GENERATING SYSTEM
Paragraph
Description 90
Clean commutator 91
Armature bearing special lubrication 92
Remove generator 93
Install generator 94
Cut‐out relay 95
[Illustration:
=8=—GENERATOR SIGNAL LIGHT
=12=—BATTERY POSITIVE TERMINAL
=13=—BATTERY NEGATIVE TERMINAL (GROUND)
=14=—“SWITCH” TERMINAL OF GENERATOR
=15=—“RELAY” TERMINAL OF GENERATOR
=18=—FRONT JUNCTION TERMINAL
=26=—IGNITION AND LIGHT SWITCH
=32=—CUT‐OUT RELAY
=*H=—NOISE SUPPRESSION CONDENSER
RA PD 317200
_Figure 55—Generator to Battery Wiring Diagram_]
90. DESCRIPTION (fig. 55).
=a.= The generator is shunt connected. The two field coils, regulating
coil, and shunt coil are not connected in series in the conventional
manner. The regulating field coil provides adequate current output
(approx. 4 amperes) for daytime operation. The shunt field coil is
controlled through the ignition and light switch to increase current
output (approx. 8 amperes) when vehicle lights are in use. Generator
uses the third (regulating) brush system of current regulation. A
cut‐out relay serves as a magnetic switch in the generator‐battery
circuit, also operating the instrument panel green signal light to
indicate generator charge.
[Illustration: RA PD 310259
_Figure 56—Generator Cover Removed for Commutator Cleaning_]
=91. CLEAN COMMUTATOR= (fig. 56).
=a.= If battery is in good condition, cut‐out relay is functioning,
and wiring connections are made according to diagram (fig. 55), yet
generator does not charge or charge rate is low, proceed to clean the
commutator.
(1) Remove left footboard, sidebar, and clutch foot pedal assembly,
following procedure outlined under paragraph 102 =a= (1) to (6),
to permit generator cover removal.
(2) Remove the two end cover screws and pull end cover off generator.
(3) Clean armature commutator with No. 00 sandpaper until bright and
clean. Blow out with air. CAUTION: _Do not remove or disturb brushes in
their holders. Never use emery cloth to clean the commutator._
[Illustration: RA PD 310260
_Figure 57—Generator End Cover and Grease Retainer Removed_]
(4) Temporarily install footboard assembly and operate engine, to
observe whether or not generator is charging (green signal light
goes off at above 20 mph). If cleaning commutator does not remedy
generator charge, and/or commutator is badly worn, then generator must
be replaced (par. 93). If cleaning of commutator remedied generator
charge, reinstall generator end cover, and the footboard and clutch
pedal assembly (par. 102 =b=).
=92. ARMATURE BEARING SPECIAL LUBRICATION= (fig. 57).
=a.= At the 6,000-mile second echelon preventive maintenance service
period, the commutator end bearing must be hand‐packed. In performing
this operation, care must be taken not to shift or move the generator
third (regulating) brush, thus disturbing generator current regulation.
Generator drive end bearing is adequately lubricated by oil circulating
through engine.
=b. To Lubricate Commutator End Bearing.=
(1) Remove left footboard, sidebar, and clutch pedal assembly,
following procedure outlined in paragraph 102 =a= (1) to (6).
(2) Remove the two end cover screws and pull end cover off generator.
(3) Remove two of the three screws which secure the outer grease
retainer plate to end of generator (fig. 57).
(4) Loosen the other grease retainer plate screw slightly to permit
shifting plate to one side.
(5) Pack ball bearing with general purpose grease No. 2, pressing
lubricant into bearing with finger.
(6) Shift the outer grease retainer plate back into position. Install
the two screws removed, and securely tighten all three screws.
(7) Install generator end cover and the two retaining screws.
(8) Install left footboard, sidebar, and clutch foot pedal assembly,
following procedure outlined in paragraph 102 =b=.
=93. REMOVE GENERATOR= (figs. 58 and 59).
=a.= Generator is gear driven through engine timing gear train.
Generator can be removed and installed without removing timing gear
case cover, or affecting alinement of timing gears.
=b.= Before replacing generator because of failure of instrument panel
green signal light to indicate charge, check panel light wiring and
bulb for good condition (par. 120).
=c.= When it has been determined that generator must be removed for
replacement, proceed as follows:
(1) Disconnect wires from the two generator terminals marked SWITCH and
RELAY.
(2) Remove the two long screws, through timing gear case cover, that
secure end of generator against gear case (fig. 58).
(3) Remove strap nut, lock washer, and curved washer from end of strap
that clamps generator in its cradle on engine crankcase (fig. 59).
[Illustration: RA PD 310261
_Figure 58—Removing Generator End Mounting Screws_]
[Illustration: RA PD 310262
_Figure 59—Removing Generator Strap Nut_]
(4) Lift strap high enough to permit raising generator so that oil
slinger (on end of generator gear) will clear adjacent gear, and allow
generator to be removed from engine. Be sure to observe and count
number of paper shims between generator and cradle. Lay these shims
aside to be used again when generator is reinstalled. Also, note
location of hole in shims for oil drain. These shims were required in
original assembly to adjust driving gears for proper mesh and, if left
out, gears may mesh too deeply and “howl,” even though considerably
worn. Unless a new generator gasket is available, to be used when
generator is reinstalled, be careful not to damage the old one.
94. INSTALL GENERATOR.
=a.= When installing generator, the important point to consider is
correct shimming of generator in its cradle to provide correct mesh of
driving gear with intermediate timing gear. Make sure same number of
paper shims are used in reassembling as were found underneath generator
when it was removed. After an engine has been run a considerable
length of time and gears have worn to some extent, they have possibly
developed sufficient lash or play to safely remove one or more of the
original shims, and thus affect closer meshing and quieter operation.
However, this should not be done unless timing gear case cover is
removed so that gear mesh and lash can be carefully checked.
(1) Pass generator drive gear end through gear case hole, lifting
generator so that oil slinger clears intermediate timing gear. Turn
generator in its cradle so that end holes line up with long mounting
screws which pass through gear case cover. Tighten mounting screws
securely.
(2) Install curved washer, lock washer, and nut on end of clamp strap;
tighten nut securely.
(3) Connect red‐black wire to generator terminal marked RELAY, and
green wire to generator terminal marked SWITCH. Refer to wiring diagram
(fig. 55).
(4) Operate engine and check generator for current output, as well as
check for gear noise. If shimming under generator is proper, generator
and timing gears will run quietly. If necessary, readjust shimming
until gears operate quietly.
95. CUT‐OUT RELAY.
=a.= Operation of the instrument panel green signal light, indicating
generator charge, is controlled by the cut‐out relay. Therefore, if
relay is faulty the signal light will not operate properly, falsely
indicating generator trouble. Rust around the contact points, burned
points, and loss of armature spring tension are sources of most relay
trouble. NOTE: _Before condemning a relay because of failure of green
signal light, make light test_ (par. 120).
=b.= Correct adjustment of relay point gaps and tensioning of armature
springs require use of precision electric meters and expert knowledge
on the subject. A faulty relay, other than removing cover and cleaning
with air, should be replaced. No adjustment of points should be
attempted.
=c. Remove.=
(1) Disconnect the three wires from relay terminal screws.
(2) Remove the two mounting screws and lock washers. Remove relay from
engine base.
=d. Install.=
(1) Mount relay on engine base with two screws and lock washers. Make
sure that mounting is clean to make good electrical ground contact
between relay and engine.
(2) Reconnect the three wire terminals to relay terminal screws. Follow
wiring diagram, figure 55.
(3) Operate engine and observe action of relay, also action of
instrument panel green signal light to indicate generator charge.