Does Your Gaggia need a new thermal fuse?

The thermal fuse is located on top of the boiler, inside a piece of silicone rubber tubing held to the boiler by a metal clip.

Check the fuse by placing one lead of a multimeter on one end of the fuse and the other lead on the other end of
the fuse. If there's no continuity, then the fuse has blown and needs replacement.

Things you'll need:
* Phillips screwdriver #2
* Wire crimpers
* Wire cutters
* 2 non-insulated butt connectors
* 184º C thermal fuse

The following are step-by-step instructions for replacing a Gaggia espresso machine thermal fuse. The following models are included: Classic, Baby, Coffee, Espresso, Evolution and  Carezza.
Read These Instructions Completely Before Starting.
1. Unplug the espresso machine.
2. Remove the top of the machine.
3. Check to make sure that the machine is not plugged in; then check it again to be safe!
4. With the top off you can see the aluminum boiler.
5. Locate the Phillips head screw on top of the boiler that is holding down a clip.
6. Under the clip is a silicone tube with wires coming out of both ends of it. The thermal
fuse is in this rubber tube.
7. Remove the Phillips head screw and cut the two small plastic ties at either end of the
rubber tube.
8. Slide the rubber tube towards the front of the machine. You may have to move the
switches on the machine if they are in the way. You will also have to cut two or three
plastic ties that hold he wires together so that you may move the rubber tube forward.
9. Leave the rubber tube on the wires so that you can slide it back over the new fuse.
10. Cut the wires that lead to both sides of the fuse. Cut it very close to the existing crimp
connector so that the wires will not be shortened very much by cutting the wires.
11. Strip the wires that you just cut back about ¼”.
12. Before you install the new fuse make sure that that the rubber tube will be long enough to
cover the whole fuse and it connectors with at least ¼” to spare. Cut the fuse shorter if
necessary.
13. Install the new fuse (does not matter what way it faces) using non-insulated butt
connectors (Radio Shack).
14. Crimp the connectors onto the wire and fuse firmly but not so firm as to cut the
connector.
15. Pull on the fuse and the wire to make sure that there is no movement and the connection
is secure.
16. Slide the rubber tube over the fuse.
17. WARNING: Make sure that that all wires and the fuse are in the rubber tube.

18. Install new wire ties on the ends of the fuse link and replace any that where cut when
moving the rubber tube.
19. Install the clip and Phillips head screw making sure that the fat part of the fuse link is
located under the clip.
20. Make sure that the fuse/rubber tube is securely held in place by the clip.
21. Put the machine back together plug it in and test it out.

 

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