The gear that drives the brew group has broken 3 times. we have had it fixed each time and now it is outside the warranty date. What is the reason it keeps breaking?
First, you're going to need to get the brew group out. Check this out to get the brew group out. You need to remove a screw and pull unless you're really crafty.
This video will help.
After that:
a) Yes, lubing will help.
b) Replace the o-ring on the piston in the brew group (it should be orange). It gets old and gummy creating resistance.
c) Reinforce the weak plastic that gets over-torqued.
I own three of these units, one from 2007 (made in Italy, never broke, has tens of thousands of brews) and two newer units (made in Eastern Europe, fewer brews, both broke). I can distinguish the newer ones because they have a "sleep mode". They really overtorque the gear.
I tried repairing with just glue and that lasted (surprisingly) several months. I tried again by using a thick paperclip as a drill bit and that lasted 7 months.
Now with the holes piloted, I drilled a little wider and put in heavier metal from a heavy-duty binder clip. Cheap and very strong! Let's see how long this lasts.
See before and after pictures. This metal won't bend!
The coffee is being ground too fine usually. Also not cleaning the brew group and lubricating it regularly can cause this.
The gears are standard plastic and any excessive force will cause them to break. The only things that cause excessive force to gears on saeco machines is fine coffee compacting in the brew group and/or a dirty brew group that gets stuck and does not cycle properly.
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