How To Fit The Overheat Repair Kit

How to use the overheat repair kit 

Overheating your machine can be frustrating, but with the right tools and a bit of time you should have your machine back up and running again! 

Tools and parts required 

• 3mm Hex key
• 13mm combination spanner/wrench 

Components you’ll need to keep 

• 3 x 3mm hex screws
• 1 x boiler pipe 
• 1 x grouphead o-ring 

Step 1 

Follow our disassembly instructions and remove all the damaged components from the machine. You can find these instructions here, along with a video at the bottom of the page which shows the final assembly. 

Keep hold of your 3mm hex screws as you will need those to fit your new grouphead!

Step 2 

Starting with the heat exchanger coil, we will begin by replacing the thermal break. Take your boiler pipe and insert the threaded end into the hole in your thermal break. 

Step 3 

Take the assembled boiler pipe and thermal break and reinsert it into the base of the heat exchanger coil. Screw in the boiler pipe to the point where the threads are just engaged and then using your 13mm combination wrench, screw the boiler pipe in until it is hand tight. 

Tip: when screwing in the boiler pipe, ensure that the pipe is straight before tightening to avoid cross threading the heat exchanger threads. 

Step 4 

Take the valve body seal and boiler o-ring seal and carefully seat them into their positions on the heat exchanger. 

 Tip: When putting the o-rings into position, try to avoid putting the boiler o-ring over the threads on the heat exchanger as this can damage it. We always recommend inserting this o-ring into place by putting it over the top of the heat exchanger to avoid the threads!

Step 5 

Take the newly assembled heat exchanger and reinsert this into your boiler. You do not need to screw it in all the way, just enough to engage the threads on both parts. This will stop the heat exchanger wobbling around in the boiler whilst you fit the next parts.  You can see how this is done in our disassembly video which you can find here!

Step 6 

Insert your new valve spring and pin into the top of your heat exchanger coil. Push it up and down to test that it moves freely without any obstruction. 

Step 7 

Place your grouphead on top of your heat exchanger, your valve pin should poke through the hole at the bottom of the grouphead. 

Tip: At this stage you can position the grouphead in a different spot if you wish. Here at the factory, we always align the grouphead handle to the left of where the coil enters the top of the heat exchanger. This positions the handle away from the safety valve. Some models do vary however, so if you find that this does not work for yours simply undo the screws and move the grouphead to your desired position. 

Step 8 

Position your grouphead o-ring and valve chamber seal back onto your grouphead insulator. This can be a bit fiddly, 

Step 9 

Carefully picking up the assembled grouphead insulator, reinsert your 3mm Hex screws into the three holes on the insulator and place this on top of the valve pin with the top of the pin going into the hole at the base of the insulator. 

Step 10

Align the screws with the holes on the grouphead and also the heat exchanger, then whilst pushing down on the insulator begin to tighten the screws until they are hand tight. 

Now you should have the grouphead insulator securely fixed to the heat exchanger! 

Step 11

Finally, using your 13mm spanner, screw your new safety valve onto the boiler until the safety ring is sitting flat against the boiler.

That’s it! If you have any questions please do get in touch with us!