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RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE (continued)
TROUBLESHOOTING AND REPAIR
F-30 F-30
POWERARC® 5500
PROCEDURE
1. Remove the spark plug wire.
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 allen wrench, loosen the
screw that holds the knob to the
rheostat shaft. The shaft has a flat
for locating the knob at reassembly.
4. With a 9/16” open or box end
wrench, remove the nut that holds
the rheostat to the control panel.
Support the rheostat with your hand
as you turn the nut. There is a
shake-proof washer under the nut.
5. Pull the rheostat back out of the con-
trol panel and lay it out on its wires to
loosen the nuts that hold them.
6. With the 11/32” open or box end
wrench, remove the brass nuts from
the wire terminals. Support the ter-
minals as you turn the wrench to
avoid ripping the terminals from their
foundations. Note the wire locations
for reassembly.
Note: The brass screws are double-nut-
ted with a shake-proof star wash-
er under the screw head.
7. To reinstall the rheostat, replace
each of the brass screws. Place a
shake-proof star washer under the
head, insert the screw into the
rheostat and tighten down one nut.
Replace the appropriate wires and
tighten down the second nut.
Again, support the terminals as you
turn the wrench to avoid ripping the
terminals from their foundations.
8. Reassemble the rheostat to the
front of the control panel. Line up
the locating tab on the rheostat
with the slot on the control panel
hole.
9. Reassemble the shake-proof star
washer and nut and tighten secure-
ly with the 9/16” wrench.
10. Locate the flat spot on the shaft,
line up the knob locking screw,
push the knob onto the shaft and
tighten the screw with the allen
wrench.
11. Check the rheostat knob for proper
rotation, minimum to maximum.
12. Replace the top cover of the con-
trol box and tighten the 8 sheet
metal screws with the 5/16” nut dri-
ver.
FIGURE F.8 - RHEOSTAT REMOVAL
See Figure F.8 for steps 3 - 9.
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