NETA Level III
One of the most common issues found on DS and DSL circuit breakers is a broken spring charge indicator. The problem comes from a lack of exercise. If not regularly exercised, the factory mechanism grease will harden over time, causing the indicator to become stuck on its shaft. Once locked, a pull of the charge handle will force down the indicator, causing it to become locked in place.
Lucky for us, this problem is an easy fix that requires only a flat head screw driver and some penetrating solvent. This repair can be performed with the draw-out breaker on its rails. If work is being done on a bench or lower cubicle, the unit should be raised at least a foot from the floor to easily access the bottom side.
To get started, uncover the operating mechanism by first unscrewing the charging handle ball and then removing the four screws found on the face plate of the breaker. Once you've got the breaker uncovered, reference the procedure below:
Step 1: Locate the spring charge indicator near the L.H. spring crank arm. Liberally spray penetrating solvent around the indicator pivot point. I recommend using PB Blaster or CRC Knock'er Loose. Stuff a rag underneath the spring charge indicator to catch leakage and over-spray. Re-lubricate with penetrating oil.
Step 2: Put your finger through the access hole underneath the breaker to push forward on the small latch located behind the spring charge indicator. With the latch pushed in, try to work the spring charge indicator up and down until it moves freely. Depending on the environment, steps 1 and 2 may have to be repeated multiple times.
Step 3: Inspect the spring charge indicator latch and return tension spring for damage and make sure that the spring is properly connected both through the small hole on the spring charge indicator, and around the small black shaft located on the interlock found in Step 2.
If the repair was successful the spring charge indicator should be able to move up and down quickly and effortlessly. With the front cover removed, now would be a good time to inspect and lubricate the rest of the mechanism as well.
Once you are satisfied, replace the front cover and charge the circuit breaker manually. The spring indicator should change immediately after the charge cycle is completed. Close the breaker to verify that the indicator changes state.
PS: Even with a broken spring charge indicator the circuit breaker will still function. You might find these breakers manufactured by Westinghouse, Cutler-Hammer, EATON, and Square D.
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