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1. be detached from the frame when check ing for grounded fields To check the field windings for opens connect the 110 volt test lamp prods across the windings If the lamp fails to light the windings are open A shorted grounded or open field will result in abnormal generator output A shorted field wind ing will cause excessive burning of the voltage regulator contact points resulting in reduced gen erator output An open field winding will result in no generator output A grounded field can cause excessive generator output on A circuit generators if the ground is near the F terminal If the ground is near the end of the winding con nected to the insulated brush reduced generator output will be obtained On B circuit generators a grounded field will cause excessive pitting and burning of the voltage regulator contact points resulting in reduced generator output On bucking field generators Fig 7 a shorted grounded or open bucking field winding can cause excessive generator voltage at high speeds REASSEMBLY Reassembly is the reverse of disassembly Care should be taken to avoid damage to grease seals and oil seals during reassembly and the brushes should be checked after reassembly to make sure they are free in their holders and the brush arms move freely THIRD BRUSH ADJUSTMENT On some generators the third brush location can be adjusted by loosening the third brush ring clamping
2. grease cups turned down one full turn at vehicle or engine lubrication per iods Generators having sealed bearings and those with grease reservoirs in the end frames require no periodic lubrication and are designed to oper ate between engine or generator overhaul periods without lubrication attention There are two types of grease recommended for bearings in d c generators For generators of the type shown in Figures 2 and 4 any high grade grease of reputable manufacture is satisfactory On these types of generators the bearing should be refilled only one quarter full so that the balls are completely covered but the separator remains exposed Also grease reservoirs should be only half filled with grease so that when the generator wi essen pled the reservoir will be only half led CAUTION Overfilling will cause the bearing to overheat resulting in premature failure Keep lu bricants perfectly clean as the smallest amount of dirt or other foreign matter in a bearing will cause premature failure For other d c generators such as those shown in Figures 5 6 8 9 and 10 Delco Remy lubricant No 1948791 is recommended On these types of generators the bearing may be reused if the ser vice mileage is low and if a reasonable amount of the grease supply in the bearing remains and if the bearing is otherwise not defective However if the grease supply in the bearing is nearly or com pletely exhausted it should be replaced wi
3. outputs that the distortion would be excessive causing poor commutation and short brush life The interpole windings reduce distortion and assure good brush life The generator circuit shown in Figure 16 has a bucking field coil which is connected across the generator armature The magnetism produced by the bucking field coil opposes the magnetism created by the main field coil On generators of this type only a small amount of magnetism is needed at high generator speeds for the generator to produce specified voltage Since the main field magnetism and bucking field magnetism oppose each other the current through both of these wind ings remains at a normal level at high speeds but the opposing effect results in the small magnetic field needed at these speeds With the normal amount of current in the main field windings at high speeds the regulator is able to retain voltage control Without the bucking field the main field current would have to decrease to an abnormally low value at high speeds At such a low value the regulator would not be able to control the voltage The split field generator circuit Fig 17 consists of two separate sets of field coils Each set is indi vidually controlled by separate voltage and cur Figure 17 Service Bulletin 1G 150 Page 8 D C GENERATORS Figure 18 A circuit generator Figure 19 B circuit generator rent regulators On this type of generator high current
4. screws and then moving the third brush in the direction of rotation or in the opposite direc tion Moving the brush in the direction of rotation Service Bulletin 1G 150 Page 10 D C GENERATORS De will increase generator output and in the opposite direction will decrease generator output If the battery remains consistently undercharged or overcharged relocating the third brush may cor rect the condition CHECKING AND ADJUSTING NEUTRAL POINT Many of the higher output shunt generators have adjustable brush plates which can be shifted to obtain the proper brush locations with respect to the neutral point Proper adjustment is necessary in order to obtain best commutation and therefore maximum brush and commutator life The neutral point refers to a particular relationship between the poles armature windings and brushes When the relationship of these parts is correct minimum arcing and best commutation will be obtained Whenever new brushes armature or poles are installed or whenever a generator has been dis assembled the brush position must be checked and adjusted as follows With the generator assembled and the brush ring attaching screws just tight enough to hold the brush ring in place in the commutator end frame connect a battery between the generator A ter minal and ground or between the A1 and A2 terminals on insulated units and note the ten dency for the armature to rotate The genera
5. Delco Remy ANDERSON INDIANA U S A SERVICE BULLETIN Bulletin 1G 150 Date 7 3 61 10 Pages Page 1 File Under G GENERATORS Supersedes Bulletin 16 150 Dated 3 24 53 ADJUSTMENTS TESTS AND MAINTENANCE OF D C GENERATORS HINGE h CAP OILER DRIVE END FRAME Figure 1 Typical D C Generator INTRODUCTION Delco Remy d c generators are manufactured in a wide range of sizes and types but the basic de sign of each generator is the same Regardless of size each generator has an armature mounted at both ends on bearings The armature rotates be tween pole shoes over which are wound field coils The voltage and current developed in the arma ture windings is supplied through brushes riding on a commutator to the generator terminals and then to the battery and other electrical accessories in the circuit Since all d c generators adhere to the same basic design the maintenance and test ing procedures for all sizes are similar A typical generator is shown in Figure 1 This bulletin covers the different types and designs of dic generators along with recommended service procedures for each The subject of Operating Principles is covered in Delco Remy Training Chart Manual DR 5133E CO 1 2 1 WDS amp PS 1 2X 131 132 16 1FD FIELD FRAME GROUND SCREW TERMINALS HINGE COMMUTATOR END FRAME TYPES AND DESIGNS The following cross sectional views illustrate the various types of generato
6. OMMUTATOR END FRAME ARMATURE The assembly in Figure 9 has four brushes and four poles and a frame diameter of 8p inches On some models the four field coils are connected in series and in other models a split field arrange ment is used as shown in Figure 17 Provision is made on the commutator end frame for attach ment of a filter screen to remove dust dirt and other foreign material from the cooling air drawn GREASE CUP ROLLER BEARING fa DRIVE END FRAME Figure 8 Cross sectional view of typical 6 frame diameter generator Service Bulletin 1G 150 Page 5 D C GENERATORS GREASE ARMATURE CUP TERMINAL COVER BAND ARMATURE BALL BEARING COMMUTATOR END FRAME FIELD TERMINAL F 1 GROUND TERMINAL FIELD TERMINAL F 2 FIELD COIL POLE SHOE GREASE CUP Z J y DRIVE END FRAME Figure Cross sectional view of typical 8 frame diameter generator with split fields through the generator by the fan Ball bearings are used in each end frame and lubrication is provided by grease cups The generator shown in Figure 10 is also of the 8 inch frame diameter type but the frame length is shorter as compared to the assembly pictured ARMATURE TERMINAL GREASE CUP w GRouNo terminat AIR CLEANER commutator ENO FRAME COVER SAND commutator ARMATURE in Figure 9 This type generator also has grease cups and a filter cover but uses a roller bearing in the drive end fr
7. RY and ARMATURE terminals after all leads have been connected but before the engine is started If the generator is a 24 or 32 volt unit temporarily insulate the ground brush or brushes from the commutator to avoid excessive current through the armature The brushes can be temporarily insulated from the commutator with a piece of cardboard or other suitable insulating material B Circuit Generator To polarize a B circuit generator disconnect the lead from the regulator FIELD terminal and momentarily touch the lead to the regulator BATTERY terminal This should be done after all other leads have been connected and before the engine is started Polarizing the generator allows a surge of current to flow through the field windings which insures that the polarity of the generator will match the polarity of the battery
8. ame with a ball bearing in the commutator end frame This type assembly fea tures six brushes and six poles along with three interpoles connected in series with each other See Figure 15 AND TERMINAL J omast cur ROUER BEARING pi een SS on se 4 a a INTERPOLE con Figure 10 Cross sectional view of typical 8 frame diameter generator having six poles Service Bulletin 1G 150 Page 6 D C GENERATORS MAINTENANCE Maintenance procedures may be divided into two sections Lubrication and Inspection Lubrication It is very important that proper lubrication pro cedures be followed in order to obtain maximum life from the generator All bearings used in generators use grease to re tain the oil which bleeds to the bearing surfaces to provide proper lubrication On some generator models hinge cap oilers are used so that the oil supply in the grease can be replenished Other models feature grease cups which permit direct application of additional grease to the bearing as the original supply becomes exhausted Some gen erators contain a built in reserve supply of grease in a reservoir located in the generator end frame and others use bearings which are sealed on both sides to retain the original grease supply On generators having hinge cap oilers a few drops of SAE No 20 oil should be added at vehicle or engine lubrication periods Generators with grease cups should have the
9. ameter of 55 or BRUSH ASSEMBLY a BALL BEARING WOODRUFF Lpuuey ano FAN LDRIVE END FRAME BLAST TUBE COMMUTATOR at a TERMINALS BALL BEARING COVER BAND POLE SHOE ARMATURE DRIVE END FRAME COIL ENO FRAME Figure 3 Cutaway view of typical 4 frame diameter gen erator with provision for forced air cooling 5 inches and a cover band that can be removed to permit easy inspection of the brushes and com mutator The generator illustrated in Figure 6 has two brushes two poles and a frame diameter size of 5 or 5 inches This type generator features grease reservoirs providing permanent type lubri TERMINALS FIELD COIL COMMUTATOR END FRAME ARMATURE j PULLEY DRIVE END MAND FAN FRAME Figure 4 Cross sectional view of typical 514 frame diameter generator COMMUTATOR Service Bulletin 1G 150 Page 3 D C GENERATORS FIELD COIL COMMUTATOR COMMUTATOR END FRAME omer PULLEY BEARING rey z AND FAN ARMATURE E j DRIVE END FRAME Figure 5 Cross sectional view of typical generator having frame diameter of Si or S4 cation and extra long brushes with special con stant tension brush springs These design features eliminate the need for periodic lubrication and brush replacement between engine overhaul periods Cover plates which are mounted over windows in the field frame can be e
10. asily removed for inspection of the brushes and commutator m GREASE RESERVOIR HEAVY DUTY BALL BEARING j z gt p INSPECTION WINDOW Al AND COVER PLATE aid REPLACEABLE MOUNTING BUSHING The assembly shown in Figure 7 has a frame di ameter size of 67 inches The ball bearings in each end frame in this generator are sealed for life and no periodic generator lubrication is required Generators in this frame size have four poles and some models have two brushes whereas others have four brushes GREASE RESERVOIR HEAVY DUTY j BALL BEARING SEAL _ Figure 6 Cross sectional view of 5 or 5 frame diameter generator with special brushes and permanent bearing lubrication Service Bulletin 1G 150 Page 4 D C GENERATORS ASSEMBLY BEARING mN COMMUTATOR END FRAME ARMATURE DRIVE END FRAME 4 FIELD cot Figure 7 Cross sectional view of typical 6y frame diameter generator The generator illustrated in Figure 8 is a four brush four pole unit having a frame diameter of 61 inches On this type generator a roller bear ing is used in the drive end frame and a ball bear ing in the commutator end frame The inner race of the ball bearing is secured to the shaft with a nut threaded over the shaft at the commutator end Grease cups are used on each end frame for periodic lubrication POLE SHOE y FIELD COIL BALL BEARING C
11. cal defects The armature should be checked for shorts grounds and opens To check for shorts place the armature in a growler and slowly rotate with a metal blade held on the armature If the metal blade vibrates the windings are shorted To check the armature for grounds touch one prod of a 110 volt test lamp to the commutator and the other test lamp prod to the shaft or lami nations If the lamp lights the windings are grounded To check the armature for opens visually inspect the wiring connections to the commutator bars and inspect the commutator for a burned or dis colored commutator bar An open circuit will cause one of the bars to burn and become dis colored Also the armature may be checked for opens on a growler meter If the meter reads low the winding connected to the commutator bars to which the prods are connected is open RHEOSTAT The generator field wind ings should be checked for shorts grounds and opens To check for shorts con nect an ammeter and bat tery in series with the field windings and refer to Service Bulletins 1G 180 1G 185 and 1G 186 for specifications If the current reading is higher than specified the windings are shorted To check the field wind ings for grounds connect one prod of a 110 volt test lamp to the field terminal and the other prod to the generator frame If the lamp lights the windings are grounded On B circuit generators the ground lead must
12. cations To check the generator for electrical output con nect an ammeter in series with a battery to the generator output terminal Also connect a volt meter from the generator output terminal to ground and a load rheostat across the battery Refer to the above Service Bulletins to determine if the generator is A circuit or B circuit Then connect a jumper lead to the generator field ter minal as shown in Figure 20 for A circuits and as shown in Figure 21 for B circuits Operate the generator at specified speed and adjust the load rheostat as required to obtain the specified output If the generator does not perform according to specifications it should be disassembled for further testing DISASSEMBLY Generator disassembly can be accomplished first by removing the thru bolts or end frame attaching bolts and then separating the two end frame as semblies from the field frame On some models it is necessary to detach leads from the brush holders before the commutator end frame can be removed Also on generators of the type shown in Figure 8 the commutator end frame retainer plate and the cotter pin and nut on the shaft must be removed before the end frame can be separated from the field frame When removing bearings from the armature shaft or end frame care should be taken to avoid dam age to the balls and raceways If the bearing is a press fit over the shaft use bearing pullers against the i
13. nner race only If the inner race is inacces sible and it is necessary to pull against the outer race the balls will be loaded and may be damaged Similarly when removing a bearing whose outer race is a press fit into the end frame use an arbor press against the outer race to avoid loading the balls After bearing removal wash in a clean solvent and carefully inspect for worn surfaces looseness broken separators a cracked ring or race and a rough or catchy feeling Always replace any bear ing if its condition is doubtful Figure 20 Connections for checking output on A circuit generators M Service Bulletin 1G 150 Page 9 D C GENERATORS JUMPER LEAD LOAD BATTERY VOLTMETER GENERATOR B CIRCUIT Figure 21 Connections for checking output on B circuit generators IMPORTANT Refer to the section entitled OINTENANCRE for proper lubrication proce ures When remounting bearings use an arbor press and press firmly and evenly against the proper race to avoid loading the balls If the mountin surfaces are clean and the bearing is start properly and is not cocked or mis aligned it can be mounted without undue pressure Grease and oil seals should be replaced after ap preciable mileage or if the seal is worn or dam aged in any way ELECTRICAL TESTS After the generator has been disassembled tests can be made of the armature and field coils to determine any electri
14. od of checking the spring tension on generators of the type shown in Figure 1 is illustrated in Figure 11 The spring gauge should be hooked under the brush arm where it contacts the brush and the reading taken when the brush arm first starts to move off the brush GENERATOR CIRCUITS The main types of generator circuits are shown in Figures 12 through 17 The third brush generator circuit is shown in Figure 12 This type of circuit arrange ment provides automatic control of the gen erator output thereby eliminating in most cases the need for a voltage regulator con trol However this type of generator is limited to applications requiring lower cur rent outputs The shunt type generator circuit shown in Figure 13 requires a voltage and current regulator for output control and this gener ator is used in a wide variety of applications having low to moderate current output re oe quirements The insulated generator circuit Fig 14 has both brushes connected to terminals on the generator frame This type generator is used with a wire return from the battery and other accessories in place of using the vehicle frame and engine block as the re turn circuit POLE SHOE The generator circuit shown in Figure 15 has inter pole windings which minimize distortion of the magnetic fields at different generator outputs While distortion of the magnetic fields is normal this type of generator supplies such high current
15. outputs are obtained at engine idle speed For a more detailed description of the generator circuits shown above see the Delco Remy Train ing Chart Manual DR 5133E A Circuit and B Circuit The generator cir cuits shown in Figures 12 through 17 can be classi fied as either A circuit or B circuit An A circuit generator is shown in Figure 18 In this type circuit the field winding is connected to the insulated brush inside the generator and is con nected to ground through the contact points in the regulator In the B circuit generator Fig 19 the field winding is grounded inside the generator and is connected to the armature circuit inside the regulator The insulated generator circuit shown in Figure 14 may be used either as an A circuit or B circuit generator If the A1 terminal is connected to the regulator and the A2 terminal is grounded or connected to the battery return circuit the gen erator becomes an A circuit type If the A2 terminal is connected to the regulator and the Al terminal is grounded or connected to the battery return circuit the generator becomes a B circuit type The type of circuit for each generator model is listed in the Test Specification Bulletins 1G 180 1G 185 and 1G 186 GENERATOR Av CIRCUIT LOAD RHEOSTAT P gt OUTPUT CHECKS Refer to Service Bulletins 1G 180 1G 185 and 1G 186 for Specifi
16. rs manufactured by Delco Remy The extruded frame two brush two pole type of generator shown in Figure 2 has a frame diameter size of 4 inches Each end frame has hinge cap oilers for periodic lubrication and the commu tator end frame features a bronze bushing and an oil reservoir Continuous lubrication to the bush ing and shaft is provided by a wick which extends through a hole in the bushing to contact the shaft A special version in the 45 inch frame diameter size is the generator shown in Figure 3 This as sembly features a blast tube for forced air cooling and sealed ball bearings in each end frame which are lubricated for the life of the bearing The generator shown in Figure 4 has a frame di ameter size of 5 inches It features ball bearings PRINTED IN U S A Service Bulletin 1G 150 Page 2 D C GENERATORS Be POLE SHOE GROUND ScREW p POLE SHOE SCREW us J mwsuanong A EA mr BRUSH ARM poner _ om CsPRING 7 L COMMUTATOR END FRAME Figure 2 Cross sectional view of typical 4 frame diameter generator and hinge cap oilers in each end frame and a cover band which can be removed for easy inspec tion of the brushes and commutator This genera tor is of the two brush two pole type In Figure 5 is illustrated a two brush two pole generator which is similar in construction but larger in size than the assembly shown in Figure 4 This generator has a frame di
17. th a new bearing CAUTION Do not add grease to a bearing used on these types of generators Always replace with a new bearing instead of adding grease to the old bearing On these generators No 1948791 grease may be added to the grease cups and to the reservoirs in the end frames as required CAUTION Add only enough grease to the reser voirs so that when the generator is reassembled the reservoir will be only half filled Overfilling will cause the bearing to overheat resulting in premature failure Keep lubricants perfectly clean as the smallest amount of dirt or other foreign matter in a bearing will cause premature failure The generators shown in Figures 3 and 7 have sealed bearings On this type of assembly no per iodic lubrication is required and the bearings should be replaced at engine overhaul periods Inspection Inspection procedures are limited mostly to visual checks for loose mounting bolts a loose drive belt damaged wiring and worn commutator brushes All mounting bolts should be kept tight and the belt tension should be adjusted to conform with engine or vehicle manufacturer s recommenda tions Wiring with frayed insulation should be replaced and all connections should be checked for tight ness and cleanliness If the commutator is dirty it may be cleaned with No 00 sandpaper or with a brush seating stone with the generator in operation Blow away all dust after the cleaning operation If
18. the commu tator is rough out of round or has high mica the armature must be removed so the commutator can be turned down in a lathe and the insulation be tween bars undercut Remove only enough ma terial to make the commutator smooth and round and undercut the insulation 1 32 inch deep and Figure 11 Measuring brush spring tension on generators of the type shown in Figure 1 Service Bulletin 1G 150 Page 7 D C GENERATORS HELD con Figure 14 033 inch wide Finish with No 00 sandpaper and blow away all dust particularly between Tes If the brushes are worn down to less than half their original length they should be replaced New brushes can be seated to make good contact with the commutator by holding a brush seating stone on the commutator with the generator in operation or by applying brush seating compound to the commutator Blow away all dust after the seating operation A visual inspection will often reveal the condi tion of the brush springs If the springs are cor roded or if they are blued and discolored from excessive heat they should be replaced If the brush arms move freely and if the brush moves freely in the holder with no spring corrosion or discoloration the springs most likely are satis factory If an additional check is desired use a spring tension scale to measure the brush spring tension and compare with specifications given in Bulletins 1G 180 1G 185 and 1G 186 The meth
19. tor should be on a test bench with the armature free to rotate and without any connection to the gen erator field terminal The voltage to use in making this check is the minimum amount of voltage which will cause the armature to rotate when it is free to turn This voltage may be obtained by connect ing a variable resistance into the circuit from the battery The neutral point is found by shifting the brushes into the position at which there is no ten dency for the armature to rotate in either direc tion If the generator has interpoles the brush setting must be exactly on the neutral point Gen erators without interpoles must have the brushes shifted ahead commutator bar width in the direction of armature rotation so that the arma ture will tend to rotate very slowly in the direc tion of the generator s normal driven rotation After the brush position is found the brush plate locking or attaching screws should be tightened securely POLARIZING GENERATOR After a generator has been tested and repaired and installed on the engine or vehicle it must be polarized so it will have the correct polarity with respect to the battery polarity Failure to polarize the generator may result in burned or stuck cut out relay contacts in the regulator along with damage to the wiring and generator windings A Circuit Generator To polarize an A circuit generator momentarily connect a jumper lead be tween the regulator BATTE

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