Ascaso Dream over-pressure valve removal tool

Ascaso Dream (PID) Over-Pressure Valve (Bypass) Removal Tool

I'm a lazy person. I regularly forget to descale my Ascaso Dream PID espresso machine. Over time, this causes the over-pressure valve (also called the bypass) on the left side of the machine (the one you adjust with a screwdriver to regulate the maximum pressure that is exerted on the coffee puck during production) getting stuck closed so the machine doesn't limit the pressure anymore and the pump always produces maximum pressure.

This can't be good for the pump over time, and the espressi that are produced tend to be overly acidic. I don't want to replace the whole over-pressure valve (which, should you ever need it, is part no. I.2639 - By-Pass Ascaso), so whenever it happens again, I open the top cover of the machine and remove the valve, disassemble it and leave it in descaling solution overnight whenever that happens again. The only component that isn't easy to remove is the cylinder with the gasket itself, which is stuck to the top of the pipe and blocks the bypass.

This model solves the problem by simply disassembling the valve and gently tapping it onto the cylinder with a hammer. You can then rotate the tool a bit, which dislodges the cylinder and allow it to be removed from the pipe. You can then clean the cylinder and gasket, descale it and apply some fresh food-grade grease before reassembling both valve and the espresso machine. You should then be able to avoid descaling your machine for another year or so, before it jams again.

Quick Instructions

1. Remove the top cover of the espresso machine
2. Unscrew and remove the pipes going into and out of the over-pressure valve
3. Remove the snap ring from the valve and unscrew the set screw until it comes out of the pipe. You might need some force to pull it out, because it has a seal around the neck.
4. Remove the spring from the pipe
5. Push the removal tool into the pipe on top of the pin of the cylinder. Using a hammer, fix it to the pin.
6. Twist and turn the tool, dislodging the cylinder from the pipe
7. Remove the cylinder and clean all parts
8. Reassemble the valve, put it back into the machine, fasten the tubes and quickly test whether everything is water-tight
9. Put the top lid back on and start using your pressure-limited espresso machine again

Print advise

The cylinder pin you want to hammer the tool onto has a diameter of around 3.55 mm. After printing, check that the hole in the tool just about matches this measurement (it should be a little smaller). On the one hand, the tool has to be tight so you can turn the cylinder with it, on the other it mustn't be too tight so it breaks and gets stuck. Experiment with your filament's flow ratio to match the hole size as exactly as you can, or edit the model to increase or shrink the hole's size.