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| TROUBLESHOOTING AND REPAIR |
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
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STATOR REMOVAL PROCEDURE
1.Remove engine spark plug wire to prevent accidental kickback or starting.
2.With the 5/16” nut driver, remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover.
3.With the slot head screw driver, remove the 6 sheet metal screws that hold the control panel to the control box - 2 on each side and 2 on the bottom. You may need to use the 5/16” end wrench on the engine side because of limited clearance. Pull the panel away from the control box.
4.Using the 7/16” wrench, remove the two bolted reactor lead connections. See
Figure F.15.5.Using the 1/2” socket wrench, remove the two bolts and star washers mounting the reactor to the stator assembly. See Figure
F.15.6.Carefully remove the reactor.
7.Using the 1/2” socket wrench, remove the two remaining bolts and star washers securing the control box to the stator assembly. See Figure F.16.
8.Using the 5/16” wrench, remove the five sheet metal screws securing the control box to the stator frame. CAUTION: One of the screws secures the green grounding lead to the frame of the machine. See
Figure F.16.9.Unplug the large molex plug. See Figure
F.16.10.Carefully remove the flashing lead #205 from diode D2 and clear lead from the con- trol box. See Figure F.15.
11.With the 9/16” open end wrench, remove lead W2 from the output terminal. With the diagonal cutters, cut the cable tie that holds the two output leads together. Pull lead W2 back out of the way. Screw the bolt back into the output terminal hole loosely for reassembly. See Figure F.11.
12.Remove the brush holder assembly. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fin- gernail. The cover will drop open on its bottom hinge. With the 1/4” nut driver, remove the 2 screws that hold the brush holder assembly in place. With the needle nose pliers, gently remove the two leads #201 and #202A. Note lead placement for reassembly. Set the brush holder aside. Pull the wires up into the control box.
13.Slide the control panel and box assembly out of the machine cradle. Carefully pull the wire leads down through the box as you remove it.
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FIGURE F.11 - OUTPUT LEAD LOCATION
TIE WRAP |
2 |
W |
1 |
W |
OUTPUT |
TERMINALS |
POWERARC® 5500 |
