How to Replace a 3-Position Switch on a Benchtop Battery Charger

As reliable as they are, the components in benchtop battery chargers still experience significant wear over time. One common issue is a three-position switch that becomes difficult to move between charging rates or stops working properly. Fortunately, replacing the switch can be a straightforward repair when you have the correct replacement part and understand how the switch is wired.

In this guide, Scott from PLP Battery Supply walks through the replacement process for a three-position switch commonly found on handheld and benchtop battery chargers.

Key Takeaways

• Three-position switches allow a tabletop battery charger to operate at different charging rates or outputs.
• A worn switch may become difficult to move or may no longer function properly.
• The PLP Battery Supply 696364 switch kit includes the components needed to replace the original riveted switch.
• The original switch uses a contact bridge to provide three operating positions.
• Another three-position slide switch, part 696363, is available but does not include the contact bridge, meaning the center position usually functions as an “OFF” state.
• When replacing a switch, transfer the terminals one at a time to help maintain the correct wiring configuration.

Why Replace a Benchtop Battery Charger Switch?

Many handheld or benchtop battery chargers use a three-position switch to select between different charging rates or outputs. With repeated use over the years, the switch can become stiff and difficult to move between positions.

Rather than replacing the entire charger, replacing the worn switch may be an option. PLP Battery Supply offers replacement switches designed to help restore the functionality of compatible tabletop battery chargers.

How the Original 3-Position Switch Works

The original switch is mounted at the front of the charger and is secured with rivets. Inside the switch is a contact bridge that moves power between the different sets of terminals.

The switch has three positions: left, center, and right. The contact bridge allows the charger to use all three positions to provide its different charging outputs.

Because the original switch is held in place with rivets, replacing it requires drilling out the existing rivets before installing the replacement.

Installing the Replacement Switch

Always make sure the charger is disconnected from power before working on its internal components, and if you're not comfortable performing electrical repairs, consult a qualified technician.

PLP Battery Supply's 696364 switch kit provides an alternative to the original riveted switch installation. Instead of using rivets, the replacement switch is secured with screws and nuts. The kit also includes a contact bridge and a fish paper insulator for the back of the switch.

Once the original switch has been removed, the terminals can be transferred to the replacement switch. Scott recommends moving and attaching one terminal at a time, which can help keep the wiring configuration organized during the replacement.

The replacement switch is installed from the backside of the charger's faceplate and secured using the included screws and nuts.

696364 vs. 696363 Switch Kits

PLP Battery Supply also carries another three-position slide switch, part 696363. While the two switches may look similar, there is an important difference.

The 696364 replacement kit includes the contact bridge needed for all three operating positions. This allows the switch to function in the left, center, and right positions.

The 696363 kit does not include the contact bridge. As a result, it functions in the left and right positions, while the center position is usually an “OFF” state.

Choosing the correct switch is important because these two parts don't provide the same functionality.

Need a Replacement Switch for Your Battery Charger?

A worn or difficult-to-operate switch doesn't necessarily mean it's time to replace your entire tabletop battery charger. The right replacement component may be all you need to get your charger functioning properly again.

If you're unsure which switch your charger requires, the PLP Battery Supply team can help. Have questions about the 696364 kit, 696363 kit, or another battery charger replacement part? Give PLP Battery Supply a call at 800-642-3451 for assistance.