The steps detailed below apply to: Magic
Deluxe, Magic Comfort Plus, Royal Professional, Royal Coffee
Bar, Royal Office, Royal Digital and Gaggia Synchrony Digital
For parts location in these
machines, see exploded diagram of the models, made available
on this web site.
for any repair work undertaken using the following
instructions: Make copious notes to help put things
back as they were. This is especially important for electric
wires. Tag them, color mark, make notes or even take a
picture or two.
| Information on this page is for
use of technicians. Others do so at their own
PulyCaf, Cafiza and CleanCaf are only for cleaning coffee and
machines. Using these products as descaling chemicals will not serve
clogging of grinder and doser. Use non-oily espresso beans,
recommended by manufacturer. Try our non-oily roast Guru's
Choice Espresso or Bristot imported Italian beans - Ideal
for Italia, Charisma, Divina Deluxe, Titanium, Syncrony,
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Tools Required for
Removing the Top Cover:
1. Torx screw driver
(star-shaped screw head instead of Philip
2. Philip screw
driver (One long and a short arm)
3. Nose pliers
4. A test meter (analog or
5. A small magnet that is
strong enough to pick weight of a
6. 1/4" plastic tube, 3
to 4 ft. long
7. Vacuum cleaner with
narrow long nozzle
8. Exploded diagram of
Steps to Remove the
1. Remove the water
2. Remove two philip screws to lift the bean
3. Remove the grind
adjustment lever. Place index fingers on either side under
the bottom of the lever and pull up from both sides (for help, see
instructions for adjusting and cleaning the Magic/Royal grinder
for illustrations, on this website).
4. Remove two torx screws
located on the rear edge, under the water
5. Remove two philip
screws, under each corner in the front, below the top
Pull the cover up by lifting
it about 1/2" from the back, then move it to the front a
1/2", to free it from the bent edge in the front, the steam
knob and the touch pad. Lift the steam pipe to its top to slide it
out through the slot as you lift the top cover out. A wire
connecting the hot plate with the electronic board will
still be attached and will limit the complete removal of the top. Do
not disconnect the wire. If you have to, then make note of which end
you disconnect and where to re-connect the wire back. Lay the top
towards the back of the machine. Now the entire machine is exposed
for open-heart surgery!
To find leaks, look for the obvious white
calcium deposits first. For other malfunctions, machine has to be
operated. To operate the machine with the top
removed, a water source has to be connected and the water
level sensor activated (cheated) with a magnet placed next to the
location of the level sensor.
To Connect the
Machine with Source of Water:
1. Take the 24" long
plastic or silicone tube.
2. Disconnect the hose from
the water inlet (from under side of the top
3. Connect the hoses 1
& 2. Make sure that the connection is air
4. Dip the loose end of the
extension tube (1) in a clean water container. Make sure that
the tube stays immersed inside the water container all the
Replace the brew group.
Close the door. Slide the waste box in. Plug the machine in the
electric outlet. Make sure
there are no loose wires inside the machine that were accidentally
or otherwise disconnected and there is no
metal object touching the naked wires of the machine,
before plugging the machine into electric outlet. Turn the
power switch on. No water sign will come on.
To remove the no water sign,
place the magnet next to the water level sensor. The
water level sensor is a white rectangular piece (1" x 1/2"
x 1/4") located between the water tank and the grinder. Move the
magnet around the sensor, on its left or the rear to find the
location where the "no water" light turns off and leave the
magnet clinging at the spot to the metal body of the
You will hear the machine
reset as you turn the power switch of the machine on. Next, prime
the machine by opening the steam knob and purging about 2 to 3 oz.
of water. If water does not purge, then check the warning
lights on the touch pad if the machine will tell you why (no water,
no dump box, no brew group light may be on). If these lights are not
lit, then there may be other parts malfunctioning. It could be the
pump, the flow meter or the blocked hydraulic system that will
prevent water flowing through the machine. The machine
should not be left on when water is not pumping through the system.
Turn the machine off. Disconnect the wires to the heating element
(tag the loose ends) and wrap the naked ends with electricians tape.
Now the machine can be turned on and left on for longer duration
while other parts are checked for malfunction.
When the pump
operates, the water pressure will show the spot
where leakage is occurring. Protect the electronic
board from sudden stream of water or steam spilling on it.
Once warmed up, test by making a fake espresso (pre-ground
cycle without adding coffee in the shoot) to see if any
leakage of water or steam can be spotted. Look for the hose
connections, seams of heat exchanger, steam valve, solenoid
valves (when seen in the machine) & brass
Look for any
other functional faults and unusual noise during the cycle. To
find leaks, two or more espresso cycles have to be worked.
Replace seals/o-rings causing leakage.
Replace faulty parts as
If the machine is not
heating, check the following:
thermostat (mounted on the heat exchanger and steam boiler if
heating element (on the lower side, not seen in the
d. the electronic sensor
that initially brings water to temperature for
Finally, before replacing
the top cover, make an espresso with coffee. To do so, use the
preground cycle with ground coffee or hold the bean hopper on the
grinder inlet and add beans in the bean hopper just enough for
one espresso (excess beans will spill around and
inside and be difficult to clean, especially
from around the doser assembly). Vacuum the spilled beans
If all functions are working
good, the coffee grind is like the table salt grain and there
is still no espresso dispensed, the chances are that the:
1. The pump is weak and
unable to exert the pressure necessary to pump water through the
tamped coffee grounds. In that case, replace the
2. The heat exchanger outlet
nozzle is blocked or its lower end is broken. In that case, replace
3. The brew group is
blocked. Clean the shower screen & the valve under the
outlet nozzle flange.
To Remove the Pump
(avoid removing the pump mounting pads, it's a lot of
1. Disconnect the 90 degree
plastic water inlet connector from the rear of the pump.
2. Slide the rear mounting
pad off of the water inlet of the pump.
3. With the rear end of the
pump free, hold the front brass nozzle of the pump with pliers
and unscrew the front pressure release valve (make sure that
the body of the pump does not spin on
its outlet nozzle).
4. Remove old o-rings and clean space
around o-rings and then replace with new o-rings. Use light coating
of lube for easy connection without twisting the
5. Install new pump by
reversing the above steps.To connect hoses, slide o-rings on the
hose end first, and wet new o-rings with lube, before inserting.
new o-rings on the teflon hose connections. Replacing
o-rings will be easy if the heat exchanger is taken
out from the machine. The heat exchanger is mounted with only
one supporting bracket and two screws.The screws are
visible from inside the door when brew group is
the heat exchanger is to be replaced, disconnect wires going
from heat exchanger to the electronic board. Make copious notes
and take two or three pictures to remember each wire
disconnected from the heat exchanger or the electronic circuit
board. There can be no help available, if a lose wire is left
out without knowing where it re-connects. In such a case the
only choice is finding the path by a
lengthy process with an electrical diagram.
showing opened brew drive gear box. Picture
shows position of gears and timing switches in the home