Instructions for Opening and Replacement of Piston Rings,Explained with the Example of the AEG Ca Famosa Fully-

Automatic Coffee Machine

Also applicable for the Jura E & F series as well as for the AEG fully-automatic coffee machine

Ca Famosa CF 80 -200 series, and Krups machines of the Orchestro and Siziliana series.

Created by www.coffeemaker-spareparts.com

Elektrogeraete & Kaffeeautomatenservice Endress Bahnhofstr. 9, 83088 Kiefersfelden, Germany

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Attention! Before starting any works inside an electrical device, please disconnect the machine from the mains supply. Only perform works on

de-energized machines.

If you are not sure, do not hesitate to call us. We will be glad to help you!

0049-(0)8033-3041193

Required tools and auxiliaries

1 Phillips head screwdriver 1 flat screwdriver1 TORX 10 screwdriver 1 TORX 20 screwdriver 1 flat pliers/combination pliers (maybe an oval head key)

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1 reel of paper towel or a cleaning cloth1 brush Vacuum cleaner

One sealing ring kit of www.kaffeemaschinendoctor.de (ideally)

Introduction

Place the machine on a solid base which provides enough space for the repair works and ensure good lighting conditions - now you are ready to start. First remove the water tank, the drip tray, and the coffee grounds container. Empty the bean container as far as possible (can be best emptied by means of a vacuum cleaner). Now remove the 4 screws at the rear side of the housing, either using an oval head key or flat pliers/combination pliers. Put on the combination pliers at the oval head screw and turn it until the screws can be removed manually after a few turns. Replace these screws later on by simple cross-head screws.

Now unscrew both TORX screws (or cross-head screws in case of older models) at the top side of the front under the two lids and carefully take off the lid by lifting it upwards.

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Now pull the two side parts backwards applying gentle forceand the housing is opened. (That was not too difficult!)

View from top into the opened machine:

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And from the side:

The next step is to remove the water tank inlet (also secured by a screw). Lift it up and tilt it aside. 4

Now pull off the hopper at the grinder on top of the brew group (is a bit difficult to remove as it is retained by a plastic lug. In some models it is additionally fixed by a screw or cable tie. In this case just cut through the cable tie!)

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Remove the suspension clamp at the outlet valve to the brew group and pull the Teflon tube out of the valve. Please also remove the small black O-ring if it remains stuck in the valve.

Now the 2 screws that fix the motor at the brew group drive (arrows) can be unscrewed. Depending on the year of manufacture, these are cross-head screws or TORX T20 screws. The screws are equipped with a screw lock to prevent that they come loose during operation. It might be difficult to unscrew them. Be careful to prevent damage of the screw head. Unscrew both screws completely!

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Now loosen the screws on this side of the brew group holder (TORX 10 screws or cross-head screws). The upper two holes never contain screws! (provided that you have not bought the machine from a do-it-yourselfer; in this case there might be screws in these holes. Anyway, believe us – usually there are no screws!)

Now swivel the brew group outwards at the bottom lowering it a bit to ensure that the retaining lugs on top release the part and take out the brew group. Note! The Teflon tube tends to be clamped in the bushing. Just push or pull it a bit if necessary.

Disassembly of the Brew Group

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Pull out the brew group guidance upwards and the coffee outlet (white or brown) as well (remember the position of both snap brackets). Now first release the wiper on top and then pull it downwards.

Put the parts aside!

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Lift the upper cap of the brew group at all 4 edges using a screwdriver and pull it off upwards.

Now it is going to become a bit tricky. Both side covers must be removed. To remove them, first have a detailed look at the brew 9

group. The side covers are held by 4 plastic lugs. 3 of the 4 lugs are easy to recognize. The fourth one, however, is hidden under the drainage valve! There you must push into the indentation using a screwdriver. Then push the other 3 plastic lugs outwards (one after another) using your fingers and take off the side covers.

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Now take off the drainage valve (red arrow) at the bottom of the brew group pulling it downwards.Remove the Teflon tube in the drainage valve. To do so, take off the securing clip and pull it upwards. Later on put on a new seal before reassembling it and fix it by means of a locking spring.

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Now the two guideways can be taken off easily on both sides. Take off the two metal rings and unscrew the white toothed wheel.

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Now the upper brewing piston can be removed very easily.

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The red arrow points at the riser tube!The riser tube is still to be removed from the upper brewing piston. Turn the riser tube in its guidance and pull it out upwards. Note! A spring with a plastic pushrod is located at its end (this is the famous crema valve) Now remove the two seals on the riser tube and also take off both sealing rings from the brewing piston (slightly lift them off by means of the screwdriver and just pull them off).

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Then turn the brew group and lift off the two retainer rings from the bottom side of the guide shaft using a screwdriver.

Be careful! They easily jump off, but they are important!

Now pull out the guide shaft. This often requires a certain force. It is best to turn it inside into both directions using pliers until it becomes loose. Please do not knock it out by means of a screwdriver and hammer!!!

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Now it is going to become tricky again. Take out the entire lower brewing cylinder. To do so, pull the two side parts of the brew group apart and take out the complete brewing piston. (We admit that it is hard to do and it is an ordeal, but it is possible.) Now the next two metal rings fall out (these run inside the guidance and are important)

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If this is done, telescope the cylinder and the cylinder drive and the lower brewing piston will come out. Take it out.

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When reassembling later on it is important to make sure that the piston is mounted true sided! The lower arrow indicates the water inlet!

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Now the following dismantled parts must be there:

Clean all parts, (with warm water and a brush or, as we do, just cleaning them in the dishwasher at max. 50°C). You will see – the brewing unit will look as if it was brandnew! Also place the drainage valve into the dishwasher after having removed the pertinacious coffee deposits and incrustations using a brush. Thoroughly dry all parts after the washing. Pull the two O-rings over the piston and already slightly grease them.

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Now slightly grease the lower piston cylinder.

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And then completely slide in the frame with the toothed wheels and insert the piston.

For this purpose, have a detailed look at the figure below. Otherwise the piston could be inserted with the wrong orientation by mistake, which would cause that the coffee and the water end up in the coffee grounds container!

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Position the brewing unit into the brewing unit frame before reassembly of the unit!

On the picture you can see the brewing unit half way inserted into the brew group. Please consider that both side parts of the frame are to be slightly pulled apart!

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After the brewing unit has been reinserted into the frame, also insert the metal shaft and mount the retaining rings.

Important! Both retaining rings must snap into the notch provided for this purpose when mounting them!

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Slightly lift up the plastic bracket with the pin for the mounting of the inner guide ring and insert the guide ring underneath until it snaps into the pin.

Repeat the same procedure at the other side!

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The inner guide rails must NOT be greased!

Now put on the guide rings on the two outer pins. The black arrow indicates the position in which the frame that takes up the lower piston is to be inserted into the brew group. The position of the notch is extremely important for a smooth run of the cylinder inside the brew group. The part could be incorrectly mounted turned by 180° by mistake.

Now mount the two new seals on the riser tube (slightly grease them as well), insert the spring with the plastic pushrod at the bottom end and then reinsert the entire riser tube into the upper piston. (When reinserting it turn the two lugs in the lateral guidances until it is fixed)

Then reinsert the upper piston into the brew group and make sure that the riser tube is located at the right hand side, as shown on the picture!

Screw on the large toothed wheel. Once again one of the two outer guide rings is marked on the picture.

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Mount the control arms on both sides as shown on the picture On the left and on the right side!

The picture below shows the brew group after mounting both control arms.

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Now put on the upper head part true sided and let it snap in.

Then reinsert the drainage valve into the guidances.

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The picture below shows the brew group before mounting the side parts. 28

Mount the side covers and let them snap in securely.

Please consider the notches at the drainage valve as they fix the drainage valve inside the brew group. Prevent tilting and carefully move the drainage valve until the covers are snapped in properly!

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The brew group should now look as follows:

Assembly of the drive carriage with the gear-driven spindle.

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Brew group with drive carriage

Now plug on the coffee outlet (white or brown) and let it snap in.Then remount the wiper and insert the brew group into the machine.

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Reassemble the parts, close the machine, and ready!

1. Plug in the pressure tube into the drainage valve (do not forget the seal) and engineer the tube through the housing wall.

2. Then mount the brew group.

3. Screw in the four Torx screws (at the right point – especially the screw at the bottom side of the drainage valve should not be omitted!) and the two cross-head screws /Torx20 at the other side. Do not tighten the screws too much!)

4 Insert the pressure tube into the outlet valve at the heating cartridge (do not forget the O-ring) and fix it by means of the securing clip!

5. Remount the water tank inlet and the hopper for the coffee powder and fix them.

6. Now insert the drip tray and the coffee grounds container, fill the water tank and put it onto its position. Trial run with opened side parts: If everything has worked well and the coffee is coming out you can remount the side parts and put the lid on. Screw on all remaining parts and your machine is ready for the next coffee!

Should you have any question, do not hesitate to call us – we will be glad to help you!

Phone: +49 8033 / 3041193