Saeco Vienna is making loud noises (clack clack clack) at the end of the brew process, and the brew unit gets stuck in the infusion position (left side - piston up) ... At this point it really is a pain to remove. I tried lubricating the whole brew unit, but it seems to keep on doing this. I will try to change the orange O-ring, but is it possible that the gears have been damaged permanently by that ? Have you ever seen this happening ?

Sounds like the brewing unit, or infuser, has not been properly seated into its holder. Are you sure that the two red retainer fittings are in their snapped out positions? See page 16 of your owner's manual.
If the infuser has not been properly seated it could cause a loud noise when the servo drive tries to raise the unit into its brewing position.

This needs looking at by a Saeco repair shop - the brew unit travels in a distinct 'pathway' from being empty, to filled, to coffee being tamped, then to being emptied. Yours is obviously not working as intended.
It may be the brew unit needs lubricating ( NOT OIL) or it may be the gear system that drives the brew units movements that needs attention.
Cheers
Mike.

Check the grind and or clean the brew unit screen.

Have you tried to clean the screen on the brew unit? If yes then try this remove the brew unit, and you will see the white plastic valve, gently lift the little lever to see if water flows out, if it does then problem is in the brew unit. If not then try another descale using scalekleen.

The red oring on the brew unit needs to be replaced or lubed as does the track on the unit it needs to be cleaned of coffee grounds and lubed.

Hi,

If you open the door and take a flashlight, light in the front/middle of the brewing unit. You will see a little screw, take a screwdriver and loosen it, bend little on the little plastic above where the screw was and pull out the brewing unit.
When you have the brewing unit out then you need to reset the machine and brewing unit.

To reset the machine you have to turn off your machine, open the door.
Look in the down left corner, you will see a hole, look in the middle of the machin you see another hole and in the upper right corner.
put a screwdriver or similarly in the left corner and in the middle of the machine, turn on the machine and put another screwdriver in the upper right corner. hold it in place to the machine not get any noise more.

To reset the brewing unit, first put the plastic back again (that one you loosen with the screw first).
If you look back on the backsida of the brewing unit, in the middle you will see a plastic that looks lika a handle, force it down and you will see all the other parts will move around little. Turn it to you can see the little mark on the front goes to the N mark.

Best regards
/Mirran

There is a lever inside the door on the right. It is at the top in the center. Pull it back one click and try again. The crunching noise does it sound like a clicking noise?

The brew group is out of place.
--> --> The brew group cannot be taken out.
--> --> Turn on the machine and close the service door. The brew group will automatically go back into place.
The brew group is out of place.
--> --> The brew group cannot be taken out.
--> --> Turn on the machine and close the service door. The brew group will automatically go back into place.
The brew group is out of place -Turn on the machine and close the service door. The brew group will automatically go back into place.

I had the same problem and got on the Saeco US website and talked to an online support person. She downloaded me a couple of pages of "fixes", I tried them and they worked! You have to take the two screws out of the brew group, remove the spring and a little clear plastic ball. Then clean out the hole thoroughly. I stuck a toothpick up into it from underneath to clean out the coffee that was stuck in the hole. I then put it back together and now it works perfectly.

jammed brew unit, possibly also damaged gears.

Do not keep turning the unit on at this point, cuz it can damage it even further.

Has to be sent out for service, be sure to tell them to check gear system and mention jammed brew drive.