In this instructable i will show you how to fix a fresh roast plus 8 home coffee roaster. this will fix you coffee roaster ONLY if it overheated from adding to many beans. the reason it will overheat if you add to many beans, the way it is designed it has to have a certain amount of air flow to keep the machine cool enough and if you happen to put to many beans, they will block the airflow somewhat and cause the machine to overheat. the reason this is fixable, there is a thermal fuse located on the bottom of the heating element, this is what burns out when it overheats, that way it will protect the other pieces of the machine and keep from having a FIRE! in this instructable i will show you how to take apart the roaster, replace the thermal fuse and then put it back together.

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Step 1: Things You Will Need

from left to right in the image you will need: needle nose pliers, a small phillips head screw driver, dikes, a medium phillips head screw driver and a new thermal fuse, you can order a new fuse on ebay. then of course you will need a broken fresh roast plus 8 coffee roaster.

Step 2: Disassembly of the Coffee Roaster

remove the lid, and the bean container (you will not need these pieces until you are finished). then please make sure the roaster is NOT plugged in. you DONT want to be shocked, or possibly killed.

Step 3: Disassembly of the Coffee Roaster 2

now turn the roaster over (making sure it is not plugged into the outlet). take the medium screw driver and take out the 2 screws. you can see the 2 holes on the bottom of the roaster in the picture.

Step 4: Disassembly of the Coffee Roaster 3

you will now need to take your small screw driver and unscrew the 3 phillips head screw from the black plastic cover ( now on the bottom of the picture). you should end up with 3 screws and 3 metal tabs and the plastic cover. set those aside.

Step 5: Disassembly of the Coffee Roaster 4

you should now have something that looks like this. this is the fan for moving the hot air and the heating element. please be careful about damaging (or pulling loose) the wires, they will still be attached to the base of the machine.

Step 6: Disassembly of the Coffee Roaster 5

next you will need to take the fan off of the heating element. take the small screw driver and take the 3 screws out that were in the middle of the tabs from a few steps back. if you do this right, it will release the fan from the heater element. move the fan aside you will not need it for a few steps.

Step 7: Replacement of the Thermal Fuse

you should now have something that looks like this. this is the bottom of the heating element (piece that looks somewhat like a jet engine). the fuse is held in only by the bending the wires around the terminals. you can see the fuse in the picture, it is a small cylinder with 2 wires coming off of each end. you will need the needle nose pliers at this point. take the pliers and unbend the wires so the fuse can be taken off the element. now take your new thermal fuse and install it in the reverse way. the fuses are not polarity sensitive. just be sure that your new fuse is THE SAME temperature rating of you old fuse. if it is not it can cause your roaster to catch on fire or shut off for no apparent reason. make sure the fuse is touching the back of the heating element. now take your dike pliers and clip any extra wire off the thermal fuse (there will be some extra). this is the actual piece that caused the roaster to "break". now it is as simple as putting the roaster back together.

Step 8: Reassembling the Roaster

now take the heating element and fan assembly, put them together the reverse of taking apart. making sure you are not pinching any wires in between the 2 pieces, put the 3 screws back in, make sure to just snug the screws, DO NOT tighten very tight, they will strip being in plastic.

Step 9: Reassembling the Roaster 2

it should now look like this again. get the plastic top cover, lining up the gasket, put the ring back on the heater element using the 3 tabs.

Step 10: Reassembling the Roaster

you will need to line up the top and base, so you can put the 2 base screws. this is the most tricky part of the process, it is possible to pinch a wire so MAKE SURE you did not pinch a wire. once you are sure that you did not pinch any wires you can replace the 2 screws with the medium screw driver.


now you are ready to grab the bean container and lid. remember to only add 2 standard coffee scoops of beans so you dont overheat the machine again. you are ready to roast!

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    2 Discussions


    Question 2 years ago on Step 5

    Any suggestions on replacing the fan motor?


    4 years ago

    LOL I tossed my Fresh Roast about 3 months before you posted this instructable. Sad, I LOVED that thing. I think I just wore it out.