7.1.

2 GENERATOR
Contents [show]
Standard generators are shunt wound (armature and field circuits connected
in parallel), two-brush, high output generators. The generating system is a
negative (—) ground system. Output is controlled by a regulator which is
connected between the armature and field. The field is grounded internally
(Figs. 1 and 2).

Fig. 05: generator mountings

The front end of the armature shaft is supported by a permanently-lubricated

ball bearing which fits into the front end plate (Fig. 13). The shaft is keyed to an
integral pulley and cooling-fan assembly. The pulley is connected to the engine
crankshaft pulley with a belt. Thus the armature receives its mechanical energy
from the engine. The rear end of the 8-cylinder engine generator armature shaft
is supported by a permanently lubricated ball bearing in the brush end plate.
The rear bearing on the 6-cylinder engine generator shaft is a bronze bushing,
and requires periodic lubrication. On some heavy duty 6-cylinder engine
generators, the rear bearing is permanently lubricated. Generator mountings
for the various engines are shown in Fig. 5.
Generator Tests
The necessary equipment used in the six generatortests outlined below is as
follows:
Ammeter 0-5A
Ammeter 0-50 For Standard Generator
Ammeter 0-100 For Heavy Duty Generator
0-20 Voltmeter
“Growler” Tester
Storage battery, assorted connecting wires, and jumper wires equipped with
suitable connectors.
Various makes of generator and regulator test benches combine all the above
listed items into one unit and are equipped with a motor drive. Such equipment
can be used to facilitate the generator tests. When such combined equipment is
used, be sure to follow the manufacturer’s instructions.
Only two of the six generator tests outlined below, namely “Generator Output
Test” and “Field Open or Short Circuit Test,” can be made either on or off the
vehicle. All other tests must be made off the vehicle only. Unless otherwise
specified, all “off the vehicle” tests can be made either with a generator-
regulator test bench or with the separate equipment as listed above.
 Fig. 06: generator output test—schematic

GENERATOR OUTPUT TEST. When a generator output test is conducted off

the vehicle, a generator-regulator test bench must be used. In this case, the
generator is placed on the test bench and driven by the motor. Follow the
procedure given by the manufacturer.
To test the output of the generator on the vehicle, proceed as follows (see Figs.
6 or 7):

Fig. 07: generator output test connections

Disconnect the regulator “ARM” and “FIELD” wires at the generator. Connect
a jumper wire from the generator “ARM” terminal to the generator “FIELD”
terminal and the positive lead of a 0-50 ammeter to the generator “ARM”
terminal (use 0-100 ammeter on heavy duty systems). Start the engine and
while it is idling, connect the ammeter negative lead to the battery. Run the
engine at 1500 r.p.m., and read the current output on the ammeter. The
generator output should reach or exceed 30 amperes (40-60 amperes on the
heavy duty generators). Slop the engine and disconnect the test leads as
soon as the test is completed to prevent overheating the generator.
ARMATURE TESTS. Checking the armature for open, short, or grounded
circuit can be done “off the vehicle” only.
Open Circuit Test
An open circuit in the armature can sometimes be detected by examining the
commutator for evidence of burning. The spot burned on the commutator is
caused by an arc formed every time the commutator segment connected to the
open circuit passes under a brush.
Short Circuit Test
 Fig. 08: growler test for shorted armature

To test the armature for a short circuit in the windings, a “growler” must be
used as shown in Fig. 8, Rotate the armature slowly. When the shorted winding
is under the steel strip, it will cause the strip to vibrate.
Grounded Circuit Test

Fig. 09: grounded circuit armature test

To determine if the armature windings are grounded, make the connections

as shown in Fig. 9. If the voltmeter indicates any voltage, the armature windings
are grounded to the frame.
FIELD TESTS. Only two tests are necessary for checking the field. Both open
and short circuits can be tested in one operation. The second test is for a
grounded circuit.
Open Or Short Circuit Test
The field can be checked for open or short circuits either on or off the vehicle.
 Fig. 10: open circuit test of field—schematic

ON VEHICLE. Disconnect the “FIELD” lead from the generator terminal.

Connect a 0-5 ammeter from the battery to the “FIELD” terminal as shown in
Fig. 10. The normal current draw, as indicated by the ammeter, should be 1.5 to
1.6 amperes. If there is little or no current flow, the field has a high resistance or
is open. A current flow, considerably higher than that specified above, indicates
shorted or grounded turns.

Fig. 11: open circuit test of field—off vehicle

OFF VEHICLE. The field circuit can be tested off the vehicle in the same
manner as described in the “on vehicle” test above with the exception that a
return lead must be used to connect the generator frame to the battery (Fig. 11).

Fig. 12: grounded circuit test of field—off vehicle

To test the field windings for a grounded circuit, remove the “GRD” terminal
stud from the generator frame. Make the voltmeter and battery connections as
shown in Fig. 12. If the voltmeter indicates any voltage, the field coils are
grounded. Be sure that the “GRD” terminal stud is not touching the
housing.
Generator Repair

Fig. 13: disassembled generator—typical

Of the five repair operations outlined in this paragraph, the first, “Removal
and Installation” must be used when performing any one of the other four. The
complete disassembly procedure is given in “Generator Overhaul.” However,
“Armature Replacement,” “Commutator Turning and Undercutting,” and
“Brush Replacement” can be accomplished without completely disassembling
the generator. Therefore, these latter procedures eliminate those disassembly
steps that do not apply. A disassembled view of the standard generator is shown
in Fig. 13.
REMOVAL AND INSTALLATION.
Disconnect the armature, field, and ground wires at the generator terminals.
Remove the adjustment arm to generator bolt, the generator belt, and the two
pivot bolts from the mounting bracket. Then remove the generator (Fig. 5).
To install the generator, first clean the mating surfaces of the generator frame
and mounting bracket. Install the generator in the bracket with the two pivot
bolts and lockwashers. Install the generator belt, and the adjustment arm to
generator bolt. Adjust the belt tension and tighten all bolts securely. Install the
armature, field, and ground leads on the generator terminals.
GENERATOR OVERHAUL. Use the procedures outlined below for generator
overhaul or when it is necessary to completely disassemble a generator for such
purposes as bearing replacement or field coil replacement.
Disassembly

Fig. 14: pole shoe screw removal

 Remove the two generator through bolts and the brush end plate. Slide the
armature assembly out the other end of the frame. Do not lose the locating
dowels if they drop out of the end plates. Clamp the armature in a vise equipped
with soft jaws, and remove the retaining nut, lockwasher, pulley, and woodruff
key from the armature shaft. Slide the front end plate off the armature shaft.  Be
sure to remove any burrs from the keyway before removing the front end
plate.
Remove the “FIELD” and “GRD” terminal screws from the generator frame,
and unscrew the field pole shoe screws as shown in Fig. 14. The arbor press
prevents the tool from slipping out of the screw socket. Slide the pole shoes and
field windings out of the frame, and separate the windings and shoes.
Cleaning and Inspection
Wash all parts except the armature, field coils, and ball bearings in solvent
and dry the parts thoroughly. Wipe off the armature and field windings, the
commutator, and the armature shaft.
Check the condition of the bearings.
If the ball bearings are worn or have lost their lubricant they must be
replaced. If the 6-cylinder engine generator brush end plate bushing is worn or
scored, replace the brush end plate assembly.
Check the armature winding for worn insulation, overheating, and unsoldered
connections. Check the armature for shorts, opens or grounds. Check the field
windings for worn insulation and unsoldered connections at the terminal
screws. Resolder any connections as required. Replace the armature or the field
coils if the insulation is worn.
Check the commutator for runout and uneven or scored surfaces. Turn down
the commutator and undercut the mica if necessary.
Inspect the brush end plate for cracks, poor insulation or loose rivets. Replace
the end plate if it is cracked or if the positive brush insulation is broken or
cracked. Tighten any loose brush holder rivets.
Check the brush spring tension. If the tension is not between 26-34 ounces,
replace the springs.
Assembly
Install the field coils on the pole shoes, and mount the shoe and coil
assemblies in the frame. Tighten the field pole shoe screws (Fig. 14). As the
screws are tightened, strike the frame several sharp blows with a soft faced
hammer to seat and align the pole shoes.
Install the “GRD” terminal screw, washer, and nut in the frame. Install the
“FIELD” terminal screw, insulators, washer, and nut in the frame.
Insert new brushes in the brush holders, install the “ARM” terminal screw
and insulators, and install the ground brush screw. Move the brushes back in
the holders until the brush springs ride against the side of the brushes to retain
them in the retracted position. On 8-cylinder engine generators, first install the
bearing in the brush end plate and insert the snap ring.
Install the bearing in the front end plate and insert the bearing stop ring.
Slide the plate on the armature shaft (with the snap ring toward the armature
windings), and install the woodruff key, pulley, lockwasher, and retaining nut.
Install the armature and front end plate assembly in the frame, locating the
dowel in the frame groove. Install the brush end plate (aligning the dowel and
frame groove), and install the through bolts with lockwashers. Use a piece of
stiff wire with a hooked end to reach through the ventilating slots, and position
the brush springs on top of the brushes. Lubricate the brush end plate bushing
with a few drops of engine oil (6-cylinder engine generators).
POLARIZING GENERATORS. Normally, it is only necessary to polarize a
generator when a generator has been rebuilt and if new pole shoes have been
installed.
Generators are polarized during manufacture, and normally, there is enough
residual magnetism left to allow the generator to start charging.
To polarize a rebuilt generator mounted on the vehicle, disconnect the field
wire and the battery wire from the regulator and momentarily connect the two
wires together, engine not running.
CAUTION: Do not polarize a generator by any method that applies battery
voltage to the field terminal of the regulator, such as shorting from the battery
terminal to the field terminal of the regulator, or by connecting a jumper wire
directly from the battery to the generator field terminal. This action causes
excessive current to flow from the battery through the regulator contacts to
ground, thus burning the points.
ARMATURE REPLACEMENT. Remove the two through bolts and the brush
end plate. Slide the armature and front end plate assembly out of the frame.
Clamp the armature in a vise equipped with soft jaws, and remove the retaining
nut, lockwasher, pulley, and woodruff key. Remove any burrs or scratches from
the keyway or shaft, and slide the drive end plate off the shaft.
Install the front end plate on the new armature. Install the woodruff key,
pulley, lockwasher, and retaining nut. Slide the armature and front end plate
assembly into the frame, aligning the dowel with the frame slot. Install new
brushes in the brush end plate, retract the brushes, and install the end plate
(aligning the dowel and the frame slot). Install the through bolts with
lockwashers.
Use a piece of stiff wire with a hooked end to reach through the ventilating
slots, and position the brush springs on top of the brushes. Lubricate the brush
end plate bushing with a few drops of engine oil (6-cylinder engine generators).
COMMUTATOR TURNING AND UNDERCUTTING.
Check the commutator runout as shown in Fig. 15. If the surface of the
commutator is rough or more than 0.002 inch out of round, turn it down in a
lathe or with a turning and undercutting tool (Fig. 16). Remove no more copper
than necessary to clean up the commutator.

Fig. 15: commutator runout check

 Fig. 16: generator commutator turning

After the commutator is turned down, undercut the mica between the bars ^
inch below the copper using the undercutting tool as shown in Fig. 17.
Figure 18 illustrates samples of proper and improper undercutting. Polish the
commutator with #00 to #000 sandpaper to remove all burrs. Brush all
particles of copper from the mica insulation between the commutator
segments.

Fig. 17: generator commutator undercutting

 Fig. 18: examples of proper and improper undercutting

BRUSH REPLACEMENT. Replace the generator brushes when they are worn
to V2 inch. Always change both brushes when replacement is required.

Fig. 19: generator brush seating

Remove the two through bolts from the generator frame. Remove the brush
end plate and the armature and front end plate assembly from the generator
frame. Disconnect the brush terminals and remove the brushes. Clean the
carbon and dirt from the brush end plate. Repair or replace the insulation
between the brush holders and end plate and the “ARM” terminal and end plate
if it is worn or cracked. Make sure that the new brushes slide freely in the brush
holders. Seat the new brushes by sanding them in as shown in Fig. 19.
Retract the brushes until the brush springs ride against the side of the
brushes, to retain them in the retracted position. Install the armature and front
end plate assembly and the brush end plate (aligning the dowels and the frame
slots). Install the through bolts with lockwashers. Use a piece of stiff wire with a
hooked end to reach through the ventilating slots and position the brush springs
on top of the brushes. Lubricate the brush end plate bearing cup with a few
drops of engine oil (6-cylinder engine generators).