ctek mode switch fix

[richardfleming]

I have a couple of 3.6 ctek trickle chargers and irritatingly both seemed to stop working at more or less the same time. I thought they'd both barfed completely but given two of them the same that was unlikely, I did a bit of diagnosis and research and discovered it was the mode switch at fault, rest of it was fine.

the fault was that the mode switch when pressed - did nothing - plugged in to car or not, it would not activate.

But when I took it apart and bypassed the switch it worked perfectly. So did a quick search through RSonline for a suitable part and found it.
got some new switches, modified them a bit, de-soldered the old one, soldered in the new one - and perfectly working ctek chargers again (both of them perfect).

if anyone has the same issue, you need this part from RS Electronics (there might be more exact replacements but I couldnt find - and this one works)
[*]RS Stock No. 479-1435 [/LIST]a screwdriver, a soldering iron, and a steady hand for desolering/resoldering the switch in.
here's what you need to do

disconnect from the power supply (...sorry have to say that don't I...)
unscrew the back plate
pull out both power cables at each end from the main housing (they pop out with gentle pulling)
lift out the circuit board gently about half way (grab metal heat sinks and lift from there)
and rotate it around the longitudnal axis 180 degrees so the bottom faces up
you can now see the mode switch with a black cap
pull the black cap off
desolder the switch below it
now get your new switch
bend it's legs carefully flat to match the old one
clip off excess leg length
clip off the top of the switch to the same height as the old one (incl black cap)
solder back in
you may want to epoxy the old cap onto the new switch or such but not critical
flip the board back around and pop the cable ends in and screw the back on again
job done!
p.s. check switch height is right by trial reassembling before gluing any new switch cap on - the switch should be just below the plastic outer cover so it doesn't get pressed when the case is reassembled. if too high, just clip a little bit more off the switch actuator to lower it a bit.

takes about 15 minutes - and if you're as mean as me and irritated at buying a new ctek because of minor malfunction then here's the solution
or you can just buy a new one.

 

[turbo jonny]

Great post , thanks

 

[Tony]

Excellent!
Have a couple of these one of which has the same problem.

Thanks for this
Tony

 

[kennyrobinson]

Very useful ...... thank you

 

[richardjjs1]

Is this a design fault
Why are so many failing Have you spoken to CTEK

 

[richardfleming]

Is this a design fault
Why are so many failing Have you spoken to CTEK

probably yes, or designed end of life - either way from my perspective my receipt is long gone, and I can't even remember where I bought it - and with ctek all warranty claims are via the reseller. So given it's age and lack of paperwork, my choices were limited - bin it and buy new or fix it.
if you have a dig around google on this topic you'll see several hacks to fix it or repair the switch - all looked like ugly bodges to me - so replacing the switch is neater and pretty easy so I did that.

 

[991JAW]

https://www.youtube.com/watch?v=F1NRN2u8d5E this link might help but basically what Rich has posted but in pictures.

 

[TerryUrquhart]

# Me Too

Thanks great post.....
I like the CTek charger but it has had a few little design issues along the way ....

The MX 5.o Xs is a good result now though ( so far )

 

[991JAW]

This is the issue I had and found this gem on youtube ..... it worked for me .....

https://www.youtube.com/watch?v=5Rx_RXGKGj4
followed the video clip and now it works better than ever as it was always a bit hit and miss to start with .