Originally Posted by vinr
The housing on my breakaway switch appears to be melted and I have to force the actuator pin in. I am going to replace it but I'm wondering why it happened and if there is something I can do to prevent it from happening again. The other possibility is that it is just defective. Any thoughts will be helpful.
If you pull the pin for anything other than for testing very briefly, you risk ruining the switch. It happens a lot to those who inadvertently have the pin pulled by hanging the cord up on something accidently......or for those who are under the false premise that you use the breakway switch as a parking brake.
If the pin was pulled/removed for very long then they very commonly do melt with the full 12 volts from the battery being applied....as well as the converter trying to recharge the battery if plugged into a 120 volt outlet at the same time.
Did you pull the pin for some reason? Children are sometimes guilty and I think we even had one member whose dog was doing it.