gaggia syncrony digital pump replacement · disassembly, pump replacement, and reassembly. the...

GAGGIA SYNCRONY DIGITAL

PUMP REPLACEMENT

David Hambleton

www.oldsalt@oldsaltweb.com

Purpose/Scope:

This slide presentation covers three processes; Disassembly, Pump Replacement, and Reassembly.

The slides are in order first for Disassembly, then Pump Replacement, and in reverse order for Reassembly.

Some slides are positioned in order for Reassembly, so they appear among but are marginally relevant to the Disassembly process.

Color Coding of slide text is as follows:

Disassembly – slide symbol:

Pump Replacement – slide symbol:

Reassembly – slide symbol:

Tools Needed:

#1 Phillips/Cross-tip driver

#5 Torx Driver

14mm Open End Wrench

Slip-Joint Pliers

Ulka EAXP 115VAC (or 220VAC) Pump

Teflon Tape

Small-tipped electronics vacuum (grounded to prevent static charges on the tip) - optional

Spray-and-wipe cleaner – optional, but... please...

Lint-Free Rags or Towels

Frother Steam Control Knob

For Disassembly: I took

off the frother knob by

simply pulling it

straight outward

For Reassembly: There

is a key on the post

(shown here at the top

of the hexagonal post)

and slot in the knob.

Align the key and slot

and press to fit.

Frother Steam Control Knob

For Reassembly:

Steam Control Knob

in the off or closed

position.

Frother Steam Control Knob

For Reassembly:

Ensure the steam

control will pass

through its entire

range.

Steam control knob in

the on or open

position.

Frother Tube Disassembly

For Disassembly: I unscrewed

the keeper ring on the frother

tube, pulling all the pieces

down and off.

For Reassembly: note the rings

on the tube (hard to see in this

picture), placing the parts in

place to just cover them when

it is all screwed finger-tight.

This is a plastic nut, and will

break if over-tightened. It is

not a flight risk. Finger snug

does it.

Frother Handle

For Disassembly: I pulled the

frother handle off. It is

friction-fit, so just pull it out

with a bit of an upward

motion while pushing back

against the tube below it.

For Reassembly: Set the tube

all the way down and press

the handle back on, making

sure not to pinch or overly-

stretch any of the legs.

Front Right Corner Screw

Front Left Corner Screw

Under Water Tank Torx Screw 1

I didn’t anticipate Torx screws,

so only brought a #1 Phillips

driver from the shop to my

desk. Like so very many things

in my engineering world, life

would not be complete without

a Leatherman. My Surge

being out for repair, I used my

ready-standby Charge TTi

with the handy bit holder and

Torx bits available from

www.leatherman.com – ever

ready at my hip – to manage

the surprise Torx screw

removal.

Under Water Tank Torx Screw 2

Bean Hopper Screw 1

Bean Hopper Screw 2

Grind Selector Removal

For Disassembly: The

grinder fine/coarse

adjuster had to be

lifted off its pins – it

is just pressed down

into the guide holes.

Grind Selector Reassembly

For Reassembly:

align the dots

and press the

handle in place

centered on them.

Rear Right Lid Screw

Lift off the lid

For Disassembly: Then it was

just lifting it clear of the

electronics panel and the

frother tube, which I pushed

up as I pulled up and slightly

forward (to get around the

tabbed front edge screws)

on the lid, and setting it

aside being careful of the

wires.

For Reassembly: Fit the lid

over all, avoiding pinched

wires and tubes.

Pump Removal

The two white-shelled spade-lugged

wires on the pump are AC power, so

they are not specific to which post

they are attached.

Reach a finger around below the

ends of the motor assembly just next

to the black rubber mount brackets.

Mash the release buttons, and push

the motor mounts forward and aft,

away from the motor, to clear their

clips. Pull the friction-fit nipple off

the inlet side, remove the hold-down

kotter pin in the out-flow tube and

extricate the tube, and lift out the

pump.

A 14mm wrench and pliers takes the

pump apart from the output

manifold.

Release Button

under here

Release Button

under here

Pump Reassembly

A small-tipped vacuum was handy to

clean up the compartment before

reassembly.

I used two wraps of Teflon tape to

help the pump seal to the output

manifold, and again I was careful

not to over-tighten the brass threads,

leaving out the pliers and using my

hand and the wrench to snug the fit.

The black and white wires to the

vibratory pump provide alternating

current (AC) power, so are not

polarity-specific – they don’t care

which wire is attached to which post.

Reassembly

Reverse the Disassembly process, taking special

note of the slides with orange Reassembly

instructions.

Clean as you go with a small-tipped vacuum for

reaching into tight spaces – I use a purpose-built

electronics vacuum that is grounded so I don’t cause

electrostatic shocks to electronic components – and

spray-and-wipe cleaner with lint-free rags or

towels.

Coffee Time!!!