ASCO — Operator Coil Replacement
Repair & overhaul · Solenoid coil assembly
From a ASCO service manual — check it applies to your exact model before use.
Before you start
- Do not insert any metal tool inside the core tube.
- Hold coil assembly securely when removing screws; spring exerts substantial force.
Procedure
- Disconnect all power sources to switch before working on it.
- Close top main contacts using manual operator handle to Emergency position.
- Disconnect rectifier: pull off four terminal lugs, bend wire leads away.
- Remove clip assembly: remove two screws with 5/32" hex key wrench.
- Remove core spring from core.
- Remove retaining ring from groove in stub core.
- Remove core tube and stub core from frame.
- Remove coil and washers from side of frame.
- Install new coil with washers at far end, leads up facing large hole.
- Install new core tube with stub core through frame, coil, spacer washer, spring washer.
- Install retaining ring to secure core tube.
- Apply lubricant from kit 625550-001 to inside of core tube and new core spring; insert spring.
- Install coil assembly onto solenoid core and secure with two screws.
- Replace rectifier if necessary; reconnect coil leads (pink lugs) and ac control wires (white lugs).
- Manually operate switch to check solenoid action; return to Normal position.
Tools required
- 5/32" hex key wrench Amazon
- screwdriver Amazon
- pliers Amazon
- pencil or wood dowel Amazon
- manual operator handle Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Lubrication kit 625550-001 Amazon
Source: ASCO service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.