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Breville Oracle BES980XL Thermal Fuse Replacement/Detailed Disassembly

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  • Breville Oracle BES980XL Thermal Fuse Replacement/Detailed Disassembly

    I went down the rabbit hole of replacing the thermal fuse on my Breville Oracle BES980XL steam boiler. The problem started when I descaled for the first time. When I tried draining the steam boiler during the normal descale process, it seemed like nothing would come out. I didn't realize this meant the boiler was empty and burning itself up. After the cycle, the steam boiler would not heat up and my machine temp would not go beyond 150 degrees. I tried to run the water through to do the trick some people have advised to clear an air lock, but no luck. After investigation on many forums, I decided it was likely I blew the thermal fuse on the steam boiler. I inherited the machine for free, so I didn't want to pay the $500 to send it back to Breville. I began tear down.

    Disclaimer: I ended up with 5 extra small screws, probably from the base assembly, when I put it all back together. Hope it's not a problem! Maybe you'll catch where I lost them:

    Open the top and back panel the way you would to replace its o-rings. Lay the machine gently on the grind side.

    Remove bottom parts as follows:
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    Last edited by littleyip; 25 May 2019, 03:42 AM.

  • #2
    Remove tubing as follows:
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    Be careful of this washer in the connection to the largest pump.
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    Remove wiring as follows, mainly to make space for moving the steam boiler out:
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    Unscrew 2 screws on the top of the steam boiler assembly, which free it from the case.
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    Remove the rear metal panel and unscrew this white electronics box as follows. Gently pull it back.
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    • #3
      Using a super long screwdriver, maybe with an extension bar, unscrew these 2 screws at the bottom of the Steam boiler assembly. You access these from the top of the machine all the way towards the bottom. They are visible from behind the white electronics box. Note, I was unable to screw one of the screws back in on reassembly, but I don't think it'll be a big problem.
      Click image for larger version

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      Cut the cable ties on these 2 tubes and detach where marked:
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      • #4
        The entire steam boiler assembly should now be free to extract a couple inches. Gently pull it out and tilt away from the side of the machine, towards the grinder, until you can see down the side space. You should see this thermal fuse attached to the side of the boiler. Use plyers or a screwdriver to gently pry the metal tabs to loosen slightly. Then pry out the white rubber sheathed fuse with a flat screwdriver.
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        Trace the brown wire from the right/front side of the fuse to the back of the machine. It ends in a wire nut with another brown wire. Cut off the wire nut as close as you can to the tip.
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        With that end of the wire free, you can pull the fuse out further and slide the rubber sheath off. Cut the fuse off as close to the fuse as possible on the far side of the wire you loosened. Don't cut it on the side you loosened yet. Once you have the fuse and wire free of the machine, take note of the direction of the fuse.

        Here are the specifications on the fuse. 167 degrees Celsius and rated to 10 Amps. I replaced it with a 172 degree C fuse I picked up at Fry's for $1.89.
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        • #5
          Here are just a few more pics that may be useful here or in general for the Oracle.

          The steam boiler heating element ends and drain are at the bottom of the Steam boiler. You can see them through a square hole or the descale access hole, in the base after removing the base as described in my first post. You can test the ends of the heating element with an ohmeter to check it has continuity and some small resistance, which should mean it did not burn out. If burned out, there will probably not be continuity.
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          Remember the wire orientation of the solenoids. White wires on the left, black or red wires on the right, yellow ground on the bottom.
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          Here is what a disassembled Americano/hot water solenoid looks like. My solenoid coil was melted so I just replaced that part from ebay.
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          • #6
            Hey Littleyip this is great. I have almost the exact same problem after doing a descale for first time HOWEVER the coffee boiler heats to 93 and can poor a coffee just fine. It is only the steam wand that won't fill up and work. Do you think it will be the thermal fuse? Or will a dead fuse also effect the coffee

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            • #7
              Thermal fuse on steam boiler only effects the steam boiler. Likely culprit.

              Cheers

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              • #8
                Cool. I did notice that the steamer boiler doesn't even fill with water. Still the fuse you think?
                Jaycar only sell a 192° or a 157° fuse. Which one should I get
                Last edited by Bucky101; 16 June 2019, 10:23 AM.

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                • #9
                  Breville Oracle BES980XL Thermal Fuse Replacement/Detailed Disassembly

                  That would be too high IMO. They sell one a lot closer from memory, or maybe it’s altronics? I would go the lower one.

                  Clean the water probes.

                  Cheers

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                  • #10
                    Sorry, Bucky101 I didn’t see these messages. I am surprised it heats to 93C if the steam boiler isn’t working but yes, it could still be the steam boiler thermal fuse. Mine did not fill until I replaced the fuse. 157C fuse could approximate the 167C original fuse, but closer would be better.

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                    • #11
                      Hello there. I have the Oracle and I have loved it up until I tried to descale it thru the descale option and not it will not heat above 160 degrees. When descaling the right drain screw would not allow anything to drain. The left drain screw drained fine. I let it sit overnight in descaling solution and it open up and drained. I turned it on and it seemed to take for ever and did finally reach 200 degrees. I opened the right drain valve and steam and water shot out. The temperature dropped and has never returned to 200 just sticks at around 160 degrees, Pulled top and and the small boiler above the wand is very hot and large boiler is cold enough to touch. Before I pull it all apart does this sound like a thermal fuse? I know it is not safe but is there a way to bypass thermal fuse w/o all the teardown to be sure that is the issue?

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