Breville BCG400SIL Troubleshooting Guide

Page 2 - INTRODUCTION; during use at some point. This is usually due to a worn out impeller; This is a 3D printed part.

INTRODUCTION Many users of the BCG800XL SmartGrinder experience jamming or clogging and a horrible gear- stripping, clacking sort of sound during use at some point. This is usually due to a worn out impeller or -less commonly- a stripped drive gear. This guide will show you how to inspect the and re...

Page 3 - Step 1 — Inspect your grinder impeller

Step 1 — Inspect your grinder impeller Unplug your grinder before completing this repair to avoid electric shock.  Remove the hopper and take the upper burrs out. Empty out any coffee grounds (An air gun orvacuum helps) and then inspect the impeller blades.  If the impeller can fit through the hol...

Page 4 - Step 2 — Obtaining a new impeller; Shapeways BCG800XL Impeller Shop; Step 3 — Tools you'll need

Step 2 — Obtaining a new impeller I modeled and 3D printed this replacement part it several times at the local library. I've made thefinal design available for printing at www.shapeways.com (See link below). Of course, you canalso model your own design if you wish to spend the time.  Shapeways BCG8...

Page 5 - Step 4 — Remove hopper, upper burrs, and lower burrs; Remove the hopper and upper burrs.

Step 4 — Remove hopper, upper burrs, and lower burrs Remove the hopper and upper burrs.  Use a 10mm socket to remove the nut for the lower burrs.  The nut for the lower burrs is reverse threaded. Rotate clockwise to loosen.  Turn the grind-adjustment knob to the finest setting.  Remember what or...

Page 6 - Step 5 — Remove the base; Unwrap the power cord and remove the 4 screws from the base.

Step 5 — Remove the base Unwrap the power cord and remove the 4 screws from the base.  Remove the four rubber pads  Slide the power cord through the hole in the base while lifting the base away from the grinder.  BCG800XL Grinder Jamming due to Worn… Draft: 2020-12-02 Guide ID: 62905 - This docum...

Page 7 - Step 6 — Remove 4 screws holding the top on; Flip the grinder over and slowly lift away the top.

Step 6 — Remove 4 screws holding the top on Use the long Phillips #2 driver to remove the 4 screws holding the top in place.  Flip the grinder over and slowly lift away the top.  The top is still attached to a wire so the lid will hang off to the side.  BCG800XL Grinder Jamming due to Worn… Draft...

Page 8 - Step 7 — Remove the front display; Remove the two screws from the top of the display.

Step 7 — Remove the front display Remove the two screws from the top of the display.  Lift the display up and out of the frame.  BCG800XL Grinder Jamming due to Worn… Draft: 2020-12-02 Guide ID: 62905 - This document was generated on 2020-12-04 12:47:34 PM (MST). © iFixit — CC BY-NC-SA www.iFixit....

Page 9 - Step 8 — Gear / Burr holder Assembly Removal; Be sure the grind knob is turned to the finest setting.

Step 8 — Gear / Burr holder Assembly Removal Be sure the grind knob is turned to the finest setting.  It's critical that the alignment be preserved when removing the gear assembly. The small gear inthe picture is an encoder. Its purpose is to track the position of the grind adjustment level so itca...

Page 11 - Step 11 — Installing the 3D Printed Impeller Replacement; of the fit-up with the Shapeways printed part.

Step 11 — Installing the 3D Printed Impeller Replacement It is important for the 3D printed part to fit properly. Tolerances of the design error on the tight side.  Check that the burr drive pegs fit the holes of the conical burrs. If it’s too tight, apply a smallamount of sanding to the impeller a...

Page 12 - Step 12 — Checking Fit and Burr Elevation; and then come

Step 12 — Checking Fit and Burr Elevation Before reassembly, check that the conical lower burr and impeller fit well onto the driveshaft withboth steel washers underneath. Make sure all parts in the cutaway diagram are accounted for.  The lip on the drive shaft should be within about 0.5mm of the t...

Page 13 - Step 13 — Reinstall the Gear / Burr holder assembly; Avoid rotating these pieces to maintain alignment.

Step 13 — Reinstall the Gear / Burr holder assembly With the following pieces aligned carefully set the gear assembly into place:  Avoid rotating these pieces to maintain alignment.  As you set the assembly into place, make sure the two stop-screws are on the left side of theblack plastic stop.  ...

Page 14 - Step 14 — Optional Modification for Better Grind Adjustment Range

Step 14 — Optional Modification for Better Grind Adjustment Range Advanced Modding Tip: If you wantgreater grind-control range, you canback out the two screws in the biggear in the photo. You will then beable to adjust the grind muchbeyond the normal range. Caveats:Go too fine and the grounds become...

Page 15 - Step 15 — Reinstall the Display and the Conical Lower Burr

Step 15 — Reinstall the Display and the Conical Lower Burr Place the display back into theframe and screw in the two screwsthat hold it in place.  Put the conical burr in place makingsure it sets on the drive pegs of thenew impeller properly.  Place the washers on whilemaintaining their original o...

Page 16 - Step 16 — Put the top back on and screw it back in; Put the plastic top back on.

Step 16 — Put the top back on and screw it back in Put the plastic top back on.  Flip the grinder over and use the long Phillips #2 screwdriver to reinstall the 4 screws that hold thetop in place.  If the screwdriver is not already magnetized, it'll be worth rubbing a magnet on it to do so prior t...

Page 17 - Step 17 — Reinstall the bottom; Screw back in the four base screws.

Step 17 — Reinstall the bottom Put the four rubber feet back inplace.  Screw back in the four base screws.  Re-wrap the cord.  BCG800XL Grinder Jamming due to Worn… Draft: 2020-12-02 Guide ID: 62905 - This document was generated on 2020-12-04 12:47:34 PM (MST). © iFixit — CC BY-NC-SA www.iFixit.c...

Page 18 - Step 18 — Reinstall upper burrs and hopper; and perhaps help us spread awareness. Cheers!

Step 18 — Reinstall upper burrs and hopper Put the upper burr back on and reinstall the hopper (without coffee beans yet).  Run the (empty) grinder briefly to make sure it all sounds OK. Try both coarse and fine grindsettings.  If all sounds well, add some coffee to the hopper. Dial in the grind a...

Page 20 - Step 20 — Troubleshooting #2 - Burr Clearance

Step 20 — Troubleshooting #2 - Burr Clearance TOO CLOSE (ie: grinding too fine): If the burrs are too close, or even touching (but centered), thenut on the lower burr may not be tight enough. With the ratchet and 10mm socket, give it a quickcounter-clockwise jerk. If that fails, recheck your fit-up ...

Page 22 - This is not yet verified to

The drive gear on the right has apotential source found by a userbelow (Thanks Dave Gordon!): http://www.forumappliances.com/breville-... This is not yet verified to work, but the price is reasonable, soif you try it out and it works, postbelow so we can know!  BCG800XL Grinder Jamming due to Worn…...