I have replaced the pot(s) in both a G5400 and a G5500, both had AC motors. It is not too hard, but you need to make sure you align everything before you start putting it all back together.

I also learned there is an inherent flaw in the setup and the pot isn’t exactly what usually fails. There is a wire that runs from the bottom center of the pot to the small circuit board that is part of the pot. This wire twists every time the pot turns. This wire likes to fail right where it is soldered to the center of the pot. It usually looks intact, but is in fact intermittent.  Resoldering the wire pushing it further into the solder bead usually fixes it temporarily (a year or two).

A more permanent fix is to replace the wire with a longer (more flexible) stranded piece of wire. The wire likes to ‘harden’ where it is heated to accept the solder. Some additional heat shrink, or some epoxy can add strain relief making the wire flex away from the solder joint. The units I have done this to did not fail afterwards.

Just my experience.

73,

Joe kk0sd

From: alex weimer <[email protected]>
Sent: Thursday, March 31, 2022 12:54 PM
To: [email protected]; Calvin McDonald <[email protected]>; [email protected]
Subject: [AMSAT-BB] Re: Yaesu G5500DC problems?

I had the same problem with my G450A and sent it in twice to Yaesu . They replaced the pot twice and again the same problem happened. Thanks for the info 73 JACK KC7MG

On March 31, 2022 at 1:49 PM Calvin McDonald <[email protected]> wrote:

I bought one just short of a year ago.  Out of the box or shortly thereafter (not sure exactly) it starting having problems with the azimuth position pot.  Not enough to cause problems - just bouncing the meter needle a little.  It progressively got a little worse over the first 2-3 months so I called Yaesu support the we ran a few tests to prove it was the azimuth pot.  It has a 3 year warranty but the round-trip repair time was quoted at 1-2 months!  Because it still isn't malfunctioning (even under computer control), and seems to be less of a problem through the colder winter months, I have put off sending it in ... and have even considered ordering the pot and putting it myself (would like to hear from someone who has done this).  So at present I'm kicking the can down the road.  I use it almost daily and other than the pot being a bit flaky it has worked fine for the year I have had it.

Cal - N7AY

On 3/31/2022 11:18 AM, alex weimer wrote:

I am contemplating buying a new Yaesu G5500DC rotor but have heard that the new DC motors were having problems. I wonder if there is anybody that has purchased the new DC rotors and what their comments are. I bought a new G350DC azimuth rotor and had to send it back twice for erratic needle movement. I would hate to pay $800 for a new G5500DC rotor and have the same problem. 

Thanks for any info   JACK  KC7MG

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