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Steel
Shaft
Coil
Spring
Spring
Clip
Flat
Washer
Insulator
Tube
Springs
Contacts
Insulator
(Short Insulator Tube Not Shown)
Output
Stud
Output
Stud
Bracket
Brush
Holder
FIGURE F.21 – INSULATOR & SPRING LOCATIONS
OUTPUT CONTROL UNIT (VARIABLE REACTOR)
INSPECTION AND SERVICE PROCEDURE (continued)
PROCEDURE
Servicing the rotating brush holder and output
stud assembly:
Thoroughly clean and inspect the rotating brush holder
assembly and the output stud assembly.
10. Examine the insulators on both assemblies. See
Figure F.21. Replace any that are worn, damaged
or missing. If the shaft insulation tube requires
replacement, position the shaft and tube per
Figure F.22, and torque the two 5/16-18 Hex head
screws to 8 Ft-Lbs.
11. Disassemble the output stud assembly and check
the insulating washers and tube. Replace them if
they are damaged or worn and re-assemble the
output stud assembly. See Figure F.21
12. Check for grounded output stud and brush holder
assemblies by measuring the resistance as fol-
lows:
From the steel shaft to the rotating brush holder
From the copper output stud to the output stud bracket
The resistance should be very high, 500,000 (500k)
Ohms min.
If any of the contacts on the brush holder assembly are
damaged, install all new contacts and new springs.
13. Assemble the flat washer, spring clip, and coil
spring to the shaft. See figure F.21
14. Apply a thin layer of grease to both the output stud
and the inside of the brush holder that mates to the
output stud. Grease should also be applied to the
area around the hole where the shaft passes
through the front panel.
15. Insert the brush holder and output stud assembly
through the output control unit and through the
hole in the front panel. Be sure the output stud
bracket is positioned correctly. The insulated stop
should be on the left when facing the back on the
output control unit.
TROUBLESHOOTING AND REPAIR
F-62 F-62
SAE-400 SEVERE DUTY
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