having

dispensed at least one coffee,

before switching off

DREG DRAWER Description and values

Time-out for dreg drawer 5 sec.

Empty dreg drawer alarm after

(double coffee is the last product dispensed)

Warning to empty dreg drawer after No

Reset dreg counter Every time the dreg drawer is removed for at

least 5 seconds, even if the "empty dregs" alarm

POWER/OFF Description and values

Inlet time (min. - max.) 60 minutes

Inlet time (default) No

Inlet time prog. by the user No

Inlet time prog. by Production / Service departments No

WATER TANK Description

Level sensor Yes

8 lots of dregs

(9 lots of dregs)

has not been activated

Water reserve (pulses) with water lter 200

Water reserve (pulses) with no water lter 200

Water reserve modiable by Production/Service departments No

"Fill tank" alarm Yes

"No tray" alarm No

Water mains No

Rev. 00 OCTOBER 2009 Page / 04

02

CHAPTER 3

BRIEF INSTRUCTIONS

Rev. 00 OCTOBER 2009

GAGGIA

03 BRIEF INSTRUCTIONS

3.1. Customer and programming menu

Indications Causes Solutions

Machine at correct temperature

Steady on

- for coffee bean dispensing

- for hot water dispensing

Proceed with the dispensing process

Steady on

Steady on

Steady on

Steady on

Steady on

Machine at correct temperature

- for ground coffee dispensing
(pre-ground)

Machine dispensing steam

Machine dispensing
hot water

Machine dispensing
a coffee

Machine dispensing
two coffees

Proceed with the dispensing process

Proceed with steam dispensing

Proceed with hot water dispensing

Wait for the dispensing process to end
(dispensing stops when you press the
key again)

Wait for the dispensing process to end
(dispensing stops when you press the
key again)

The machine is being programmed with
the coffee cup ll level

Blinking

Stop dispensing as desired

Machine in pre-heating phase for coffee,
hot water and steam dispensing Wait until heated

Blinking

Rev. 00 OCTOBER 2009 Page / 03

(see bar)

01

GAGGIA

03 BRIEF INSTRUCTIONS

Indications Causes Solutions

Machine in rinsing phase

Cyclic blinking

- wait for the machine to complete
the procedure

Wait until end of procedure

Steady on

Steady on

Steady on

Blinking

Blinking

The appliance requires a
descaling cycle

Perform the descaling cycle

To enter the descaling cycle press the
aroma/pre-ground coffee key for 5
sec.

No coffee beans inside hopper After lling the coffee bean hopper, start the

cycle again

No water Fill the water tank

Service door open: Close it
If the service door is opened while product is being dispensed, the appliance stops
dispensing and starts a 30 sec. countdown before cancelling the dispensing process.
The countdown can be stopped by closing the service door and operation will resume
from its stopping point.

Turn the hot water/steam valve knob to the correct position.
If the knob is turned (open) while product is being dispensed, the appliance stops
dispensing and starts a 30 sec. countdown before cancelling the dispensing process.
The countdown can be stopped by closing the knob and operation will resume from
its stopping point.

Blinking

Steady on

Steady on

Blinking

No brew group
If the brew group is removed while product is being dispensed, the appliance stops
dispensing and starts a 30 sec. countdown before cancelling the dispensing process.
The countdown can be stopped by re-inserting the brew group and closing the
service door; operation will resume from its stopping point.

Rell circuit Turn the knob to the cup

Empty the dreg drawer

Insert dreg drawer

To reset the dreg counter, wait for the
icon to ash (5 sec.)

When the dreg counter is reset, the icon
ashes

Rev. 00 OCTOBER 2009 Page / 03

02

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3.2. Operation, cleaning and maintenance

Operating the machine

1 Fill water tank
2 Fill the coffee bean hop-

per
3 Switch on the appliance
4 Fill the circuit Place a container under the steam wand and turn the selector

03 BRIEF INSTRUCTIONS

to the ”

and wait for the appliance to return to coffee ready status.

5 Press the coffee key Press once for one coffee; twice for two coffees

CLEANING AND TECHNICAL SERVICING

A Empty the dreg drawer When indicated or every three (3) months which-

B Empty the drip tray As necessary
C Clean the water tank Weekly
D Clean the coffee bean hopper As necessary
E Clean the casing As necessary

Clean the brew group
F

H Descaling When indicated or every three (3) months, which-

Lubricate the brew group Once a month or every 500 dispensing procedures

Clean the group housing Weekly

“ symbol

ever occurs rst

Every time the coffee bean hopper is lled or weekly

ever occurs rst

Descaling cycle frequency

Hard-

ness

1 Soft water (up to 7°dH) Approx. every 3 months /

2 Medium water (7° - 14°dH) Approx. every 2 months /

3 Hard water (15° - 21°dH) Approx. every 6 weeks or

4 Very hard water

(over 21°dH)

Rev. 00 OCTOBER 2009 Page / 03

Water hardness Without water lter With water lter

Approx. every 6 months /

120 litres

90 litres

60 litres
Approx. every 4 weeks or

30 litres

240 litres
Approx. every 4 months /

180 litres
Approx. every 3 months /

120 litres
Approx. every 6 weeks or

60 litres

03

CHAPTER 4

OPERATING
LOGIC

Rev. 00 OCTOBER 2009

GAGGIA

4.1. Water circuit

04 OPERATING LOGIC

HOT WATER/STEAM

BOILER

RINGNUT

OPERATION

SPOUT

DISPENSING

VALVE

COMPENSATION

VALVE

WATER TANK

TURBINE

PUMP

• Traditional water system

• Turbine - Amount of coffee dispensed into the cup

• Reciprocating piston type pump (13 - 15 bar)

• Compensation valve (opening pressure 16 - 18 bar)

• Boiler - 1400 W

• Presblok valve - select coffee - hot water - steam

Rev. 00 OCTOBER 2009 Page / 06

01

GAGGIA

4.2. Control ringnut and valve

5

4

3

2

1

When dispensing coffee the mushroom valve opens at 4 bar +/- 0.5

No. DESCRIPTION

1 Mushroom valve cap
2 Spring for mushroom valve
3 Mushroom valve support
4 Mushroom valve
5 Sealing OR

04 OPERATING LOGIC

Manual opening when dispensing water

Manual opening when dispensing steam

TOTAL STROKE

COFFEE CLOSED

-30° + 30°

Valve opening
stroke

STEAM

OPEN

Extra stroke Extra stroke

Rev. 00 OCTOBER 2009 Page / 06

Valve closing
stroke

WATER

OPEN

02

GAGGIA

4.3. Coffee cycle operating diagram

04 OPERATING LOGIC

Main

START STOP

switch ON
Time

Coffee grinder

Heating

Pump

approx.
45 sec.

Pulses
(Dosage)

Pump activity

(turbine pulses)

depending on the

product quantity

selected

*

Gearmotor
Brew group

Status Heating Ready Coffee cycle

Notes: * Only with Prebrewing

MS status

OFF

Single microswitch gearmotor

ON

Switching on

When the machine is switched on, the gearmotor repositions itself as follows:

- It acts on microswitch 1 (see following section)

- The gearmotor changes its rotation direction and moves upwards again by approx. 1-2 mm

- The boiler begins to heat water for approx. 45 seconds. It absorbs all the available heating
power in order to reach the optimal temperature. The temperature will then remain at a con­stant level.

Coffee cycle

1. The coffee grinder starts the grinding process (controlled by pulses generated by a sensor)

2. The gearmotor (brew group) moves to the dispensing position

3. Preliminary dispensing phase (short pump activity, short pause)

4. Product dispensing (the pump operation period is dened by the amount of product dispensed)

5. The gearmotor moves to its home position (the dregs are expelled automatically).

Rev. 00 OCTOBER 2009 Page / 06

03

GAGGIA

4.4. Single microswitch

2

04 OPERATING LOGIC

The gearmotor is powered by a direct
current motor that engages with the smaller
double toothed wheel using a worm screw.
The brewing unit is mounted on the axle of
the large gear wheel and when a coffee is
requested, it moves from the standby position
to the dispensing position, and then back to
the standby position again.

- Standby position: 1

- Dispensing position: 2

1

4.5. Temperature sensor (adjustment)

Temperature sensor

An NTC is used as a temperature sensor; in the event of overheating this reduces boiler ele­ment power consumption.
The electronic system detects the current boiler temperature from the drop in voltage of the
sensor and adjusts it accordingly.

Heating element values: see table

Temp. (°C) R nom (kΩ) ΔR (+/- %)

20 61,465 8,6
50 17,599 5,9
75 7,214 4,1
80 6,121 3,7
85 5,213 3,4

90 4,459 3,1
100 3,3 2,5
125 1,653 3,9
150 0,893 5,1

Rev. 00 OCTOBER 2009 Page / 06

04

GAGGIA

4.6. Coffee grinder operation

6

04 OPERATING LOGIC

5

4

1

2

3

Ceramic coffee grinder

The coffee grinder is driven by a direct current motor (1) using a worm screw helicoidal wheel
transmission (2).
The worm screw (2) drives a plastic gear wheel (3), which turns the lower grinder (4) and the
increment pin (5).
There are two magnets (6) in the gear wheel; at every rotation these induce two pulses to a Hall
sensor, which in turn transmits them to the electronic system.

4.7. Low bean level detection, dose quantity adjustment,
coffee grinder blocked

V

t1

t2

Without beans n=100%

With beans n=100%

No coffee

A low coffee bean level is detected by the Hall sensor, after

variations in the pulse frequency (with or without coffee).
If there are no coffee beans (operation while empty),
the number of rotations - and therefore the number of
pulses - will be greater

t1 = no coffee indication

If, however, there are coffee beans, the number of rota­tions will be lower due to the force created by the grinding

t2 = no indication

t3

Rev. 00 OCTOBER 2009 Page / 06

Without beans n=50%

t4

With beans n=50%

t3 and t4 = this measurement is taken at the end of

each grinding cycle

Dose quantity adjustment

The dose quantity is adjusted in accordance with the
pulses detected (number of rotations proportional to the
weak/medium/strong aroma setting)

Coffee grinder blockage

If the coffee grinder becomes blocked for any reason,
pulses will no longer be transmitted to the electronic
system and the grinder will come to a stop

t

05

GAGGIA

4.8 Dose self-learning

With an algorithm based on three pieces of information (listed below) detected by the machine
computer, the average dose is adjusted automatically (SELF-LEARNING).

1. Number of coffee grinder pulses taking place during the grinding cycle

2. Max. average value of the power consumed by the gearmotor during the cycle for coffee

brewing

3. Aroma selected by the user

The algorithm compares the maximum average value of the power consumed by the unit with the
value listed in the table for the selected aroma, in order to calculate the new grinding pulse value
for the next coffee produced.

If the value of the current absorbed by the gearmotor is lower than the value of the minimum cur­rent, the grinding pulses will be increased by 2.

04 OPERATING LOGIC

If the value of the power consumed by the gearmotor is greater than the value of the maximum
current, the grinding pulses will be decreased by 4.
If the "pre-ground" aroma is selected by the user, no modication will be made.

Min. current (mA) Max. current (mA) Aroma (pulses)

200 300 Mild (- 10% of the average value)
301 450 Average (nominal)
451 600 Strong (+ 10% of the average value)

– – pre-ground

If the gearmotor power consumption value falls within the “overwork” interval,
the grinding pulses will be decreased by 10 and the product will be dispensed.

If the gearmotor power consumption value falls within the “expulsion” interval,
the grinding pulses will be decreased by 10 and the pad will be dispensed.

Min. current (mA) Max. current (mA) Aroma (pulses)

800 1000 Overwork

1001 - - Pad expulsion

Rev. 00 OCTOBER 2009 Page / 06

06

CHAPTER 5

SERVICE MODE

Rev. 00 OCTOBER 2009

GAGGIA

5.1. Test mode

05 SERVICE MODE

To enter Test Mode

1. place the control knob in the water position

2. keep the espresso coffee key pressed

3. switch the appliance on from the 0/I button
located at the rear of it; the icons scroll
through in sequence

4. release the espresso coffee key

Cyclic blinking

Operational check - keys

PRESS No key

SETTINGS

Steady on

PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP

Operational check - microswitches and sensors

PRESS

Control knob in

water pos.

SETTINGS

Steady on

RHS service door

PRESS

open

Steady on

Control knob in

coffee pos.

Steady on

Steady on

Control knob in

steam pos.

Steady on

No dreg drawer No unit

Steady on

No water

Steady on

SETTINGS

Steady on

Steady on

Steady on

PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP

Rev. 00 OCTOBER 2009 Page / 02

01

GAGGIA

05 SERVICE MODE

Brew group operational check

PRESS NOTES

SETTINGS

FUNCTION

PRESS

SETTINGS

Steady on

Group in work position (up)
when the limit is reached,
illumination of
In the event of a
malfunction, illumination
of

PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP

Operational check - pump

Steady on

Steady on

Group in standby position
(down)when the limit is
reached, illumination of
In the event of a
malfunction, illumination of

Illumination of

icon

When absorption is greater than 300
mA with the group inserted and 200
mA with the group not inserted.

When the group limit microswitches are
not activated in both standby and work
positions

NOTES

If the control knob is set to hot water
or steam and the

key pressed,
water is dispensed from the steam
wand

FUNCTION

Pump operation
(the turbine
monitors the
water ow and
the

icon

begins to ash)

Return to the previous level, set the
brew group to its work position (up),
return to this level, set the control
knob to coffee and press the
button ; water will be dispensed from
the dispensing spout

PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP

Coffee grinder and boiler operational check

PRESS NOTES

Boiler:

SETTINGS

Steady on

Steady on

Connect the machine (closed) on a
counter with ammeter and check its
absorption level; if using an ammeter
with needles, open the machine
and connect the device to the boiler
heating element

FUNCTION

Boiler operation.
Increase
absorption

Coffee grinder
operation.
The

icon
ashes to conrm
sensor operation

Rev. 00 OCTOBER 2009 Page / 02

02

CHAPTER 6

SERVICING AND
MAINTENANCE

Rev. 00 OCTOBER 2009

GAGGIA

06 SERVICING AND MAINTENANCE

6.1. Repair schedule

Action

1 Visual inspection (transport damage)
2 Machine data check (rating plate)
3 Operational check / problem analysis
4 Opening machine
5 Visual inspection
6 Operational tests
7 Repairing the faults encountered
8 Checking any modications (view info, new sw, etc.)

9 Service activities in accordance with the operating schedule
10 Internal cleaning
11 Operational test while the appliance is open
12 Assembly
13 Final inspection test
14 Draining the circuit (in winter)
15 External cleaning
16 Lubricating the brew group with suitable grease
17 Insulation test HG 701 (dielectric)
18 Documentation

6.2. Service schedule

S Replacement P Cleaning
ES Visual inspection TR Noise test
D Descaling R Adjustment

Component Action Support/tool

Water lter P/S
Water tank lip seal S
Boiler pin O-ring S
Brew group ES/P Grease solvent / Grease
Hoses, attachments and Oetiker clamps ES
Pump ES/TR
Gearmotor ES/TR
Coffee grinder P/R Vacuum cleaner / brush
Water circuit D Saeco descaler
Hot water/steam valve ES/S

Rev. 00 OCTOBER 2009 Page / 02

01

GAGGIA

6.3. Final test

06 SERVICING AND MAINTENANCE

Test Procedure

Espresso

Coffee

Noise Standard

Amount of
cream

Cream colour Hazel brown

Temperature

Grinding level

Hot water Dispense water
Steam Dispense steam
Dreg drawer
missing
indication
Missing
indication
coffee beans

2-3 Espressos for
adjustment purposes
2-3 Coffees for
adjustment purposes

Blow into the cup until
the cream separates

Reading taken while
dispensing
Check the grain size of
the ground coffee

Remove the dreg drawer

Start brewing a coffee
while the coffee bean
hopper is empty

Support/
tool

Measuring
scoop
Measuring
scoop

Thermometer 84 ˚C ± 4 ˚C

Standard Tolerance

Same amount 15%

Same amount 15%

The cream should
come together
again to form a
complete layer

Dreg drawer
missing indication

Missing indication
coffee beans

Rev. 00 OCTOBER 2009 Page / 02

02

CHAPTER 7

DISASSEMBLY

Rev. 00 OCTOBER 2009

GAGGIA

11

22

33

44

66

55

77

88

99

1010

7.1. Outer elements disassembly

07 DISASSEMBLY

1) Remove the dreg drawer, water
tank, coffee bean hopper cover,
drip tray, brew group, steam wand
cap and pannarello (frother)

2) Unscrew the screws shown
and remove the nger protection
device and coffee bean hopper

3) Lift and remove the top cover

4) Slide out the service door, lifting

it upwards

7.2. Dispensing spout disassembly

5/6) Unscrew the screws shown

and slide out the rear cover, side
cover and coffee grinder sound
insulating cover

7) Slide out the control knob cover, un­screw the screws shown and slide out
the dispensing head cover

8) Unscrew the screws shown and slide
out the dispensing head xed support

9) Slide out the front panel support by
lifting it

10) Remove the fork

Rev. 00 OCTOBER 2009 Page / 08

01

GAGGIA

121

2

33

44

55

77

88

99

1010

7.3. Keypad card and valve card disassembly

07 DISASSEMBLY

1) Unscrew the screws shown

2) Release the stop device and the

at cable Slide out the front panel

3) Disconnect the connector shown
and unscrew the CPU card support
screws shown

4 /5) Unscrew the screws shown

7) Slide out the keys, seal, light

guide and LED glass

8) Unscrew the screws shown

9) Slide out the top cover, knob

support assembly, gear and card
support

10) Release the card from the
support

Rev. 00 OCTOBER 2009 Page / 08

02

GAGGIA

2

A

B

D

E

F

C

2

A

B

D

E

F

C

4

H

L

4

H

L

3

B

P

3

B

P

11

22

11

7.4. Power/CPU card disassembly

7.5. Gearmotor disassembly

07 DISASSEMBLY

1) Unscrew the screw shown and re­move the card protection

2) Slide out the card, removing all con­nections

1) Unscrew the screws holding the boiler pin in
place, remove them and unscrew the other screws
shown

2) The following are located inside the compart­ment protected by the casing:

- Brew drive (A) with gears (B) and (C) for trans­mission and timing of the dispensing head.

- Dreg drawer present microswitch (D)

- Dispensing head present microswitch (E)

- Microswitch (F) intercepting both the standby
phase of the dispensing head and the dispensing
phase

- Slide out the gear (C) that meshes with the brew
drive

- Remove the large gear (B)

- Remove the brew drive (A), complete with trans­mission shaft

3) Replace the gear (B), making sure that the im-

print of the arrow is aligned with the opening con­taining the pin (P).

4) When replacing the brew drive and the transmis-

sion shaft, make sure the bearings (L) are in the
right position.
Grease the shaft thoroughly and evenly

Rev. 00 OCTOBER 2009 Page / 08

03

GAGGIA

7.6. Boiler disassembly

07 DISASSEMBLY

1) Remove the coffee grinder sound
insulating cover

2) Remove the boiler insulation

1

3

2

3) Unscrew the screws shown.

4) Unscrew the screw and remove the plastic

support.
Disconnect the hoses and the connections

7.7. Valve disassembly

1

2

Front piece

4

5

3

1) Remove the boiler pin

2) Remove the control knob cover

and unscrew the screw as indicated

3) Lift and remove the dispenser as­sembly, slide out the fork shown and
unscrew the screws holding the front
piece

4) Unscrew the screws shown to
remove the front piece support.

5) Remove the spring washer and
the control knob gear (steam/water)

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6

07 DISASSEMBLY

6) Unscrew the screws shown
to remove the insert on the
base of the casing

7) Unscrew the screws shown
and disconnect the valve from
the water connections.

7

7) Unscrew the screws shown

and disconnect the valve from
the mesh hoses

7.8. Pump and turbine disassembly

2

PUMP

Remove the connection 1, disconnect the silicone
hoses 2
Unscrew the safety valve and remove the pump from
the two supports

TURBINE

1

Remove the connection and disconnect the silicone hoses

2

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7.9. Disassembling and tting OETIKER clamps

1

1) Boiler connection

2

2) Other connections

07 DISASSEMBLY

2

1

Replacing the hoses

1) Use a suitable pair of pliers to

remove the clamp (as illustrated)

2) Tighten the clamp as illustrated

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7.10. Coffee grinder disassembly

1

2

07 DISASSEMBLY

1) To remove the coffee grinder, simply slide it out
and remove its connections

A

B

2) When replacing it, make sure the spring (A)

and the coffee pipe (B) are positioned correctly

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7.11. Grinder adjustment / assembly and disassembly

1) To remove the upper grinder support, using a

hex key push down and turn clockwise to release
the grinder support from the bayonet coupling

1

2) To remove the grinder blade from the upper

support, turn it anti-clockwise until it detaches
from the bayonet coupling

07 DISASSEMBLY

A

2

3) To remove the lower grinder blade, keep the

increment pin (A) locked in position and turn the
grinder blade anti-clockwise, until it detaches from
the bayonet coupling

3

4) When retting the upper grinder support, make

sure you reposition it so that the mark is as illus­trated in the photo

4

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CHAPTER 8

NOTES

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08 NOTES

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CHAPTER 9

WATER CIRCUIT
DIAGRAM

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9.1. Water circuit diagram

Linen-faced silicone tube

Tubo silicone retinato

5x8,9 11004050 (165mm)

09 WATER CIRCUIT DIAGRAM

To the Dispensing spout

All'erogatore caffè

Linen-faced silicone tube

Tubo silicone retinato

5x8,9 11003557 (260mm)

Steam wand pipe tting

Flow meter

Turbine

Water drain

Scarico acqua

Raccordo tubo vapore

Boiler

1300W

Steam wand

5x10 9972.176 (130mm)

Caldaia

Tubo silicone retinato

Linen-faced silicone tube

5x8,9 11005599 (190mm)

Pump

Pompa

Steam/Water dispensing

Tubo vapore

Erogazione vapore/acqua

Silicone tube - Tubo silicone

Silicone tube - Tubo silicone

5x10 9912.122 (290mm)

Silicone tube - Tubo silicone

5x10 9972.176 (130mm)

Water tank

Water tank

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11010166

Safety valve

Valvola di sicurezza

CHAPTER 10

ELECTRICAL DIAGRAM

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10.1 Wiring diagram

10 WATER CIRCUIT DIAGRAM

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01