DeLonghi "Insert infuser assembly" error
Easy Fix - Delonghi Coffee machines which have built-in coffee grinders often suffer from a problem that produces an error, "Insert infuser assembly" that appears at random times.
The problem is usually caused by distortion of infuser lifting mechanism limit switch mounting (Orange colored plastic)!
The mounting is very close to the water heater so with heat and pressure from the infuser lifting mechanism the mounting gets bent over time. The switch mounting (Orange colored plastic) gets permanently distorted so the striker arm on the lifting assembly only just presses the micro switch button causing the error message "Insert infuser assembly".
To easily fix the problem on ESAM 5500 machines and should work on other similar machines:-
1.Unplug the machine and remove the rear cover screws and remove.
2.Slide out the two side covers.
3.Remove the grinder lever screw in the top cover coffee bean compartment.
4.Carefully lift the top cover pushing it slightly back so it does not stick under the front cover (you may have to loosen the 4 front cover screws on the side).
5.The limit switch is clearly visible on the top (see photos).
6.Wedge some insulated material (wood, plastic etc, I used bamboo) between the heater assembly and the switch mounting so the switch is in a VERTICAL position. The thickness of the packing is around 3-4mm (see photo).
7.Re-assemble the machine and enjoy your coffee. JTS