Thermal Fuse Assembly From Pdc SP0022078

I found other guides online but my unit was slightly different. I had to drill a rivet out of the back thermal shield cover. I put in a screen slightly larger than the hole to fix it. Basically need to remove all the screws off the back. Unscrew the thermal shield, drill out the rivet. Then you can unscrew the mounting bracket which holds the thermal fuse and sleeve. That will give you room to move the wire around to get at the connections. I pulled of the electrical 'twists', forgot what they are called, the things which twist together a couple connections. These are pressure sensitive ones though. Carefully squeeze it to open it up. Pull out the old thermal fuse wire, put in the old, and squeeze it back together. Be sure you put the fuse back in the right way. One side has a black mark.

This was for a Breville Smart Oven BOV800XL, I believe. Symptom was oven was dead - no power, no lights. There are a number of resources online about how to fix, so check those out. My comments are additions to those instructions. First, definitely remove the feet from the oven fully as it makes it much easier to remove the back. The back removes after taking out a bunch of screws. Note carefully that the screws on the back are similar to but not the same as the small screws at the center of the feet. The back is snug but can be pried off after the screws are removed. Some instructions mentioned needing to remove the interior back plate, involving drilling out a rivet. This was unnecessary in retrospect, and could be a real problem since the door spring attaches to it. To replace the fuse, pull back the two clips that hold the white insulation in place. They are held against the interior back plate with friction only. Gently pull back the insulation and you'll see the fuse. You will need to remove the bracket that holds the fuse by unscrewing the screws via the interior of the oven (come from the front). I used pliers to remove the friction wire nuts after carefully noting the polarity of the fuse (though I'm told it does not matter). I confirmed it by pulling back the white covering to see the actual component underneath. I threaded the new wires into place, replaced the wire nuts, and put the fuse and bracket back. Then reassembled. Oven works great now.

Oven would not power up. Thermal fuse blown. Disassembled oven, back cover off first,(many screws) thermal fuse located to the front of oven so stainless shell needed to be partially removed on that side. problem, stainless shell is held in place by a crimped edge so I needed to carefully bend the shell to dislodge it. The fuse is located behind some lightweight insulation. Confirmed fuse was bad with ohm meter. UN-crimped old fuse connectors and reused them with new fuse. Carefully reassembled. Fuse replacement was easy, but the disassembly and reassemble was not fun.

Is a pain in the butt! Have to remove around 30 screws &1 rivet.
Be careful,as the metal is very sharp & cuts you easily.
The fuse is hidden behind thermal insulation that disintegrates as soon as you touch it.Two screws on the inside oven wall,clip all the plastic wire ties, then pinch the wire nuts open,remove old fuse & replace with new one.Then just reverse the order of screws you removed.

1. I unplugged the machine
2. Turned it on its front
3. Unscrewed the back cover, the rubber "feet/legs" and enough of the other screws on the left hand side in order to get access to the fuse
4. Removed insulation around the fuse as carefully as possible
5. Unscrewed the two interior screws clipping the fuse onto the oven
6. Removed old fuse (in case you're just an "ordinary" person like me, you need to squeeze the rubber protector thingies to un-crimp them and get the wires out), remembering to note which wire connected to which wires
7. Attached new fuse and clip with interior screws
8. Smushed all wires back together and reinserted into plastic protectors
9. Re-crimped them and made sure they were snug (this took a few tries on the first one)
10. Plugged the oven in to make sure it turned on
11. Shouted EUREKA
12. Unplugged machine
13. Replaced insulation as best I could over fuse area (used some metal tape to make it more "secure" and well covered
14. Tried to remember in which order I had removed the screws and screwed them back in

1. Remove back plate > 30 Philips screws.
2. Locate thermal fuse. Remove holding bracket from inside oven. Follow leads to termination points. Remove ties to locate ends.
3. Ensure the black end of the fuse is connected to the same end point as the failed one.
4. Cut the old fuse connections and attach replacement fuse.
5. Test oven to be sure it works before reassembly.
6. Recheck connections.
7. Attach bracket to inside oven. That's very difficult without help from someone.
8. Restest oven.
9. Reattach back plate. That's a little tricky too.
10. Ready for use.
It would have made things a bit easier if I had taken a few pictures of the unit during disassembly. Not being very handy, it took a long time to do as we were being extra cautious with each step.

1. Remove the screws that hold on the back of the oven. Note: In my model, you needed to unscrew the 'feet' as well to release the back.
2. Locate the main power fuse under the thermal insulation on the left-hand side of the machine.
3. Clip the wires on both sides of the blown fuse.
4. Connect the clipped wires to both sides of the fuse. I used automotive wire connectors. Note: it doesn't matter which wires connect, fuses don't have polarity.
5. Tuck the fuse down and return the insulation.
6. Reattach and screw down the back.

1. Remove all screws
2. Pull panel of rear
3. Pull thermal fuse out
4. Cut two wire connections.
5. Butt connect new fuse.
6. Replace fuse location
7. Reassemble

Opened the back of the unit and traced the power wiring to the fuse and tested it. Found it blown and ordered replacement. Breville would not sell me the part but ereplacement would.

Followed the video repair instructions.