Gaggia Fuseable Link Replacement Instructions

by Whole Latte Love Updated: August 25, 2023 3 min read
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The following are step-by-step instructions for replacing the fuseable link on a Gaggia semi automatic espresso machine. Please read all of the instructions before you start.

Applies to: All Gaggia Aluminum Boiler machines

Tools Required:

  • Phillips Screwdriver #2
  • Wire Crimpers
  • Wire Cutters

Step-By-Step Instructions:

  1. Unplug your espresso machine and make sure that it is cool before attempting any of these instructions to avoid accidental burns.
  2. Remove the top of the machine.
    • The Classic and Coffee both have 2 screws on the top, along the lip of the funnel that leads to the water tank.
    • The Carezza has one screw in the funnel that leads to the reservoir, you also have to remove the screw on top of the steam knob and then the steam knob itself.
    • The Old-Style Espresso has one very long screw that holds the top on and it is located in the funnel that leads to the reservoir. Be careful when removing the top of the Espresso, do not force it or it may crack.
    • The Evolution has a single long screw located under a small, oval cover in the cup warmer tray holding the top in place. Additionally, you will need to gently pry the steam knob off of the machine (pry straight off to the right), as the top cover loops around the base of the knob.
  3. Double check to make sure that the machine is not plugged in.
  4. With the top off you can see the boiler. It is the big silver block right over the brew group with all the wires leading to it.
  5. Locate the one Phillips head screw on top of the boiler that is holding down a brass clip.
  6. Under the brass clip is a plastic tube with wires coming out of both ends of it. The fuse link is in this rubber tube.
  7. Remove the Phillips head screw and cut the two small plastic ties at either end of the plastic tube.
  8. Slide the plastic tube towards the front of the machine. You may also have to cut two or three plastic ties that hold the wires together so that you may move the plastic 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, very close to the existing crimp connector so that the wires will not be shortened very much.
  11. Strip the wires. 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 by simply cutting the straight part a bit shorter.
  13. Install the new fuse (does not matter what way it faces) using the crimp connectors provided. The connectors are two different sizes -- the small one is for the single wire from the front of the boiler and the larger connector is for the two wires coming from the back of the boiler.
  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 were cut when moving the rubber tube.
  19. Install the brass 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 top of the machine back together, plug it in and test it out.
  22. If you run into any trouble or have any questions please give us a call or send us e-mail.