When my shop vacuum wouldn’t turn on, I started by investigating the switch. On many portable tools and small appliances, mechanical on-off switches—the ones with a satisfying click—can wear out, and they’re usually easy to replace.
Before sleuthing, unplug the tool so it isn’t energized. Next, you’ll need to access the switch. Owners’ manuals with exploded views can assist with disassembly; otherwise, start with the fasteners that appear to hold the chassis together. Work carefully, check for hidden screws under labels, and record your steps with your smartphone camera (for reference when you’re putting it together again).
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Look for melted or darkened insulation, oxidation, or corrosion on and around the terminals. Sometimes, cleaning the switch terminals with a brass brush and replacing the wire clips can get you back in the game. If the switch appears normal, remove it to test it using an electrical multimeter. With the black probe in the “com” port, the red probe in the Ω port, and the meter set to the lowest ohm (resistance) rating, check what the display reads when the probes aren’t touching anything (usually it’s 1, flashing zeroes, or OL). If the display remains the same when the switch is off and you place one probe on each of the two connections, but it gives a different reading when the switch is on, the switch is good.
If a simple on-off switch fails the multimeter test, it needs replacing. With the part number from the owners’ manual, you may be able to order a new switch from the manufacturer. Otherwise, search online—you’ll need to match the switch size and type, as well as the amperage rating. Any tiny numbers on the switch can help you narrow the search quickly. To install a switch, just reverse what you did to remove it.
This article was originally published in the June/July 2024 issue of Cottage Life.
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