Rancilio Z9 2gr Lever Rebuild (The other one)

beanflying

As I have been kicked in the pants a little by this other Z9 2group Lever Rebuild thread http://www.bestcafes.com.au/forum/projects-rebuilds/rancilio-z9-le-%28lever%29-2gr-rebuildrestoration/ of Coffeehorse, time to get into mine.

Guilty confession time I purchased mine back in April last year and due to a shift in house lack of workshop space and a host of other life niggles it has been sitting in the corner partially stripped awaiting some time. That combined with already having 4 fully functioning Lever machines too 8)

Couple of useful Threads on Z9's Info and other rebuilds. (Will add a few more later today)
http://www.home-barista.com/levers/rancilio-z9-two-group-lever-machine-t12840.html
http://www.sreweb.com/diagrams/rancilioa.htm

Not specifically Z9 stuff but relevant for the rebuild.
http://www.home-barista.com/levers/advisable-to-replate-interior-of-old-boilers-t3997.html
http://www.home-barista.com/levers/pid-controller-in-commercial-lever-t13264.html
http://www.home-barista.com/levers/early-1970s-faema-zodiac-lever-ariete-rebuild-t18123.html LPG discussion.
http://www.home-barista.com/levers/measuring-brew-temperatures-rancilio-class-6-lever-t6703.html Temp and Levers

beanflying

Plan is to leave the original Mercury switches in place because the flash of blue from under the machine is just cool  ;D Also sticking with a 70's retro colour as current or maybe even go a 'proper' Burnt Orange  8)

Brett H

All these rebuild threads are so exciting!  I've had my own rebuild request approved by my wife with one small modification... It can't be a lever and must be the upstairs bathroom  . I live vicariously through all of you rebuild champions!

coffeehorse

Hey, I had someone throw my pump + motor out when unpacking - love the mercury switches and curious if there's any way to test them without hooking them up fully. Are you finding the problem with the colours is: Red - love/hate Blue - dated Yellow - wife doesn't like this one Orange - wife doesn't like this one but it's the original machine colour and my resto colour of choice Black - limited contrast with silver and big issues with WAF. the one thing about this machine is that has a massive butt! Your painted panels seem to be in good condition, and you've done a great strip-down job so far. Makes me want to spend all week in the garage with my tools. Does yours have the 3500W element? and what year is it from? Looks like you have more pipe rust, same condition boiler, better condition groups (lovely spring condition, they look new AND black (I could only find a silver one from coffeeparts). Do you fancy making a workup of the feet? Mine appeared without the front left one and I'm not sure they're made out of anything but ABS plastic? All you need to do is dip and coat and put back together!

beanflying

on 1318774044:

Hey, I had someone throw my pump + motor out when unpacking - love the mercury switches and curious if there's any way to test them without hooking them up fully. Are you finding the problem with the colours is:...... .....d big issues with WAF. the one thing about this machine is that has a massive butt! ...... Does yours have the 3500W element? and what year is it from? Looks like you have more pipe rust, same condition boiler, better condition groups (lovely spring condition, they look new AND black (I could only find a silver one from coffeeparts). Do you fancy making a workup of the feet? Mine appeared without the front left one and I'm not sure they're made out of anything but ABS plastic?

Colour scheme is simplified by a lack of significant other and yes is does have a big butt and there is nothing wrong with that either Also have no plans to sit it on the kitchen bench so being out there in colour isn't a problem. With the Mercury switches and just for a bit of kit go buy a $10 Multimeter (preferably a $30 one with the thermocouple for other uses). If the pads in the glass tubes look ok then they will most likely be fine. Will check the feet and element and the other bits out after work tonight.

on 1318769420:

. It can't be a lever and must be the upstairs bathroom  .

Every Bathroom needs it's own Lever Espresso machine to improve morning efficiency  ;D

beanflying

Couple of pics to help explain the element layout. Note this is the pointy and dangerous end so in using this as a guide check the actual paths on the elements with a multimeter. On Ohms range this 3500W TOTAL element measures circa 45 Ohms which equates to roughly 1200W per element leg. So on the attached picture removal of the brass link on the right hand side between the lower 2 terminals will isolate the lower element electrically and reduce the power required by the boiler to circa 2400W or 10A. While this does mean the machine has a nominal power requirement that can come from a standard 10A power point it is maxed out and makes no allowance for pumps and internal electronics or other electrical items that may be on the other side of a double GPO (Power point). So with this size machine or power running a dedicated 15A circuit for the machine and leave the 10A GPO for other stuff is highly recommended/mandatory. The other pic is just of the feet they are a molded plastic item with a heavy rubber insert that keeps them off the bench, only one of my feet still has the rubber. Most likely going to change them all out for a more modern adjustable style. http://www.coffeeparts.com/misc/machine-legs.html

coffeehorse

on 1318803790:

Colour scheme is simplified by a lack of significant other and yes is does have a big butt and there is nothing wrong with that either Also have no plans to sit it on the kitchen bench so being out there in colour isn't a problem.

Going back to the original orange will look pretty sweet

With the Mercury switches and just for a bit of kit go buy a $10 Multimeter (preferably a $30 one with the thermocouple for other uses). If the pads in the glass tubes look ok then they will most likely be fine.

The main issue is that the pressure chamber seems not to be sealing. I'm going to take mine apart totally and see what's going on, there's a bit of rust and wear (looks like Alox rest rather than Ferrox)

Will check the feet and element and the other bits out after work tonight.

nice idea with the re-feet, I might do same.

Every Bathroom needs it's own Lever Espresso machine to improve morning efficiency  ;D

A push-pull approach? Boiler looks same as mine - thankfully all the circuits are wired for 30A max loads with 20A fuses and 10A GPO sockets, but longer term I'll probably add a triple loop with 10/15/20A GPOs onto front and back balcony if we stay in this rental place for years. There seem to be a few 2700W elements around, but your machine and mine must've been twins.

borat123

Hmmm, aluminium boiler rings, the sworn enemy of the coffee machine restorer....  :o

beanflying

I reckon it is as much the bolts that hold the rings or the former owners that let water leak from their machines to corrode them. Generally your correct especially on some of the earlier examples slightly dodgy most likely gravity castings then expose to heat for years can't help them either. Got the trestles out last night and started to clear a dedicated workspace so I can lay it out and leave it. Some more progress pics of the remaining dismantle later in the week.

beanflying

on 1318862044:

Boiler looks same as mine - thankfully all the circuits are wired for 30A max loads with 20A fuses and 10A GPO sockets, but longer term I'll probably add a triple loop with 10/15/20A GPOs onto front and back balcony if we stay in this rental place for years. There seem to be a few 2700W elements around, but your machine and mine must've been twins.

For domestication of these beasts it would make a lot of sense to change the element out for a 2700W with a leg decoupled back to 1800W. Unless your having a party with 30+ around boiler recovery won't be a major issue and your then back on a standard 10A outlet. This part should be the one to do the job http://www.coffeeparts.com/rancilio/700303 $115.50 currently. If mine was going in a kitchen and as I am a renter it would make sense. As mine is either the spare shed toy or going to get some commercial work sub 15A total with a grinder is fine for me.