Whelen 994PA Reapir help, por favor

[Pimp]

I have a Whelen 994PA 4 beam, rotating halogen beacon/siren speaker combo.











I applied power, I got spin and no lights. So, I tested the bulbs individually, they work.











Ok, so I figured we must have a wiring problem. I turned over the motor mount tray and found this:











The terminal/spade connector is supposed to (I assume) connect to the bottom of the spinning shaft, to deliver power to the bulbs. I touched it in this fashion and WALA, it worked. At this time the metal part that was in the terminal/spade connector broke off.











It appears as if the terminal/spade connector may be burned/melted.





Here's my problem. The connector piece doesn't stay on the shaft any more. It appears that the hole is drilled out too big. I am possibly about to sell this light and want to know how I can properly repair this. Other than this issue the light looks and functions great!

 

[badge22]

Isn't that a 994PA?

 

[Pimp]

why yes, it is! good call. I have 5 or 6 of the 5200PAs and only two of these, I was confrused.

 

[Pimp]

Wow, nobody?





I was hoping to have this fixed today.

 

[Steve0625]

Wow, nobody?



I was hoping to have this fixed today.

Burt, is the oversized hole you are talking about on the end of that cone shaped shaft that the black arrow is pointing at?


[Broken External Image]:http://i920.photobucket.com/albums/ad42/Steve_Collins/2011-08-06_22-45-18_20.jpg


If so, it looks like there is enough of the screw left to grab with channel-locks and get it out of there.


Then, determine the screw size and go buy a tap the next size larger and a screw the same length and head as the original, but in the larger size.


Gently use the tap to re-thread the hole to the new size. If the tap won't go all the way in after a couple of tries, you may have to drill a bit. Be very careful, and go no more than 1/64 larger at a time. If you over-drill, you may not be able to recover.


Once the hole is done, you should be able to replace the tab using a larger screw.


Then just replace the burned wire and spade lug and you should be good to go. (If I were working on that, I'd go one size larger on that little piece of wire, too.)