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:
Take off top cover.
Push in 2 tabs on the sides towards switch body and pull out switch assembly with wires.
Mark all wires and remove them.
Remove locking tabs - they have smaller tabs with holes and have to be slightly bend avay from the switch body.
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.
Clean contacts if dirty and lubricate them - use excess grease which you find inside the switch.
Replace neon light if faulty. One of power light leads is soldered to copper tab, brew light is not soldered.
Position movable contacts and small spring for brew pilot light in switch body.
Put springs in the rockers. Grease helps to keep them in position.
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.
Insert other 2 rockers with their springs. Release pressure on the shaft when it comes out on other side of body.
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.
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