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Delco Old Generators
Delco Old Generators
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ADJUSTMENTS,TESTSAND MAINTENANCE OF
D.C. GENERATORS
GROUND
SCREW
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HINGE
CAPOilER
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co: 1.2. I WDS. I'S, I.n, 131. 132: 16. If 0 !"'I"UD IN 1I.5.A.
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Service Bulletin IG..150
Page 2
D.C.GENERATORS
r""'" POI.E SHOE
~
i ,-POlE SHOESCREW
!I
l1 ! INSULATION 7 ,-OILER
,I, l",
flElO COIL,
'",
- 1
,
(BAll
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SEARING
Oil
,oJ k SEAL ,..
THRl/ IJ
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.(!~tpu:m AND~;~
4-' \ '
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BOLT...!. I
\ LSPRING j.. ARMATURE \.BRUSHj
- r""Tmm_"\'>-COMMUTATOR :: fAN , I
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COVERSAND
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,
LCOMMUTATOR
ENDfRAME
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L ORIVEENDFRAME
/"
DRIVE END FRAME
COMMUTATOR
END FRAME.:J
I
Figure 2-Cross secUonal view of typical 4%" frame diameter Flgut'\') 3-Cutaway view Qf typical 4%" frame diameter gen-
generator, era tor wiUt provision for forced all' cooling.
and hinge cap oilers in each end frame,and a 5% inches and a cover band that can be removed"
cover band which can be removed for easy inspec- to permit easy inspection of the brushes and com",-
tion of the brushes and commutator. This genera~ mutator.
tor is of the two-brush two~pole type.
In Figure 5 is illustrated a two~brush two-pole The generator illustrated in Figure {) has two
generator which is similar in construction but brushes, two poles, and a frame diameter size of
larger in size than the assembly shown in Figure 5% or 5% inches. This type generator features
4. This generator has a frame diameter of 5% or grease reservoirs providing permanent-type lubri-
OilER
Il ! (
0-
H, '
",.
,
BEARING
COMMUTATOR
END FRAME
FIELD COIL ARMATURE
DRIVE END
FRAME
--W
H ,
'
.
PUllEY
AND FAN
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-
Service Bulletin 1G.150
~ D.C. GENERA
Page 3
TORS
OilER ;1
BEARING ~
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i d;
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ARMATURE ,
DRIVE END'1j
FRAME
cation, and extra long brushes with special con~ The assembly shown in Figure 7 has a frame di-
stant-tension brush springs. These design features 0 ameter size of 6n inches. The ball bearings in each
eliminate the need for periodic lubrication and end frame in this generator are sealed for life,
brush replacement between engine overhaul and no periodic generator lubrication is required.
periods. Cover plates which are mounted over Generators in this frame size have four poles, and
windows in the field frame can be easily removed some models have two brushes whereas. others
for inspection of the brushes and commutator. have four brushes. .
! GREASE RESERVOIR
.
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HEAVY.DUTY
BAll BEARING ...
.
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L-
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L-IIiiSPECTION
WINDOW
AND COVER PLATE
SEAL '-
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, "'--REPLACEABLE MOUNTING BUSHING~
FIIrUI'e &-Cross sectional view of 5%" or $%" frame diameter generator with special
brushes and pemument bearing lubrication.
Service, Bulletin 1G..150 r7""=:-'
Page 4
. +ll!?)) Li'-'~'~<"--
D.C. GENERATORS
~
I :
BEARING
The generator illustrated in Figure 8 is afour~ The assembly io Figure 9 has four brushes and
brush four-pole unit having a frame diameter of four poles and a frame diameter of 8i~ inches.
61'\ inches. On this type generator, a roller hear~ 00 some models the four neld coils aTe connected
ing is used in the drive end frame, and a ball bear~ in series, and io other models a split field arrange-
ing in the commutator end frame. The inner race ment is used as shown in Figure 17. Provision is
of the ball bearing is secured to the shaft with a made on the commutator end frame for attach-
nut threaded oyer the shaft at the commutator ment of a filter screen to remove dust, dirt, and
end. Grease cups afe used on each end frame for other foreign material from the cooling air drawn
periodic lubrication.
if
POU SHOE
GREASECUP
, aC-"'fu, -FAN
COMMUTATOR
END FRAME ARMATURE
D.C. GENERATORS
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CUP
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BRU&H
COVER BAND ARMATURE
BAll BEARING
'
COMMUTATOR
END FRAME
Figure 9-Cross sectional view of typkal 8!~1" frame diameter generator with
split fields.
through the generator by the fan. Ball bearings in Figure 9. This type generator also has grease
are used in each end frame, and lubrication is cups and a filter cover, but uses a roller bearing
provided by grease cups. in the drive end frame with a ball bearing in the
commutator end frame. This type assembly fea-
The generator shown in Figure 10 is also of the tures six brushes and six poles, along with three
Stir inch frame diameter type, but the frame length interpoles connected ill series with each other.
is shorter as compared to the assembly pictured (See Figure 15.)
.UIMTU.. TMMIHM
cu,
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a.EASE ......
\ G.OUHO TE.MIN4l Ie1
j alE4SE cu,
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Figure IO--Cross sectional view of typical 8p~" frame diameter geMrator having
six poles.
Service Bulletin 1G.150
I~""-
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Page 6
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D.C. GENERATORS
be refilled only one-quarter full, so that the balls tween bars Wldercut. Remove only enough ma-
are completely covered but the separator remains terial to make the commutator smooth and round,
exposed. ALso grease reservoirs should be only and undercut the insulation 1/32 inch deep and
haLffined with grease so that when the generator
is reassembled, the reservoir will be only half~
filled.
CAUTION: OverfULing will cause the bearing to ....
-+ITTIL- Page 7
D.C. GENERATORS
FIlUm
13
(-
IWllIIUSH
FIlUm14
and other accessories, in place of using the
SHOEvehicle frame and engine block as the re-
flUDCOIL POLE
turn circuit.
.033 inch wide. Finish with No. 00 sandpaper, and The generator circuit shown in Figure 15 has inter-
blow away all dust, particularly between bars. pole windings which minimize distortion of the
If the brushes are worn down to less than half magnetic fields at different generator outputs.
their original length, they should be replaced. While distortion of the magnetic fields 'is normal,
New brushes can be seated to make good conta.ct this type of generator supplies such high current
with the commutator by holding a brush seating outputs that the distortion would be excessive,
stone on the commutator with the generator in causing poor commutation and short brush life.
operation or by applying brush seating compound The interpole windings reduce distortion and
to the commutator. Blow away all dust after the assure good brush life.
seating operation.
The generator circuit shown in Figure 16 has a
A visual inspection will often reveal the condi- bucking field coil which is connected across the
tion of the brush springs. If the springs are cor-
roded, or if. they are blued and discolored from generator armature. The magnetism produced by
excessive heat, they should be replaced. If the the bucking field coil opposes the magnetism
brush arms move freely, and if the brush moveS created by the main field coil. On generators of
freely in the holder, with no spring corrosion or this type, only a small amount of magnetism is
discoloration, the springs most likely are satis- needed at high generator speeds for the generator
factory. If an additional check is-desired, use a to produce specified voltage. Since the main field
spring tension scale to measure the brush spring magnetism and bucking field magnetism oppose
tension, and compare with specifications given in each other, the current through both of these wind-
Bulletins IG~180, 1G-185 and 1G-186. The method ings remains at a normpllevel at high speeds, but
of checking the spring tension on generators Qfthe the opposing effect results in the small magnetic
field needed at these speeds. With the normal
type shown in Figure 1 is illustrated in Figure 11. amount of current in the main field windings at
The spring gauge should be hooked under the high speeds, the regulator is able to retain voltage
brush arm where it contacts .the brush, and the control. Without the bucking field, the main field
reading taken when the brush arm first starts to current would have to decrease to an abnormally
move off the brush. low value at high speeds. At such a low value, the
regulator would not be able to control the voltage.
GENERATOR CIRCUITS The split field generator circuit (Fig. 17) consists
. ".' of two separate sets of field coils. Each set is indi~
The mam types of generator ClrcUlts are shown m vidually controlled by separate voltage and cur-
Figures 12 through 17.
IImRPOlE(0tIS"\
~e ,third-brush ~enerator c~cui~ is shown Aa ASF I
ill FIgure 12. ThlS type of CU:CUltarrange-
ment provides automatic control of the gen-
~
~
eratoI' 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.
IIITIRPOU (01 IU<DIG f\IUI (01
The shunt type generator circuit shown in
Figure 13 requires a voltage and current Figu~ 15 Figum 16
Service Bulletin 1G..150
Pogo8
D.C. GENERATORS
~
(ONTACT roINn
\
IIIISUIiQ OUTPUT CHECKS
<OIIMUTAfOl <ONTA(!
roINn --_/'
, (o_mOl (Refer to Service Bulletins 1G.180, 1G.185 and
16.186 for Specifications)
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.
"' ,-
.. 1M!!
meter from the generator output terminal to
ground, and a load rheostat across the battery.
Refer to the above Service Bulletins to determine
FIgure 13-UA" circuit Figure 19-"B" circuit if the generator is "A" circuit or "Bu circuit. Then
generator. generator. connect a jumper lead to the generator field ter.
minal as shown in Figure 20 for "A" circuits, and
rent regulators. On this type of generator, high as shown in' Figure 21 for liB" circuits. Operate
current outputs are obtained at engine idle speed. the generator at specified speed, and adjust the
For a more detailed description of the generator load rheostat as required to obtain the specified
circuits shown above, see the Delco-Rerriy Train- output.
ing Chart Manua~ DR-5133E. If the generator does not perform according to
"A" Circuit and "B" Circuit-The generator cir- specifications, it should be disassembled for
cuits shown in Figures 12 through 17 can be classi- further testing.
fied as either "An circuit or "B" circuit. An "Au
circuit generator is shown in Figure 18. In this DISASSEMBLY
type circuit, the field winding is connected to the
insulated brush inside the generator and is con- Generator disassembly can be accomplished first
nected to ground through the contact points in the by removing the thru-bolts, or end frame attaching
regulator. In the "B" circuit generator (Fig. 19), bolts, and then separating the two end frame as.
the field winding is grounded inside the generator, semblies from the field frame. On some models, it
and is connected to the armature circuit inside the is necessary to detach leads from the brush holders
regulator. before the commutator end frame can be removed.
The insulated generator circuit shown in Figure Also, on generators of the type shown in Figure 8,
14 may be used either as an "An circuit or "B" the commutator end frame retainer plate, and the
circuit generator. If the "AI" terminal is connected cotter pin and nut on the shaft, must be removed
to the regulator, and the "A2" terminal is grounded before the end frame can be separated from the
or connected to the battery re~um circuit, the gen- field frame.
erator be<:omes an "A" circuit type. If the "A2"
terminal is connected to the regulator, and the When removing bearings from the armature shaft
"AI" terminal is grounded or connected to the or end frame, care should be taken to avoid dam-
battery return circuit, the generator becomes a age to the balls and raceways. If the bearing is a
"B" circuit type. press fit over the shaft, use bearing pullers against
the inner race only. If the inner race is inacces.
The type of circuit for each generator model is sible, and it is necessary to pull against the outer
listed in the Test Specification Bulletins lG-1SO, race, the balls will be loaded and may be damaged.
IG-185, and IG-186. Similarly, when removing a bearing whose outer
race is a press fit into the
end frame, use an arbor
F A press against the outer
race to avoid loading the
<::::::::J balls.
~ D.C. GENERATORS
Page9
~
Service Bulletin 1G.150
Page 10
D.C. GENERA TORS ~
will increase generator output, and in the opposite setting must be exactly on the neutral point. Gen-
direction will decrease generator output. If the erators without interpoles must have the brushes
battery remains consistently undercharged or shifted ahead 114commutator bar width in the
overcharged, relocating the third brush may cor- direction of armature rotation so that the arma-
rect the condition. 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
CHECKING AND ADJUSTING locking or attaching screws should be tightened
securely.
NEUTRAL POINT
Many of the higher output shunt generators have POLARIZING GENERATOR
adjustable brush plates which can be shifted to
obtain the proper brush locations with respect to After a generator has been tested and repaired, -I
the neutral point. Proper adjustment is necessary and installed on the engine or vehicle, it must be
in order to obtain best commutation and therefore
maximum brush and commutator life. The neutral polarized so it will have the co.rrect polarity with I
I
respect to the battery polarity. Failure to polarize
point refers to a particular relationship between
the poles, armat\1re windings and brushes. When
the relationship of these parts is correct, minimum
the generator may result in burned or stuck cut-
out relay contacts in the regulator, along with
damage to the wiring and generator windings.
-I
arcing and best commutation will be obtained.
Whenever new brushes, armature, or poles are "A" Circuit Generator-To polarize an "A" circuit
installed, or whenever a generator has been dis- generator, momentarily connect a jumper lead be-
assembled, the brush position must be checked tween the regulator BATTERY and ARMATURE
and adjusted as follows: terminals after all leads have been connected, hut
With the generator assembled and the brush ring before the engine is started. If the generator is a
attaching screws just tight enough to hold the 24 or 32 volt unit, temporarily insulate the ground
brush or brushes from the commutator to avoid
brush ring in place in the commutator end frame,
connect a battery between the generator" A" ter- excessive current through the armature. The
minal and ground (or between the "Al" and "A2" brushes can be temporarily insulated from the
terminals on insulated units) and note the ten- commutator with a piece of cardboard or other
dency for the armature to rotate. The generator suitable insulating material.
should be on a test bench with the armature free "S" Circuit Generator-To polarize a "B" circuit
to rotate and without any connection to the gen- generator, disconnect the lead from the regulator
erator field terminal The voltage to use in making FIELD terminal, and momentarily touch the lead
this check is the minimum amount of voltage which to the regulator BATTERY te1iffiinal. This should
will cause the armature to rotate when it is free be done after all other leads have been connected
to turn. This voltage may be obtained by connect- and before the engine is started.
ing a variable resistance into the circuit from the
battery. The neutral point is found by shifting the Polarizing the generator allows a surge of current
brushes into the position at which there is no ten- to flow through the field windings, which insures
dency for the armature to rotate in either direc- that the polarity of the generator will match the
tion. If the generator has interpoles the brush polarity of the battery.
, '
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