Dimmer switch

Cacti_Ken · Post by **Cacti_Ken** » Thu Nov 03, 2011 12:04 pm

Dimmer switch with Douglas connectors didn't last long.
Ever have your lights go out while driving down the Hiway? Not a good feeling.
After being in service for four years but hardly ever used the switch bit the dust recently. As I was rolling down the hiway I switched to Hi Beam and everything went black. I swithed again and lights came back on. I left it alone on till I got to where I was going. Then I switched it again and the lights went out. I hit it a couple of times and the breaker popped.

jimm · Post by **jimm** » Thu Nov 03, 2011 6:38 pm

Are you sure the problem lies in the switch and not somewhere else in the high beam circuit? "Going black" sounds like an open circuit fault, which could easily be due to the switch, but popping the breaker doesn't. That's an overload condition, possibly due to a short to ground either within the switch or somewhere downstream of it.

And, to answer your question, yes, I have had the lights go out while driving at night. Guaranteed to get your attention!

Post by **wesk** » Fri Nov 04, 2011 2:03 am

The Circuit breaker in the later light switch is automatic resetting and on the road you may not even hear it trip and reset. Since it is tripping at home I would first disconnect the high beam wires from the hi/lo switch and operate the switch. If it still pops the circuit breaker then pull the switch. If it does not and you get a correct voltage reading at the hi beam wire terminal for the switch then look for a short after the hi/lo switch. Don't for get to look along both the hi beam wires going forward to the left lamp and then over to right lamp and then the wire going up to the dash indicator lamp.

Cacti_Ken · Post by **Cacti_Ken** » Fri Nov 04, 2011 2:39 pm

I am positive the problem lies in the switch. A poor quality switch (my opinion). I first used an ohm meter to determine a short in it. After taking it part, doing a little modification, reassemblying it and testing, I resolved the grounding but still have no continuity on one contact to common/Bat. Anyway this is what it looks like on the inside.

Gluing the spring to the base just made it easier to assemble,but still can't get it to work right.

Post by **wesk** » Fri Nov 04, 2011 9:48 pm

Looks like an off shore repop switch.

RICKG · Post by **RICKG** » Sat Nov 05, 2011 9:33 am

Here's an old switch marked
DOUGLAS MFG. DIV
BRONSON MICH.