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Gaggia Classic switch disassembly / pilot light repair
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witoldb
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Joined: 15 Aug 2013
Posts: 118
Location: Dubai UAE
Expertise: I like coffee

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Posted Fri Aug 30, 2013, 12:50pm
Subject: Gaggia Classic switch disassembly / pilot light repair
 

Brew ready pilot light in my machine was sometimes not working due to bad contact.
I could not find any info about repair only suggestions to replace the whole switch assembly at ridiculous price.
It's quite easy to take it apart and repair in following sequence:
  1. Take off top cover.
  2. Push in 2 tabs on the sides towards switch body and pull out switch assembly with wires.
  3. Mark all wires and remove them.
  4. Remove locking tabs - they have smaller tabs with holes and have to be slightly bend avay from the switch body.
  5. Push down on one of the outer switches while keeping in midway position and push out the shaft from other side. Do it
    in plastic bag as all internal parts will jump out.
  6. Clean contacts if dirty and lubricate them - use excess grease which you find inside the switch.
  7. Replace neon light if faulty. One of power light leads is soldered to copper tab, brew light is not soldered.
  8. Position movable contacts and small spring for brew pilot light in switch body.
  9. Put springs in the rockers. Grease helps to keep them in position.
  10. Put brew switch into the body aligning both springs, keep it horizontal, press down and insert the shaft.
    Do not release the shaft, keep it horizontal and pressed down otherwise all parts will jump out.
  11. Insert other 2 rockers with their springs. Release pressure on the shaft when it comes out on other side of body.
  12. Bend back locking sections in the tabs and push them into the switch sides until they touch the shaft.
    See photo for positioning of moveable contacts.


witoldb: contacts assembly.jpg
(Click for larger image)
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witoldb
Senior Member


Joined: 15 Aug 2013
Posts: 118
Location: Dubai UAE
Expertise: I like coffee

Espresso: Sanremo Treviso LX,...
Grinder: Vario,Elektra MXS,...
Roaster: DIY 250g drum roaster
Posted Fri Aug 30, 2013, 12:52pm
Subject: Re: Gaggia Classic switch disassembly / pilot light repair
 

Brew switch with neon light

witoldb: switch1.jpg
(Click for larger image)
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witoldb
Senior Member


Joined: 15 Aug 2013
Posts: 118
Location: Dubai UAE
Expertise: I like coffee

Espresso: Sanremo Treviso LX,...
Grinder: Vario,Elektra MXS,...
Roaster: DIY 250g drum roaster
Posted Fri Aug 30, 2013, 12:55pm
Subject: Re: Gaggia Classic switch disassembly / pilot light repair
 

Rockers with springs.
One lead of power light is soldered to copper tab - top left on the photo.

witoldb: switch assembly.jpg
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witoldb
Senior Member


Joined: 15 Aug 2013
Posts: 118
Location: Dubai UAE
Expertise: I like coffee

Espresso: Sanremo Treviso LX,...
Grinder: Vario,Elektra MXS,...
Roaster: DIY 250g drum roaster
Posted Fri Aug 30, 2013, 12:58pm
Subject: Re: Gaggia Classic switch disassembly / pilot light repair
 

Locking tab - part with small hole has to be bend back as shown before pushing back into the switch body.
Do not bend too much as it will break.

witoldb: clip2.jpg
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